17-06-2008 Im224 Page 1

ENGINE TEST SET UP

1 CYLINDR, 4 STROKE, DIESEL

(Computerized)

Instruction manual

Contents 1 Description 2 Specifications 3 Installation requirements 4 Installation Commissioning

5 Troubleshooting 6 Components used 7 Packing slip 8 Warranty

9 Theory 10 Software 11 Experiments

APEX INNOVATIONS

Product Code 224

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The setup consists of single cylinder, four stroke, Diesel engine connected to eddy current type dynamometer for loading. It is provided with necessary instruments for combustion pressure and crank-angle measurements. These signals are interfaced to computer through engine indicator for Pθ−PV diagrams. Provision is also made for interfacing airflow, fuel flow, temperatures and load measurement. The set up has stand-alone panel box consisting of air box, fuel tank, manometer, fuel measuring unit, transmitters for air and fuel flow measurements, process indicator and engine indicator. Rotameters are provided for cooling water and calorimeter water flow measurement. The setup enables study of engine performance for brake power, indicated power,

frictional power, BMEP, IMEP, brake thermal efficiency, indicated thermal efficiency, Mechanical efficiency, volumetric efficiency, specific fuel consumption, A/F ratio and heat balance. Labview based Engine Performance Analysis software package “EnginesoftLV” is provided for on line performance evaluation. A computerized Diesel injection pressure measurement is optionally provided.

Product Engine test setup 1 cylinder, 4 stroke, Diesel (Computerized)

Product code 224 Engine Make Kirloskar, Model TV1, Type 1 cylinder, 4 stroke

Diesel, water cooled, power 5.2 kW at 1500 rpm, stroke 110 mm, bore 87.5 mm. 661 cc, CR 17.5

Dynamometer Type eddy current, water cooled, with loading unit Propeller shaft With universal joints

Air box M S fabricated with orifice meter and manometer Fuel tank Capacity 15 lit with glass fuel metering column

Calorimeter Type Pipe in pipe Piezo sensor Range 5000 PSI, with low noise cable

Crank angle sensor Resolution 1 Deg, Speed 5500 RPM with TDC pulse. Data acquisition device NI USB-6210, 16-bit, 250kS/s.

Piezo powering unit Make-Cuadra, Model AX-409.

Specifications

Description

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Digital milivoltmeter Range 0-200mV, panel mounted Temperature sensor Type RTD, PT100 and Thermocouple, Type K

Temperature transmitter

Type two wire, Input RTD PT100, Range 0–100 Deg C, Output 4–20 mA and Type two wire, Input Thermocouple, Range 0–1200 Deg C, Output 4–20 mA

Load indicator Digital, Range 0-50 Kg, Supply 230VAC Load sensor Load cell, type strain gauge, range 0-50 Kg

Fuel flow transmitter DP transmitter, Range 0-500 mm WC Air flow transmitter Presure transmitter, Range (-) 250 mm WC

Software “EnginesoftLV” Engine performance analysis software Rotameter Engine cooling 40-400 LPH; Calorimeter 25-250 LPH

Pump Type Monoblock Overall dimensions W 2000 x D 2500 x H 1500 mm

Optional Computerized Diesel injection pressure measurement Product 224 Shipping details Gross volume 1.33m3, Gross weight 619kg, Net weight 543kg

Electric supply Provide 230 +/- 10 VAC, 50 Hz, single phase electric supply with proper earthing. (Neutral – Earth voltage less than 5 VAC) • 5A, three pin socket with switch (2

Nos.) Water supply Continuous, clean and soft water supply @ 1000 LPH, at 10 m. head. Provide tap with 1” BSP size connection Computer IBM compatible with standard configuration (with free PCI slot on motherboard)

Space 3300Lx3200Wx1700H in mm Drain Provide suitable drain arrangement (Drain pipe 65 NB/2.5” size) Exhaust Provide suitable exhaust arrangement (Exhaust pipe 32 NB/1.25” size) Foundation As per foundation drawing Fuel, oil Diesel@10 lit. Oil @ 3.5 lit. (20W40)

INSTALLATION • Unpack the box(es) received and ensure that all material is received as per

packing slip (provided in instruction manual). In case of short supply or breakage contact Apex Innovations / your supplier for further actions.

• Install engine test set up assembly on the foundation. • Keep panel box structure near foundation (Refer foundation drawing ) • Fit the panel box assembly on the panel box structure and fit following parts

Installation Commissioning

Installation requirements

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o Piezo powering unit o Loading unit o Load indicator o Digital voltmeter

• Complete the piping work as follows: o Exhaust: Engine to calorimeter o Water: Dynamometer inlet, outlet, Engine cooling inlet, outlet, Calorimeter

water inlet outlet and drain pipe. o Air: Air box to engine o Fuel: Fuel measuring unit to engine

• Fit the following parts o Piezo sensor in the engine head. o Pressure gauge on dynamometer inlet pipe. o Temperature sensors o Crank angle sensor on dynamometer (non driving end) o Load cell to dynamometer.

• Complete the wiring work as follows: o Crank angle sensor to Piezo powering unit o Piezo sensor to Piezo powering unit o Load cell to load indicator o Temperature sensors to engine panel o DLU unit to Dynamometer o USB cable from Data acquisition device to computer “USB” port.

COMMISSIONING • Fill lubrication oil in the engine and fuel in the fuel tank. • Remove air from fuel line connecting fuel measuring unit to fuel transmitter. • Lower jack bolts under dynamometer for free movement. • Provide electric supply to panel box

o Adjust crank angle sensor for TDC matching. o Confirm all temperatures are correctly displayed on process indicator o Confirm load signal displayed on process indicator

• Fill water in the manometer up to “0” mark level. • Keep “Load” knob on loading unit is at minimum position. • Load the NI-USB driver on the computer from Driver CD. • Connect signal cable from Data acquisition device to computer. • Load “EnginesoftLV” software package on the same computer. • Ensure water circulation through engine, calorimeter and dynamometer. Start the

Engine. • Check engine operation at various loads and ensure respective signals on

computer. Precautions • Use clean and filtered water; any suspended particle may clog the piping. • Piezo Sensor Handling:

o Ensure cooling water circulation for combustion pressure sensor. o Diaphragm of the sensor is delicate part. Avoid scratches or hammering on

it. o A long sleeve is provided inside the hole drilled for piezo sensor. This sleeve

is protecting the surface of the diaphragm. While removing the sensor, this sleeve may come out with the sensor and fall down or lose during handling.

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o Status of the sensor is indicated on the Piezo powering unit. Damages to the electronic parts of the sensor or loose connection are indicated as "open" or "short" status on Piezo powering unit.

• Circulate dynamometer and engine cooling water for some time after shutting down the engine.

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Note: For component specific problems refer components’ manual Problems Possible causes / remedies Engine does not start • Insufficient fuel

• Air trapped in fuel line Dynamometer does not load the engine

• Faulty wiring • No DC voltage at the outlet of dynamometer loading

unit Faulty air flow • Air hose leakage at connections with air-box and

with engine. Faulty fuel flow • Improper closing of fuel cock.

