ENGINE TEST SET UP 4 CYLINDR, 4 STROKE, TURBO CHARGED, CRDI DIESEL Product Code 226 Instruction manual Contents 1 2 3 4 Description Specifications Installation requirements Installation Commissioning 21-01-2014 5 6 7 8 Troubleshooting Components used Packing slip Warranty Im226.docx 9 Theory 10 Experiments Page 1 Apex Innovations Description The setup consists of four cylinder, four stroke, Turbo charged, CRDI 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 PпЃ±пЂPV 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. Provision is made to conduct performance test with and without turbocharger. The pressure after turbocharger and temperatures across intercooler are indicated separately on the dash board panel. 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 вЂњEnginesoftвЂќ is provided for on line performance evaluation. EDDYCURRENT DYNAMOMETER TURBOCHARGED ENGINE Specifications Product Engine test setup 4 cylinder, 4 stroke, Turbo, Diesel (Computerized) Product code 226 Engine Engine, Make вЂ“ Maruti Udyog Ltd, Model вЂ“Swift, BS IV CRDI Diesel with microprocessor based engine management system(ECU), 4 cylinder,4 stroke, water cooled, power 55 KW @ 4000 rpm, torque 190 Nm @ 2000 rpm, cap.1248cc, Bore 69.6 mm, stroke 82 mm, turbocharged with intercooler Dynamometer Propeller shaft Air box Fuel tank Calorimeter Piezo sensor Crank angle sensor 21-01-2014 Type eddy current, water cooled, with loading unit With universal joints M S fabricated with orifice meter and manometer Capacity 15 lit with glass fuel metering column Type Pipe in pipe Range 5000 PSI, with low noise cable Resolution 1 Deg, Speed 5500 RPM with TDC pulse. Im226.docx Page 2 Apex Innovations Data acquisition device Piezo powering unit Digital voltmeter Temperature sensor Temperature transmitter Load indicator Temperature indicator Load sensor Fuel flow transmitter Air flow transmitter Software Rotameter Pump Cooling fan Overall dimensions NI USB-6210, 16-bit, 250kS/s. Make-Apex, Model AX-409. Range 0-5V, panel mounted Type RTD, PT100 and Thermocouple, Type K Type two wire, Input RTD PT100, Range 0вЂ“100 Deg C, Output 4вЂ“20 mA and Type two wire, Input Thermocouple, Range 0вЂ“1200 Deg C, Output 4вЂ“20 mA Digital, Range 0-50 Kg, Supply 230VAC Digital, multi channel with selector switch Load cell, type strain gauge, range 0-50 Kg DP transmitter, Range 0-500 mm WC Pressure transmitter, Range (-) 250 mm WC вЂњEnginesoftвЂќ Engine performance analysis software Engine cooling 100-1000 LPH; Calorimeter 25-250 LPH Type Monoblock Type propeller, Size 450mm, Rpm 1400, 1phase W 2000 x D 2750 x H 1750 mm Shipping details Gross volume 2.05m3, Gross weight 995kg, Net weight 780kg Installation requirements Electric supply Provide 230 +/- 10 VAC, 50 Hz, single phase electric supply with proper earthing. (Neutral вЂ“ Earth voltage less than 5 VAC) п‚· 5A, three pin socket with switch (2 Nos.) Water supply Continuous, clean and soft water supply @ 4000 LPH, at 10 m. head. Provide tap with 1вЂќ BSP size connection Space 3500Lx4000Wx2000H in mm Drain Provide suitable drain arrangement (Drain pipe 65 NB/2.5вЂќ size) Exhaust Provide suitable exhaust arrangement (Exhaust pipe 32 NB/1.25вЂќ size) Foundation As per foundation drawing Fuel, oil Diesel @10 liter Oil @ 3.5 lit. (15W40) Installation Commissioning INSTALLATION п‚· 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. п‚· Install engine test set up assembly on the foundation. п‚· Keep panel box structure near foundation (Refer foundation drawing ) п‚· Fit the panel box assembly on the panel box structure and fit following parts o Piezo powering unit 21-01-2014 Im226.docx Page 3 Apex Innovations п‚· п‚· п‚· п‚· o Loading unit o Digital voltmeter o Load indicator Keep the Dashboard panel between engine and panel box. Fit the following units and connect to engine: o Battery o Gauges o Throttle unit o Temperature indicator 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 adaptor assembly on engine head with water cooling piping. 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 Temperature sensors to IC turbo dashboard panel o DLU unit to Dynamometer o USB cable from Data acquisition device to computer вЂњUSBвЂќ port COMMISSIONING п‚· п‚· п‚· п‚· п‚· п‚· п‚· п‚· п‚· п‚· п‚· 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 вЂњ0вЂќ mark level. Keep вЂњLoadвЂќ knob on loading unit is at minimum position. Load the NI-USB driver on the computer from Driver CD. Connect USB cable from Data acquisition device to computer. Load вЂњEnginesoftвЂќ software package on the same computer. Ensure water circulation through engine, calorimeter and dynamometer and piezo adaptor. Start the Engine. Check engine operation at various loads and ensure respective signals on computer. Precautions п‚· Use clean and filtered water; any suspended particle may clog the piping. п‚· Piezo Sensor Handling: o Ensure cooling water circulation for combustion pressure sensor. 21-01-2014 Im226.docx Page 4 Apex Innovations o Diaphragm of the sensor is delicate part. Avoid scratches or hammering on it. o A long sleeve is provided inside the piezo adapter. This sleeve is protecting the surface of the diaphragm. While removing sensor from the adapter this sleeve may come out with the sensor and fell down or lose during handling. Status of the sensor is indicated on the engine indicator. o Damages to the electronic parts of the sensor or loose connection are indicated as "open" or "short" status on piezo powering unit. п‚· Circulate dynamometer and piezo sensor cooling water for some time after shutting down the engine. 21-01-2014 Im226.docx Page 5 Apex Innovations Troubleshooting Note: For component specific problems refer componentsвЂџ manual Problems Possible causes / remedies Engine does not start п‚· Insufficient fuel п‚· Air trapped in fuel line Dynamometer does п‚· Faulty wiring not load the engine п‚· No DC voltage at the outlet of dynamometer loading unit Faulty air flow п‚· Air hose leakage at connections with air-box and with engine. Faulty fuel flow п‚· Improper closing of fuel cock. п‚· Air trap in pressure signal line to fuel transmitter Software does not п‚· Faulty or wrong USB port work п‚· Virus in computer п‚· Loose connections Faulty indicated п‚· TDC setting disturbed. Readjust TDC setting. power п‚· Improper configuration data Faulty pressure crank п‚· Improper earthing angle diagram п‚· Wrong reference pressure setting in configuration file. Adjust the value such that suction stroke pressure just matches the zero line. п‚· If peak pressure is not at the TDC, TDC setting disturbed, readjust п‚· If peak pressure shifts randomly with respect to TDC, coupling of crank angle sensor may be loose Faulty speed п‚· Broken coupling of crank angle sensor indication Incorrect п‚· Check the connection between thermocouple and temperature temperature indicator/transmitter. Note that yellow indication cable of thermocouple is positive and red is negative. п‚· Open or damaged temperature sensor Improper load п‚· Excessively raised jack bolts of the dynamometer. indication TDC Setting п‚· 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). п‚· Loosen the screws of clamping flange of engine crank angle sensor. п‚· 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. 