• Air trap in pressure signal line to fuel transmitter Software does not work

• Faulty or wrong USB port • Virus in computer • Loose connections

Faulty indicated power

• TDC setting disturbed. Readjust TDC setting. • Improper configuration data

Faulty pressure crank angle diagram

• Improper earthing • Wrong reference pressure setting in configuration

file. Adjust the value such that suction stroke pressure just matches the zero line.

• If peak pressure is not at the TDC, TDC setting disturbed, readjust

• If peak pressure shifts randomly with respect to TDC, coupling of crank angle sensor may be loose

Faulty speed indication

• Broken coupling of crank angle sensor

Incorrect temperature indication

• Check the connection between thermocouple and temperature indicator/transmitter. Note that yellow cable of thermocouple is positive and red is negative.

• Open or damaged temperature sensor Improper load indication

• Excessively raised jack bolts of the dynamometer.

TDC Setting • The TDC indicator provided on the engine indicator enables matching of index

pulse of crank angle sensor with TDC(Top Dead Centre) of the cylinder. Take the piston to its TDC position (match mark provided on the engine fan/pulley/flywheel).

• Loosen the screws of clamping flange of engine crank angle sensor. • Slowly rotate the crank angle sensor body till the TDC indicator lamp glows.

At this position clamp the flange screws to fix the crank angle sensor at this position.

Troubleshooting

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Components Details Engine Make Kirloskar, Model TV1, Type Single cylinder, 4

stroke Diesel, water cooled, power 5.2 kW (7 BHP) at 1500 rpm, stroke 110 mm, bore 87.5 mm. compression ratio 17.5:1, capacity 661 cc.

Dynamometer Make Saj test plant Pvt. Ltd., Model AG10, Type Eddy current

Dynamometer Loading unit

Make Apex, Model AX-155. Type constant speed, Supply 230V AC.

Propeller shaft Make Hindustan Hardy Spicer, Model 1260, Type A Manometer Make Apex, Model MX-104, Range 100-0-100 mm,

Type U tube, Conn. 1/4`` BSP hose back side, Mounting panel

Fuel measuring unit Make Apex, Glass, Model:FF0.012 Piezo sensor Make PCB Piezotronics, Model HSM111A22, Range

5000 psi, Diaphragm stainless steel type & hermetic sealed

White coaxial teflon cable

Make PCB piezotronics, Model 002C20, Length 20 ft, Connections one end BNC plug and other end 10-32 micro

Crank angle sensor Make Kubler-Germany Model 8.3700.1321.0360 Dia: 37mm Shaft Size: Size 6mmxLength 12.5mm, Supply Voltage 5-30V DC, Output Push Pull (AA,BB,OO), PPR: 360, Outlet cable type axial with flange 37 mm to 58 mm

Data acquisition device NI USB-6210 Bus Powered M Series, Piezo powering unit Make-Cuadra, Model AX-409. Temperature sensor Make Radix Type K, Ungrounded, Sheath

Dia.6mmX110mmL, SS316, Connection 1/4"BSP (M) adjustable compression fitting

Temperature sensor Make Radix, Type Pt100, Sheath Dia.6mmX110mmL, SS316, Connection 1/4"BSP(M) adjustable compression fitting

Temperature transmitter

Make Wika, model T19.10.3K0-4NK-Z, Input Thermocouple (type K), output 4-20mA, supply 24VDC, Calibration: 0-1200deg.C.

Temperature transmitter

Make Wika, Model T19.10.1PO-1 Input RTD(Pt100), output 4-20mA, supply 24VDC, Calibration: 0-100°C

Load sensor Make Sensotronics Sanmar Ltd., Model 60001,Type S beam, Universal, Capacity 0-50 kg

Load indicator Make Selectron, model PIC 152–B2, 85 to 270VAC, retransmission output 4-20 mA

Power supply Make Meanwell, model S-15-24, O/P 24 V, 0.7 A Digital voltmeter Make Meco, 3.1/2 digit LED display, range 0-20 VDC,

supply 230VAC, model SMP35 Fuel flow transmitter Make Yokogawa, Model EJA110-EMS-5A-92NN,

Calibration range 0-500 mm H2O, Output linear Air flow transmitter Make Wika, Range (-) 250 mm WC

Components used

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Rotameter Make Eureka Model PG 5, Range 25-250 lph, Connection 3/4" BSP vertical, screwed, Packing neoprene

Rotameter Make Eureka Model PG 6, Range 40-400 lph, Connection ¾” BSP vertical, screwed, Packing neoprene

Pump Make Kirloskar, Model Mini 18SM, HP 0.5, Size 1” x 1”, Single ph 230 V AC

Box No.1/8

Size W975xD475xH500 mm; Volume:0.23m3 Gross weight: 70kg Net weight: 52kg

1 Engine panel box assembly 1 No. Box No.2/8

Size W500xD400xH300 mm; Volume:0.06m3 Gross weight: 25kg Net weight: 18kg

1 Piezo powering unit 1 No. 2 Load indicator 1 No. 3 Digital voltmeter 1 No. 4 Dynamometer loading unit 1 No. 5 Pressure gauge 1 No. 6 Wiring set 1 No. 7 Load cell with nut bolt 1 No. 8 Crank angle sensor 1 No. 9 Temperature sensor 5 Nos. 10 Piezo sensor 1No/2Nos. 11 Low noise cable 1No/2Nos. 12 Data acquisition device and driver CD 1 No. 13 Set of loose nut bolts 1 No. 14 Tool kit 1 No. 15 Set of instruction manuals consisting of:

Instruction manual CD (Apex) DP transmitter Dynamometer Piezo sensor

1 No.

Box No.3/8

Size W800xD475xH500 mm; Volume:0.19m3 Gross weight: 46kg Net weight: 31kg

1 Engine panel box structure 1 No. Box No.4/8

Size W725xD250xH325 mm; Volume: 0.06m3 Gross weight: 24kg Net weight: 17kg

1 Calorimeter assembly 1 No. 2 Calorimeter support structure 1 No. Box No.5/8

Size W900xD200xH200 mm; Volume: 0.04m3 Gross weight: 16kg Net weight: 10kg

1 Exhaust pipe 1 No. Box No.6/8

Size W300xD225xH300 mm; Volume:0.02m3 Gross weight: 14kg Net weight: 7kg

1 Pump 1 No. Box No.7/8

Size W1250xD450xH350mm; Volume: 0.15m3 Gross weight: 42kg Net weight: 28kg

Packing slip

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1 Piping set (13 pieces) 1 No. 2 Fuel measuring unit 2 Nos. 3 Funnel 1 No. 4 Fuel cap 1 No. 5 Wiring channel set (5 pieces) 1 No. 6 Starting kick/Handle 1 No. 7 Engine air inlet 1 No. 8 Engine silencer 1 No. 9 Pump support 1 No. 10 Water supply hose pipe 1 No. 11 1.25” socket with pipe 1 No. 12 1.25” socket with flange 1 No. 13 ¾” Ball valve 1 No. 14 Teflon tape(2Nos.), Gasket bottle (1No.) 1 No. Case No.8/8

Open packing; Volume:0.61m3 Gross weight: 380kg Net weight: 380kg

1 Engine test setup assembly and water supply pipe

1 No.

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This product is warranted for a period of 12 months from the date of supply against manufacturing defects. You shall inform us in writing any defect in the system noticed during the warranty period. On receipt of your written notice, Apex at its option either repairs or replaces the product if proved to be defective as stated above. You shall not return any part of the system to us before receiving our confirmation to this effect. The foregoing warranty shall not apply to defects resulting from:

Buyer/ User shall not have subjected the system to unauthorized alterations/ additions/ modifications. Unauthorized use of external software/ interfacing. Unauthorized maintenance by third party not authorized by Apex. Improper site utilities and/or maintenance.

We do not take any responsibility for accidental injuries caused while working with the set up. Apex Innovations Pvt. Ltd. E9/1, MIDC, Kupwad, Sangli-416436 (Maharashtra) India Telefax:0233-2644098, 2644398 Email: san_apexinno@sancharnet.in Web: www.apexinnovations-ind.com

Warranty

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TERMINOLOGY Engine Cylinder diameter (bore) (D): The nominal inner diameter of the working cylinder. Piston area (A): The area of a circle of diameter equal to engine cylinder diameter (bore). 24/ DA ×= π Engine Stroke length (L): The nominal distance through which a working piston moves between two successive reversals of its direction of motion. Dead center: The position of the working piston and the moving parts, which are mechanically connected to it at the moment when the direction of the piston motion is reversed (at either end point of the stroke). Bottom dead center (BDC): Dead center when the piston is nearest to the crankshaft. Sometimes it is also called outer dead center (ODC). Top dead center (TDC): Dead center when the position is farthest from the crankshaft. Sometimes it is also called inner dead center (IDC). Swept volume (VS): The nominal volume generated by the working piston when travelling from one dead center to next one, calculated as the product of piston area and stroke. The capacity described by engine manufacturers in cc is the swept volume of the engine. LDLAVs

24/ ×=×= π

Clearance volume (VC): The nominal volume of the space on the combustion side of the piston at top dead center. Cylinder volume: The sum of swept volume and clearance volume. cs VVV +=

Compression ratio (CR): The numerical value of the cylinder volume divided by the numerical value of clearance volume. cVVCR /=

Theory

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Bore D

CrankshaftCrankcase

Crank

Crank pin

Connecting rod

Cylinder

Bottom dead center B.D.C.

Piston

Gudgeon or wrist pin

Top dead center T.D.C.

Intake or suction manifold

Suction valve

Exhaust manifold

Exhaust valve

Cylinder head

Stroke volume.Vs

Clearance volume.Vc

Cylinder volume’V’

Important positions and volumes in reciprocating engine Four stroke cycle engine In four-stroke cycle engine, the cycle of operation is completed in four strokes of the piston or two revolutions of the crankshaft. Each stroke consists of 1800 of crankshaft rotation and hence a cycle consists of 7200 of crankshaft rotation. The series of operation of an ideal four-stroke engine are as follows: 1. Suction or Induction stroke: The inlet valve is open, and the piston travels

down the cylinder, drawing in a charge of air. In the case of a spark ignition engine the fuel is usually pre-mixed with the air.

2. Compression stroke: Both valves are closed, and the piston travels up the cylinder. As the piston approaches top dead centre (TDC), ignition occurs. In the case of compression ignition engines, the fuel is injected towards the end of compression stroke.

3. Expansion or Power or Working stroke: Combustion propagates throughout the charge, raising the pressure and temperature, and forcing the piston down. At the end of the power stroke the exhaust valve opens, and the irreversible expansion of the exhaust gases is termed ‘blow-down’.

4. Exhaust stroke: The exhaust valve remains open, and as the piston travels up the cylinder the remaining gases are expelled. At the end of the exhaust stroke, when the exhaust valve closes some exhaust gas residuals will be left; these will dilute the next charge.

Two stroke cycle engine In two stroke engines the cycle is completed in two strokes of piston i.e. one revolution of the crankshaft as against two revolutions of four stroke cycle engine. The two-stroke cycle eliminates the separate induction and exhaust strokes.

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1. Compression stroke: The piston travels up the cylinder, so compressing the trapped charge. If the fuel is not pre-mixed, the fuel is injected towards the end of the compression stroke; ignition should again occur before TDC. Simultaneously under side of the piston is drawing in a charge through a spring-loaded non-return inlet valve.

2. Power stroke: The burning mixture raises the temperature and pressure in the cylinder, and forces the piston down. The downward motion of the piston also compresses the charge in the crankcase. As the piston approaches the end of its stroke the exhaust port is uncovered and blowdown occurs. When the piston is at BDC the transfer port is also uncovered, and the compressed charge in the crankcase expands into the cylinder. Some of the remaining exhaust gases are displaced by the fresh charge; because of the flow mechanism this is called ‘loop scavenging'. As the piston travels up the cylinder, the piston closes the first transfer port, and then the exhaust port is closed.

Performance of I.C.Engines Indicated thermal efficiency (ηt): Indicated thermal efficiency is the ratio of

energy in the indicated power to the fuel energy. FuelEnergyowerIndicatedPt /=η

100)/()/(

3600)((%) ××

×=

KgKJalueCalorificVHrKgFuelFlowKWowerIndicatedP

tη

Brake thermal efficiency (ηbth): A measure of overall efficiency of the engine is given by the brake thermal efficiency. Brake thermal efficiency is the ratio of energy in the brake power to the fuel energy.

FuelEnergyBrakePowerbth /=η

100)/()/(

3600)((%) ××

×=

KgKJalueCalorificVHrKgFuelFlowKWBrakePower

bthη

Mechanical efficiency (ηm): Mechanical efficiency is the ratio of brake horse power

(delivered power) to the indicated horsepower (power provided to the piston). owerIndicatedPBrakePowerm /=η

and Frictional power = Indicated power – Brake power Following figure gives diagrammatic representation of various efficiencies,

Energy lost in exhaust, coolant, and radiation

Energy lost in friction, pumping etc.

Energy in fuel (A)

IP (B)

BP (C)

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Indicated thermal efficiency = B/A Brake thermal efficiency = C/A Mechanical efficiency = C/B Volumetric efficiency (ηv): The engine output is limited by the maximum amount of air that can be taken in during the suction stroke, because only a certain amount of fuel can be burned effectively with a given quantity of air. Volumetric efficiency is an indication of the ‘breathing’ ability of the engine and is defined as the ratio of the air actually induced at ambient conditions to the swept volume of the engine. In practice the engine does not induce a complete cylinder full of air on each stroke, and it is convenient to define volumetric efficiency as: Mass of air consumed ηv (%) = --------------------------------------------------------------------------

mass of flow of air to fill swept volume at atmospheric conditions

10060)/(/)()(4/

)/((%) 332 ××××××

=mKgAirDenNoofCylnRPMNmLD

HrKgAirFlowv π

η

Where n= 1 for 2 stroke engine and n= 2 for 4 stroke engine. Air flow: For air consumption measurement air box with orifice is used.