21-01-2014 Im226.docx Page 6 Apex Innovations Components used Components Details Engine, Make вЂ“ Maruti Udyog Ltd, Model вЂ“Swift, BS IV CRDI Diesel with microprocessor based engine management system(ECU), 4 cylinder,4 stroke, water cooled, power 55 KW @ 4000 rpm, torque 190 Nm @ 2000 rpm, cap.1248cc, Bore 69.6 mm, stroke 82 mm, turbocharged with intercooler Engine Dynamometer Dynamometer Loading unit Propeller shaft Manometer Fuel measuring unit Piezo sensor White cable coaxial teflon Crank angle sensor Data acquisition device Piezo powering unit Temperature sensor Temperature sensor Temperature transmitter Temperature transmitter Load sensor Load indicator Temperature indicator Power supply 21-01-2014 Make Saj test plant Pvt. Ltd., Model AG80, Type Eddy current Make Apex, Model AX-153, Type variable speed, Supply 230V AC. Make Hindustan Hardy Spicer, Model 1260, Type A Make Apex, Model MX-104, Range 100-0-100 mm, Type U tube, Conn. 1/4`` BSP hose back side, Mounting panel Make Omega Glass, Model:FF0.090 Make PCB Piezotronics, Model HSM111A22, Range 5000 psi, Diaphragm stainless steel type & hermetic sealed Make PCB piezotronics, Model 002C20, Length 20 ft, Connections one end BNC plug and other end 10-32 micro 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 NI USB-6210 Bus Powered M Series, Make-Apex, Model AX-409. Make Radix Type K, Ungrounded, Sheath Dia.6mmX110mmL, SS316, Connection 1/4"BSP (M) adjustable compression fitting (5Nos) Make Radix, Type Pt100, Sheath Dia.6mmX110mmL, SS316, Connection 1/4"BSP(M) adjustable compression fitting (3Nos) Make Wika, model T19.10.3K0-4NK-Z, Input Thermocouple (type K), output 4-20mA, supply 24VDC, Calibration: 0-1200deg.C. Make Wika, Model T19.10.1PO-1 Input RTD(Pt100), output 4-20mA, supply 24VDC, Calibration: 0-100п‚°C Make Sensotronics Sanmar Ltd., Model 60001,Type S beam, Universal, Capacity 0-50 kg Make ABUS, model SV8-DC10, 85 to 270VAC, retransmission output 4-20 mA Digital Multipoint temp. indicator, Model ESD 9043, 6 points,Input thermocouple, size 92X92, 31/2 digit, range 0-1200DegC Make Meanwell, model S-15-24, O/P 24 V, 0.7 A Im226.docx Page 7 Apex Innovations Digital voltmeter Fuel flow transmitter Air flow transmitter Rotameter Rotameter Pump Cooling fan Battery 21-01-2014 Make Meco, 3.1/2 digit LED display, range 0-20 VDC, supply 230VAC, model SMP35 Make Yokogawa, Model EJA110-EMS-5A-92NN, Calibration range 0-500 mm H2O, Output linear Make Wika, Range (-) 250 mm WC Make Eureka Model PG 5, Range 25-250 lph, Connection ВѕвЂќ BSP vertical, screwed, Packing neoprene Make Eureka, Model PG 9, Range 100-1000 lph, Connection 1вЂќ BSP vertical, screwed, Packing neoprene Pump make Kirloskar, Model GMC1.542, Head 20m., HP 1.5, Single phase, Size 32x25 Type Centrifugal monoblock Exhaust fan, Type propeller, Size 450mm, Rpm 1400, 410Watt, 1phase Make Exide, Model MHD 350 06687, 12 V DC Im226.docx Page 8 Apex Innovations Packing slip Total no. of boxes: 12, Volume: 2.79 m3, Gross weight: 985 kg. Net wt. 784 kg Case No.1/12 1 Box No.2/12 1 Box No.3/12 1 Box No.4/12 1 Box No.5/12 1 Box No.6/12 1 Box No.7/12 1 Box No.8/12 1 2 Box No.9/12 1 2 Box No.10/1 2 1 2 Box No.11/1 2 1 2 Engine Set up Assembly Size W1700xD800xH1200 mm; Volume:1.63m3 Engine test setup assembly Engine + Dynamometer + Base frame Engine panel box Size W990xD475xH500 mm; Volume:0.24m3 Engine panel box assembly Transmitter panel, Fuel pipe, Fuel DP transmitter, Air transmitter, NI USB 6210, power supply and wiring, Manometer with PU tube. Engine panel box structure Size W800xD475xH500 mm; Volume:0.19m3 Engine panel box structure assembly Rotameters with piping (2) Dynamometer loading unit clamp (1) Calorimeter Size W650xD275xH325 mm; Volume:0.06m3 Calorimeter assembly Exhaust pipe Size W300xD225xH300 mm; Volume:0.02m3 Exhaust pipe Gross weight: 525kg Net weight: 525kg 1 No. Pump Size W525xD325xH425mm; Volume:0.07m3 Pump Battery Size W200xD300xH225 mm; Volume:0.01m3 Battery Dash board panel Size W500xD400xH300 mm; Volume:0.06m3 Dash board panel with support structure Fuel throttle body with cable Engine wiring swift Size W550xD300xH275 mm; Volume:0.05m3 Wiring box with support pipes Engine wiring Exhaust fan Size W1075xD575xH325 mm; Volume:0.20m3 Gross weight: 