3600/24/)/( 2 ×××××××= dendendenwaterd AAWhgDCHrKgAitFlow π

Where Cd = Coefficient of discharge of orifice D = Orifice diameter in m g = Acceleration due to gravity (m/s2) = 9.81 m/s2 h = Differential head across orifice (m of water) Wden = Water density (kg/m3) =@1000 kg/m3 Wair = Air density at working condition (kg/m3) = p/RT Where p= Atmospheric pressure in kgf/m2 (1 Standard atm. = 1.0332X104 kgf/m2) R= Gas constant = 29.27 kgf.m/kg0k T= Atmospheric temperature in 0k Specific fuel consumption (SFC): Brake specific fuel consumption and indicated

specific fuel consumption, abbreviated BSFC and ISFC, are the fuel consumptions on the basis of Brake power and Indicated power respectively.

Fuel-air (F/A) or air-fuel (A/F) ratio: The relative proportions of the fuel and air in the engine are very important from standpoint of combustion and efficiency of the engine. This is expressed either as the ratio of the mass of the fuel to that of the air or vice versa.

Calorific value or Heating value or Heat of combustion: It is the energy released per unit quantity of the fuel, when the combustible is burned and the products of combustion are cooled back to the initial temperature of combustible mixture. The heating value so obtained is called the higher or gross calorific value of the fuel. The lower or net calorific value is the heat released when water in the products of combustion is not condensed and remains in the vapour form.

Power and Mechanical efficiency: Power is defined as rate of doing work and equal to the product of force and linear velocity or the product of torque and

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angular velocity. Thus, the measurement of power involves the measurement of force (or torque) as well as speed. The power developed by an engine at the output shaft is called brake power and is given by Power = NT/60,000 in kW where T= torque in Nm = WR W = 9.81 * Net mass applied in kg. R= Radius in m N is speed in RPM

Mean effective pressure and torque: Mean effective pressure is defined as a hypothetical pressure, which is thought to be acting on the piston throughout the power stroke. Power in kW = (Pm LAN/n 100)/60 in bar where Pm = mean effective pressure L = length of the stroke in m A = area of the piston in m2

N = Rotational speed of engine RPM n= number of revolutions required to complete one engine cycle n= 1 (for two stroke engine) n= 2 (for four stroke engine) Thus we can see that for a given engine the power output can be measured in terms of mean effective pressure. If the mean effective pressure is based on brake power it is called brake mean effective pressure (BMEP) and if based on indicated power it is called indicated mean effective pressure (IMEP).

100)/(60)()(××××

×=

NoOfCylnNALKWBrakePowerbarBMEP

100)/(60)()(×××××

=NoOfCylnNALKWowerIndicatedPbarIMEP

Similarly, the friction means effective pressure (FMEP) can be defined as FMEP= IMEP – BMEP

Basic measurements The basic measurements, which usually should be undertaken to evaluate the performance of an engine on almost all tests, are the following: 1 Measurement of speed Following different speed measuring devices are used for speed measurement. 1 Photoelectric/Inductive proximity pickup with speed indicator 2 Rotary encoder 2 Measurement of fuel consumption I) Volumetric method: The fuel consumed by an engine is measured by determining the volume flow of the fuel in a given time interval and multiplying it by the specific gravity of fuel. Generally a glass burette having graduations in ml is used for volume flow measurement. Time taken by the engine to consume this volume is measured by stopwatch. II) Gravimetric method: In this method the time to consume a given weight of the fuel is measured. Differential pressure transmitters working on hydrostatic head principles can used for fuel consumption measurement. 3 Measurement of air consumption Air box method: In IC engines, as the air flow is pulsating, for satisfactory measurement of air consumption an air box of suitable volume is fitted with orifice.

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The air box is used for damping out the pulsations. The differential pressure across the orifice is measured by manometer and pressure transmitter. 4 Measurement of brake power Measurement of BP involves determination of the torque and angular speed of the engine output shaft. This torque-measuring device is called a dynamometer. The dynamometers used are of following types: I) Rope brake dynamometer: It consists of a number of turns of rope wound around the rotating drum attached to the output shaft. One side of the rope is connected to a spring balance and the other to a loading device. The power is absorbed in friction between the rope and the drum. The drum therefore requires cooling. Brake power = ∏DN (W-S)/60,000 in kW where D is the brake drum diameter, W is the weight and S is the spring scale reading. II) Hydraulic dynamometer: Hydraulic dynamometer works on the principal of dissipating the power in fluid friction. It consists of an inner rotating member or impeller coupled to output shaft of the engine. This impeller rotates in a casing, due to the centrifugal force developed, tends to revolve with impeller, but is resisted by torque arm supporting the balance weight. The frictional forces between the impeller and the fluid are measured by the spring-balance fitted on the casing. Heat developed due to dissipation of power is carried away by a continuous supply of the working fluid usually water. The output (power absorbed) can be controlled by varying the quantity of water circulating in the vortex of the rotor and stator elements. This is achieved by a moving sluice gate in the dynamometer casing. III) Eddy current dynamometer: It consists of a stator on which are fitted a number of electromagnets and a rotor disc and coupled to the output shaft of the engine. When rotor rotates eddy currents are produced in the stator due to magnetic flux set up by the passage of field current in the electromagnets. These eddy currents oppose the rotor motion, thus loading the engine. These eddy currents are dissipated in producing heat so that this type of dynamometer needs cooling arrangement. A moment arm measures the torque. Regulating the current in electromagnets controls the load. Note: While using with variable speed engines sometimes in certain speed zone the dynamometer operating line are nearly parallel with engine operating lines which result in poor stability. 5 Measurement of indicated power There are two methods of finding the IHP of an engine. I) Indicator diagram: A dynamic pressure sensor (piezo sensor) is fitted in the cylinder head to sense combustion pressure. A rotary encoder is fitted on the engine shaft for crank angle signal. Both signals are simultaneously scanned by an engine indicator (electronic unit) and communicated to computer. The software in the computer draws pressure crank-angle and pressure volume plots and computes indicated power of the engine. Conversion of pressure crank-angle plot to pressure volume plot:

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The figure shows crank-slider mechanism. The piston pin position is given by

φθ coscos lrx +=

From figure φθ sinsin lr = and recalling φφ 2sin1cos −=

( ){ }

−+= θθ 22 sin1cos lrrlrx

The binomial theorem can be used to expand the square root term:

[ ]{ }...sin)/(81sin)/(211/cos 4422 +−−+= θθθ lrlrrlrx ….1

The powers of sin θ can be expressed as equivalent multiple angles:

θθ 2cos2/12/1sin2 −=

θθθ 4cos8/12cos2/18/3sin 4 +−= …….2 Substituting the results from equation 2 in to equation 1 gives

( ) ( )[ ]{ }...4cos8/12cos2/18/3)/(812cos2/12/1)/(211/cos 42 ++−−−−+= θθθθ lrlrrlrx

The geometry of the engine is such that ( )2/ lr is invariably less than 0.1, in which

case it is acceptable to neglect the ( )4/ lr terms, as inspection of above equation shows that these terms will be at least an order of magnitude smaller than

( )2/ lr terms. The approximate position of piston pin end is thus: ( )[ ]{ }θθ 2cos2/12/1)/(2

11/cos 2 −−+= lrrlrx

Where r =crankshaft throw and l = connecting rod length. Calculate x using above equation; then )( xrl −+ shall give distance traversed by

piston from its top most position at any angle θ II) Morse test: It is applicable to multi-cylinder engines. The engine is run at desired speed and output is noted. Then combustion in one of the cylinders is stopped by short circuiting spark plug or by cutting off the fuel supply. Under this condition other cylinders “motor” this cylinder. The output is measured after adjusting load on the engine to keep speed constant at original value. The difference in output is measure of the indicated power of cut-out cylinder. Thus for each cylinder indicated power is obtained to find out total indicated power.

VCR Engines The standard available engines (with fixed compression ratio) can be modified by providing additional variable combustion space. This is done by welding a long hollow sleeve with internal threads to the engine head. A threaded plug is inserted in the sleeve to vary the combustion chamber volume. With this method the compression ratio can be changed within designed range.

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Calculations • Brake power (kw):

1000602xNTBP π

=

60000

)(2 WxRNπ=

60000

)81.9(785.0 xArmlengthWxxRPMx=

6075xTxNBHP =

• Brake mean effective pressure (bar):

100)/(4/60

2 xNoOfCylxnNxLxxDBPxBMEP

π=

n = 2 for 4 stroke n = 1 for 2 stroke

• Indicated power (kw) :From PV diagram

X scale (volume) 1cm = ..m3 Y scale (pressure) 1cm = ..bar

Area of PV diagram = ..cm2

100000)(// ×××= orYscalefactorXscalefactagramAreaofPVdiNmcylcycleworkdone

100060

)/(//×

××=

NoOfCylnNcylcycleworkdoneIP

• Indicated mean effective pressure (bar):

100)/(4/

602 xNoOfCylxnNxLxxD

IPxIMEPπ

=

• Frictional power (kw):

BPIPFP −= BHPIHPFHP −= FHPIHPBHP −=

• Brake specific fuel consumption (Kg/kwh):

BPhrkgFuelflowInBSFC /

=

• Brake Thermal Efficiency (%):

CalValhrKgFuelFlowIn

BPBThEff×

××=

/1003600

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FuelHPBHPORMechEffIThEffBThEff

100×

=

• Indicated Thermal Efficiency (%):

CalValhrKgFuelFlowIn

IPIThEff×

××=

/1003600

MechEff

BThEffIThEff 100×=

• Mechanical Efficiency (%):

IP

BPMechEff 100×=

• Air flow (Kg/hr):

AdenAdenWdenghdCdAirFlow ×××××= 3600)/(24/ 2π

• Volumetric Efficiency (%):

lAirFlowTheoretica

AirFlowVolEff 100×=

AdenNoOfCylnNStrokeD

AirFlow××××××

×=

60)/(4/100

2π

• Air fuel ratio:

FuelFlowAirFlowFA =/

• Heat Balance (KJ/h):

a) CalValFuelFlowedbyFuelHeatSuppli ×=

b) 3600×= BPulWorklentToUsefHeatEquiva

edByFuelHeatSuppli

ulWorklentToUsefHeatEquivaulWorkInlentToUsefHeatEquiva 100% ×=

C) )12(3 TTWCFateretCoolingWHeatInJack P −××=

edByFuelHeatSuppli

ateretCoolingWHeatInJackaterInetCoolingWHeatInJack 100% ×=

d) Heat in Exhaust (Calculate CPex value):

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kKgKJTTFFTTWCF

exC PP

0/..)65()21()34(4

−×+−××

=

Where, Cpex Specific heat of exhaust gas kJ/kg0K

Cpw Specific heat of water kJ/kg0K

F1 Fuel consumption kg/hr F2 Air consumption kg/hr F4 Calorimeter water flow kg/hr T3 Calorimeter water inlet temperature 0K T4 Calorimeter water outlet temperature 0K T5 Exhaust gas to calorimeter inlet temp. 0K T6 Exhaust gas from calorimeter outlet temp. 0K )3()21()/( TambTexCFFhKJustHeatInExha P −××+=

edByFuelHeatSuppliustHeatInExhaustHeatInExha 100% ×

=

e) Heat to radiation and unaccounted (%)

(%)}(%)(%){(%)100(

ustHeatToExhaateretCoolingWHeatInJackulWorklentToUsefHeatEquivaedByFuelHeatSuppli

++−=

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Installing DAQMX Software for Windows XP

Insert NI DAQMX software CD 1 of 2

Click on Install Software

Software

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Click Next.

Click Next

Select LabView 8.2 support and Click Next

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Click Next

Select I accept and Click next

Select I accept and Click next

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Click Next

Insert Disk 2 of 2

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Click Next

Click On Restart

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Installing USB-6210 Driver

1. Connect USB 6210 to Computer USB port. Following screen shall appear

2 Select No, not this time & click next

3 Select install the software automatically (Recommended) & click next

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6. Click Next

6. Click Finish

Conducting Test Run

• Confirm USB cable (From USB-6210 driver to computer USB port) are connected

and engine panel is switched on.

• Click “EngineSoftLV” and then “Run”.

• Click on “File open” screen.

• Click on “Config Setup” screen.

• The current parameter values are displayed on the screen. Note that speed =0 as

engine is not started. Confirm correctness of other parameter values

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(temperatures and load) with the values displayed on multipoint digital voltmeter

provided on control panel. If some problem is noticed at this stage resolve it

before starting the engine.

• Start the engine and observe the values displayed on the screen. A typical screen

is shown below:

• Wait for @ 3 minutes to achieve steady state. Change the fuel cock to

“measuring” and press “Log” for data logging.

After one minute software will prompt for file name. Enter the file name (file name should not start with numeric character).

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1 Study of engine performance (Manual mode) Object To study the performance of 1 cylinder, 4 stroke, Diesel engine connected to eddy current dynamometer in manual mode Procedure

• Ensure cooling water circulation for eddy current dynamometer and piezo sensor, engine and calorimeter.

• Start the set up and run the engine at no load for 4-5 minutes. • Gradually increase the load on the engine by rotating dynamometer loading

unit. • Wait for steady state (for @ 3 minutes) and collect the reading as per

Observations provided in “Cal224” worksheet in “Engine.xls”. • Gradually decrease the load. • Fill up the observations in “Cal224” worksheet to get the results and

performance plots.

Experiments

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2 Study of engine performance (Computerized mode) Object To study the performance of 1 cylinder, 4 stroke, Diesel engine connected to eddy current dynamometer in computerized mode. Procedure

• Ensure cooling water circulation for eddy current dynamometer and piezo sensor, engine and calorimeter.

• Start the set up and run the engine at no load for 4-5 minutes. • Switch on the computer and run “EnginesoftLV”. Confirm that the

EnginesoftLV configuration data is as given below. • Gradually increase load on the engine. • Wait for steady state (for @ 3 minutes) and log the data in the

“EnginesoftLV”. • Gradually decrease the load. • View the results and performance plots in “EnginesoftLV”.

Enginesoft Configuration data Set up constants: No of PO cycles : 5 Cylinder pressure plot ref : 2010 Fuel read time : 60 sec Fuel factor : 0.012 kg/Volt Orifice diameter : 20 mm Dynamometer arm length : 185 mm Engine and set up details: Engine power : 5.2 Kw Engine max speed : 1500 RPM Cylinder bore : 87.5mm Stroke length : 110mm Connecting rod length : 234mm Compression ratio : 17.5 Compression type : FCR Stoke type : Four No. of cylinders : One Speed type : Constant Cooling type : Water Dynamometer type : Eddy current Indicator used type : Cylinder pressure Data acquisition device : USB-6210 Calorimeter used : Pipe in pipe Theoretical constants: Fuel density : 830 kg/m^3 Calorific value : 42000 kJ/kg Orifice coefficient of discharge : 0.60 Sp heat of exhaust gas : 1.1 kJ/kg-K Max sp heat of exhaust gas : 1.25 kJ/kg-K Min sp heat of exhaust gas : 1.1 kJ/kg-K Specific heat of water : 4.186 kJ/kg-K Water density : 1000 kg/m^3 Ambient temperature : 300C Sensor range Exhaust gas temp. trans. (Engine) : 0-1200 C

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Air flow transmitter : (-)250 - 0 mm WC Fuel flow DP transmitter : 0-500 mm WC Load cell : 0-50 kg Sensor signal range (input for interface) : 1-5 V Cylinder pressure transducer : 0-345.5 bar

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3 Study of Pressure volume plot and indicated power Object To draw pressure–crank angle plot, pressure volume plot and calculate indicated power of the engine. Procedure

• Run the engine set up at any load and store the observation in a data file or use previously stored data file in “EnginesoftLV” for indicated power calculation.

• Export the data file in ms excel worksheet. The pressure crank angle and volume data is available in excel.

• Refer “IP_cal” worksheet in “Engine.xls”. The sample worksheet shows pressure crank angle plot, pressure volume plot and indicated power calculation. The worksheet is for single cylinder four stroke engine with 180 observations per revolution.

• Copy the pressure readings from exported data file in to the IP _cal worksheet at the respective crank angle.

• Observe the Pressure crank angle diagram, pressure volume diagram and indicated power value. (The calculations are explained in theory part).

4 Study of valve timing diagram Object To study valve timing diagram

TDC

BDC

Exh

aust

Com

pres

sion Expan sion

Induction

2 4

1 53

1 Inlet valve opensbefore TDC : 4.52 Inlet valve closes after BDC : 35.53 Fuel injection starts before TDC : 234 Exhaust valve opens before BDC : 35.55 Exhaust valve closes after TDC : 4.5

0

0

0

0

0

Valve Timing DiagramEngine Kirloskar (TV1) 1Cylinder, 4Stroke, Diesel

Procedure • Switch off the electric supply of the panel box • Open the cover on the engine head to see the rocker arms. • Lift up the decompression lever.

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• Note the TDC mark provided on the flywheel. (Also refer the valve timing diagram).

• Slowly rotate the flywheel in clockwise direction looking from dynamometer side. Identify inlet valve and exhaust valve rocker arms

• Observe the movement of rocker arms and understand the valve opening and closing.

To observe fuel injection it is necessary to remove fuel injector.

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Wiring diagram

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Rotameter (PG series) Rotameter works on the principle of variable area. Float is free to move up & down in a tapered measuring glass tube. Upward flow causes the float to take up a position in which the buoyancy forces and the weight are balanced. The vertical position of the float as indicated by scale is a measurement of the instantaneous flow rate.

Technical specifications Model PG-1 to 21 Make Eureka Industrial Equipments Pvt. Ltd. Flow Rate Max. 4000 to 40000 Lph Packing/Gaskets Neoprene Measuring tube Borosilicate glass Float 316SS Cover Glass Accuracy +/-2% full flow Range ability 10:1 Scale length 175-200mm. Max. Temp. 2000C Connection Flanged and Threaded, Vertical Principle of operation The rotameter valves must be opened slowly and carefully to adjust the desired flow rate. A sudden jumping of the float,

which may cause damage to the measuring tube, must be avoided.

Edge

Fig.1

The upper edge of the float as shown in fig. 1 indicates the rate of flow. For alignment a line marked R.P. is provided on the scale which should coincide with the red line provided on measuring tube at the bottom. Maintenance When the measuring tube and float become dirty it is necessary to remove the tube and clean it with a soft brush, trichloroethylene or compressed air. Dismantling of the measuring tube • Shut off the flow. • Remove the front and rear covers. • Unscrew the gland adjusting screws, and push the gland upwards incase of bottom

gland and downwards incase of top gland. Then remove the glass by turning it to

Components’ manuals

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and fro. Care should be taken, not to drop down the glands. Float or float retainers. The indicating edge of the float should not be damaged.

Fitting of the measuring tube Normally the old gland packing is replaced by new ones while fitting back the measuring tube. • Put the glands first in their position and then put the packing on the tube. • Insert the tube in its place. • Push the glands downwards and upwards respectively and fix them with the gland

adjusting screws. • Tighten the gland adjusting screws evenly till the gap between the gland and the

bottom plate is approximately 1mm. In case, after putting the loflometer into operation, still there is leakage, then tighten the gland adjusting screw till the leakage stops.

• Fix the scale, considering the remark given in the test report. • Fix the front and rear covers. Troubleshooting Problem Check Leakage on glands Replace gland packing Showing high/low flow rate than expected

Consult manufacturers

Showing correct reading initially but starts showing high reading after few days

Replace float Incase of gases, check also leakage

Showing correct reading initially but starts showing high reading after some months.

Clean the rotameter by suitable solvent or soft brush

Fluctuation of float Maintain operating pressure as mentioned in test report.

Frequent breakage of glass tube Use loflometer to accommodate correct flow rate. Maintain operating pressure below pressure rating of the tube. Check piping layout.

Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. Eureka Industrial Equipments Pvt. Ltd. 17/20, Royal Chambers, Paud Road, Pune – 411 038. Email: eureka.equip@gems.vsnl.net.in

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Load indicator

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Air flow transmitter

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Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. WIKA Instruments Ltd. Garmany. Web: www.wika.de

Wika Instruments India Pvt. Ltd. Plot No. 40, GatNo. 94+100, high Cliff Ind. Estate, Village Kesnand, Pune 412207

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Load cell Introduction

Load cell are suitable use for static & dynamic weighing, bin/hopper weighing, force measurement, scales and electro-mechanical conversion kit. Constructed body of special high alloy steel. Approved for group I, IIA, IIB, & IIC applications and meets temperature class T4. Technical specifications

Make Sensortronics Model 60001 Type ‘S’ Beam, Universal Capacity 0 – 50Kg Mounting thread M10 x 1.25mm Full scale output (mV/V) 3.00 Tolerance on output (FSO) +/-0.25% Zero balance (FSO) +/-0.1mV/V Non-linearity (FSO) <+/-0.025% Hysteresis (FSO) <+/-0.020% Non-repeatability <+/-0.010% Creep (FSO) in 30 min <+/-0.020% Operating temperature range -200C to +700C Rated excitation 10V AC/DC Maximum excitation 15V AC/DC Bridge resistance 350 Ohms (Nominal) Insulation resistance >1000 Meg ohm @ 50VDC Span / 0C (of load) +/-0.001% Zero / 0C (of FSO) +/-0.002% Combined error (FSO) <+/-0.025% Safe overload (FSO) 150% Ultimate overload (FSO) 300% Protection class IP 67 Overall dimensions 51 L x 20 W x 76 H mm Weight 380 gm Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. Sensortronics Sanmar Ltd. 38/2A, Old Mahabalipuram Road, Perungudi, Chennai – 600 096. E-mail: KBS@SANMARGROUP.com

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Encoder Technical specifications Make Kubeler Model 8.3700.1321.0360 Supply voltage 5-30VDC Output Push pull (AA,BB,OO) PPR 360 Outlet Cable type axial Encoder Diameter Dia. 37, Shaft size Dia.6mm x length12mm Weight 120 gm Manufacturer’s address If you need any additional details, spares or service

support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. Kuebler – Germany

Indian supplier: Rajdeep Automation Pvt. Ltd. Survey No. 143, 3rd floor, Sinhgad Road, Vadgaon Dhayari, Pune – 411 041.

Piezo sensor Introduction These miniature sensor series are intended for general purpose pressure measurements. Models HSM111A22 and M108A02 are designed for applications where acceleration compensation is not required. Other applications for these sensors include the monitoring of pulsating pneumatic and hydraulic pressures in R & D and industrial applications. This versatile transducer series is designed for dynamic measurement of compression, combustion, explosion, pulsation, cavitations, blast, pneumatic, hydraulic, fluidic and other such pressures. Technical specifications Sensor name Hydraulic pressure transducer With built in amplifier Make PCB Piezotronics, INC. Model M108A02 Range, FS (5V output) 10000 psi Useful range (10V output) 20000 psi Maximum pressure 50000 psi Resolution 0.4 psi Sensitivity 0.5 mV/psi Resonant frequency 300 kHz Rise time 2 µs Discharge time constant 1000 s Linearity (zero based BSL) 2 % Output impedance 100 ohms

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Acceleration sensitivity 0.01 psi/g Temperature coefficient 0.03 %/0F Temperature range -100 to +250 0F Vibration 2000 g peak Shock 20000 g peak Sealing Hermetic welded Excitation (Constant current) 2 to 20 mA Voltage to current regulator +18 to 28 VDC Sensing geometry Compression Sensing element Quartz Housing material C-300 Diaphragm C-300 Electrical connector 10-32 coaxial jack Mounting thread M10 x 0.1pitch Weight 12 gm Cable model 002C20 white coaxial cable Technical specifications Sensor name Dynamic pressure transducer

With built in amplifier Make PCB Piezotronics, INC. Model M111A22 Range, FS (5V output) 5000 psi Useful range (10V output) 10000 psi Maximum pressure 15000 psi Resolution 0.1 psi Sensitivity 1 mV/psi Resonant frequency 400 kHz Rise time 2 µs Discharge time constant 500 s Low frequency response (-5%) 0.001 Hz Linearity (Best straight line) 2 % Output polarity Positive Output impedance 100 ohms Output bias 8-14 volt Acceleration sensitivity 0.002 psi/g Temperature coefficient 0.03 %/0F Temperature range -100 to +275 0F Flash temperature 3000 0F Vibration / Shock 2000 / 20000 g peak Ground isolation No (2) Excitation (Constant current) 2 to 20 mA Voltage to current regulator +18 to 28 VDC Sensing geometry Compression Sensing element Quartz Housing material 17.4 SS Diaphragm Invar Sealing Welded hermetic Electric connector 10-32 coaxial jack Mounting thread M7 x 0.75 pitch Weight (with clamp nut) 6 gm Cable model 002C20 white coaxial cable

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Principle of operation 1. Hydraulic pressure transducer: Unlike conventional diaphragm type sensors,

the 108A is pressure sensitive over the entire frontal area. For this reason, extra care should be exercised to avoid bottoming in mounting hole when recessed mounted and especially when mounting into existing mounting ports. A torque wrench should be used to monitor the mounting torque valve when installing the series 108A.

• Mounting in existing recessed ports: Before installing the sensor in previously used mounting ports, clean off residue from previous tests. This can be accomplished by hand reaming the required size reamer. During prolonged testing, should waveform distortion occur, Remove sensor and remove reside.

• Flash Temperature Effects: The ceramic coating on the diaphragm of these sensors should render the flash thermal effect insignificant in most cases, especially when recessed mounted. However, if more protection from flash thermal effects is required with the recessed mount, the passage can be filled with silicone grease (DC-4 or equivalent). Several layers of black vinyl electrical tape directly on the diaphragm have proven effective in many cases. Flash temperature effects are usually longer term and will show up as baseline shift long after the event to be measured has passed. For flush mount installations, a silicone rubber coating approximately 0.010” thick can be effective. General electric RTV type 106 silicone rubbers are recommended.

2. Dynamic pressure transducer: It is necessary only to supply the sensor with a 2 to 20 mA constant current at +20 to +30 VDC through a current – regulating diode or equivalent circuit. Most of the signal conditioners manufactured by PCB have adjustable current features allowing a choice of input currents from 2 to 20 mA. In general, for lowest noise (best resolution), choose the lower current ranges. When driving long cables (to several thousand feet), use the higher current, up to 20 mA maximum.

Switch power on and observe reading of bias monitoring voltmeter on front panel of power unit.

• Flash Temperature Protection Where flash temperatures such as those generated by combustion processes are present, it may be necessary to thermally insulate the diaphragm to minimize spurious signals generated by these effects. Common black vinyl electrical tape has been found to be an effective insulating material in many cases. One or more layers may be used across the end of the diaphragm without affecting response or sensitivity. A silicone rubber coating approximately 0.010 inches thick has also been proven effective in many applications. General electric RTV type 106 silicone rubbers are recommended.

• Low Frequency Response • The discharge time constant of the sensor. • If AC – coupled at the power unit, the coupling time constant.

Depending upon the sensor’s built-in discharge time constant, repetitive output signals slowly or rapidly move toward a stable condition where the average signal level corresponds to a zero voltage position. In this position, the area contained by the signal above zero is equalized with the area below zero. Such output signal behavior is typical of an AC-coupled system. Since the signal output from the sensor is inherently AC coupled, any static pressure influence applied to the unit will decay away according to the nature of the system’s discharge time constant.

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Troubleshooting Problem Check No signal • Remove sensor and clean by dampened cloth Sensor damaged or ceases to operate

• Return the equipment to company for repair

Calibration 1. Piezoelectric sensors are dynamic devices, but static calibration techniques

can be employed if discharge time constants are sufficiently long. Generally, static calibration methods are not employed when testing sensors with a discharge time constant that is less than several hundred seconds.

2. Direct couple the sensor to the DVM readout using a T-connector from the “Xducer” jack or use the model 484B in the calibrate mode.

3. Apply pressure with a dead weight tester and take reading quickly. Release pressure after each calibration point.

4. For shorter TC series, rapid step functions of pressure are generated by a pneumatic pressure pulse calibrator or dead weight tester and readout is by recorder or storage oscilloscope.

Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. PCB Piezotronics, Inc. 3425 Walden Avenue, Depew, New York 14043-2495. E-mail: pressure@pcb.com Web: www.pcb.com

Indian supplier: Structural soluction (India) Pvt. Ltd.

Eddy Current Dynamometer Introduction The AG Series eddy current dynamometers designed for the testing of engines up to 400kW (536bhp) and may be used with various control systems. The dynamometer is bi-directional. The shaft mounted finger type rotor runs in a dry gap. A closed circuit type cooling system permits for a sump. Dynamometer load measurement is from a strain gauge load cell and speed measurement is from a shaft mounted sixty tooth wheel and magnetic pulse pick up. Technical specifications Model AG10 Make Saj Test Plant Pvt. Ltd. End flanges both side Cardon shaft model 1260 type A Water inlet 1.6bar Minimum kPa 160 Pressure lbf/in2 23 Air gap mm 0.77/0.63 Torque Nm 11.5 Hot coil voltage max. 60 Continuous current amps 5.0

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Cold resistance ohms 9.8 Speed max. 10000rpm Load 3.5kg Bolt size M12 x 1.75 Weight 130kg Technical specifications Model AG20 Make Saj Test Plant Pvt. Ltd. End flanges both side Cardon shaft model 1260 type A Water inlet 1.6bar Minimum kPa 160 Pressure lbf/in2 23 Air gap mm 0.88/0.72 Torque Nm 11.5 Hot coil voltage max. 60 Continuous current amps 5.0 Cold resistance ohms 9.8 Speed max. 10000rpm Load 5.0Kg Bolt size M12 x 1.75 Weight 220Kg Technical specifications Model AG80 Make Saj Test Plant Pvt. Ltd. End flanges both side Cardon shaft model 1260 type A Water inlet 1.0bar Minimum kPa 100 Pressure lbf/in2 14.5 Air gap mm 1.047/0.855 Torque Nm 11.5 Hot coil voltage max. 75 Continuous current amps 5.0 Cold resistance ohms 12.8 Speed max. 9000rpm Load 40kg Bolt size M16 x 2.00 Weight 330kg Principle of operation 1. The dynamometer unit comprises basically a rotor mounted on a shaft running in bearings which rotates within a casing supported in ball bearing trunnions which form part of the bed plate of the machine. 2. Secured in the casing are two field coils connected in series. When these coils are supplied with a direct current (DC) a magnetic field is created in the casing across the air gap at either side of the rotor. When the rotor turns in this magnetic field, eddy currents are induced creating a breaking effect between the rotor and casing. The rotational torque exerted on the casing is measured by a strain gauge load cell incorporated in the restraining linkage between the casing and dynamometer bed plate. 3. To prevent overheating of the dynamometer a water supply pressurized to minimum indicated in specification is connected to a flanged inlet on the bed plate. Water passes from the inlet to the casing via a flexible connection; permitting

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movement of the casing. Water passes through loss (Grooved) plates in the casing positioned either side of the rotor and absorbs the heat generated. 4. Heated water discharges from the casing through a flexible connection to an outlet flange on the bed plate. An orifice plate is fitted at the bed plate outlet and a DIFFERENTIAL pressure switch is connected to water passages either side of the plate. The switch detects a COOLANT FLOW and will function with a free discharge or under back pressure. Troubleshooting Problem Check Calibration of dynamometer not coming in accuracy limit

• Remove the obstruction for the free movement of casing

• Calibrate the weights from authorized source.

• Maintain constant water flow • Clean & lubricate properly with

grease • Bearings clean & refit properly • Load cell link tighten properly • Clean & refit trunnion bearings

Vibrations to dynamometer • Dynamometer foundation bolts tighten properly

• Arrest engine vibrations Abnormal noise • Cardon shaft cover secure properly

• Align guard properly • Replace rotor if warped • Replace main bearing

Loss plate temperature high • Check correct water flow • De-scale with suitable solution • Clear off water passages

Bearing temperature high • Grease with proper brand • Remove excess grease & avoid over

grease • Use specified grease and do not mix

two types of grease • Clear the drain • Replace the bearings • Replace shaft & coupling

Dynamometer not rotating • Replace bearings • Replace rotor / loss plates after

checking Water leakages at various locations • Replace casing ‘o’ rings

• Loss plates bolts tighten properly • Replace loss plate ‘o’ rings • Casing plugs tighten properly • Replace pipe ‘o’ rings • Pressure switch connection tighten

properly Calibration

1. It is important to note that the torque applied during calibration is: Nm = applied weight (kg) x g x arm length (m) S.I. units Lbf.ft = applied weight (ibf) x arm length (ft) Imperial units Kg.m = applied weight (kg) x arm length (m) MKS units

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2. Switch on the mains electrical supply to the control equipment at least 30 minutes before starting the calibration procedure.

3. Turn on the water supply and allow water to flow through the dynamometer at normal operating pressure.

4. With no load applied to the dynamometer ensure that the load indicator on the control unit reads “ZERO” if necessary adjust the control equipment until “ZERO” is indicated.

Operation 1. New dynamometers are run in before delivery to ensure that all components

run smoothly and grease is evently distributed within the shaft bearings. 2. The dynamometer has been calibrated the power developed by the engine on

test may be calculated using the following formula:

Power (kW) = unitsIinSRadiansxSpeedNmTorque ..1000

.)sec/()(

Power (hp) = itsimperialuninRadiansxSpeedlbfftTorque .550

.)sec/()(

3. The dynamometer will be calibrated in either Imperial or S.I. units or MKS as specified.

Power = kWN

Where N = Shaft speed in rev/min W = Torque (Indicated on torque indicator)

K = Constant dependant on units of power and torque

Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. Saj Test Plant Pvt. Ltd. 72-76, Mundhwa, Pune Cantonment, Pune – 411 036. Email:sajdyno@vsnl.com

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Load/Temperature indicator

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Differential Pressure Transmitter Introduction

The model EJA110A pressure transmitter measures the flow rates and the pressure of the liquids, gases, and steam, and also liquid levels. Technical specifications Model EJA110A-DMS5A-92NN Make Yokogawa Output signal 4 – 20mA DC with digital communication (Linear) Measurement span 1 to 100kPa (100 to 10000mmH2O) Calibration range 0 – 200, 0 – 500 mmH2O Wetted parts material Body – SCS14A, Capsule – SUS316L

Process connections without process connector (1/4BSP body connection) Bolts and nuts material SCM 435 Installation Horizontal impulse piping left side high pressure Electrical connection 1/2NPT female Cover ‘O’ rings Buna-N Supply 10 to 24VDC Process temperature limit -40 to 120 0C Housing Weather proof Weight 3.9Kg Manufacturer’s address If you need any additional details, spares or service support for this unit you may directly communicate to the manufacturer / Dealer / Indian Supplier. Yokogawa Electrical Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750, Japan.

Indian supplier: Yokogawa Blue Star Ltd. 40/4 Lavelle Road, Bangalore – 560 001.