42kg Net weight: 23kg 1 No. Gross weight: 25kg Net weight: 17kg 1 No. Gross weight: 32kg Net weight: 20kg 1 No. 1 No. Gross weight: 35kg Net weight: 22kg 1 No. 1 set Gross weight: 40kg Net weight: 28kg Exhaust fan with fan support Turbo charger filter and piping Engine wiring Size W500xD400xH300 mm; Volume:0.06m3 1 No. 1 No. Gross weight: 30kg Net weight: 12kg Piezo powering unit Load indicator 1 No. 1 No. 21-01-2014 Im226.docx Gross weight: 78kg Net weight: 50kg 1 No. Gross weight: 56kg Net weight: 31kg 1 No. Gross weight: 45kg Net weight: 22kg 1 No. Gross weight: 17kg Net weight: 9kg 1 No. Page 9 Apex Innovations 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Box No.12/1 2 1 2 3 4 5 6 7 8 9 10 11 Digital voltmeter Dynamometer loading unit Pressure gauge Wiring set Load cell with nut bolt Crank angle sensor Temperature sensor Piezo sensor Piezo adaptor Low noise cable Data acquisition device and driver CD Apex Enginesoft DVD CD Set of loose nut bolts Tool kit Fuel caps(2), Teflon tape(2) & Gasket shellac(1) Set of instruction manuals consisting of: Instruction manual CD (Apex) DP transmitter Dynamometer Calibration sheets for load cell and Piezo sensor Engine piping Size W1250xD450xH350mm; Volume: 0.20m3 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 5 Nos. 1No/2Nos. 1 No. 1No/2Nos. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. Piping set (14 pieces) Engine water inlet and outlet, Dynamometer water inlet and outlet, Calorimeter water inlet and outlet, Air hose pipe, Pump suction connection with strainer, Pump outlet, Engine water inlet and outlet hose, Water supply hose pipe, Drain pipe (3 components) Water supply pipe 1.25вЂќ hose Load cell bracket Fuel measuring unit 2Nos (one spare) Wiring channel set Engine air connection pipe Fuel filter assembly Exhaust extension pipe with socket and bend Pump bracket Air box connection Calorimeter exhaust outlet flange 1 No. 21-01-2014 Im226.docx Gross weight: 60kg Net weight: 25kg 1 1 1 1 1 1 1 1 1 1 No. set No. No. No. No. No. No. No. No. Page 10 Apex Innovations Warranty 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 21-01-2014 Im226.docx Page 11 Apex Innovations Theory 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 2 cylinder diameter (bore). A пЂЅ пЃ° / 4 п‚ґ D 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 2 is the swept volume of the engine. Vs пЂЅ A п‚ґ L пЂЅ пЃ° / 4 п‚ґ D L 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. V пЂЅ Vs пЂ« Vc Compression ratio (CR): The numerical value of the cylinder volume divided by the numerical value of clearance volume. CR пЂЅ V / Vc 21-01-2014 Im226.docx Page 12 Apex Innovations Bore D Cylinder head Suction valve Intake or suction manifold Top dead center T.D.C. Piston Gudgeon or wrist pin Exhaust valve Exhaust manifold Clearance volume.Vc Cylinder volumeвЂ™VвЂ™ Stroke volume.Vs Bottom dead center B.D.C. Cylinder Connecting rod Crankcase Crankshaft Crank pin Crank 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 180 0 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 вЂћblow-downвЂџ. 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. 21-01-2014 Im226.docx Page 13 Apex Innovations 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 springloaded 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 вЂћloop 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 (О·t): Indicated thermal efficiency is the ratio of energy in the indicated power to the fuel energy. пЃЁt пЂЅ IndicatedP ower / FuelEnergy пЃЁ t (%) пЂЅ IndicatedP ower ( KW ) п‚ґ 3600 п‚ґ 100 FuelFlow ( Kg / Hr) п‚ґ CalorificV alue( KJ / Kg ) Brake thermal efficiency (О·bth): 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. пЃЁbth пЂЅ BrakePower / FuelEnergy пЃЁ bth (%) пЂЅ BrakePower ( KW ) п‚ґ 3600 п‚ґ 100 FuelFlow ( Kg / Hr) п‚ґ CalorificV alue( KJ / Kg ) Mechanical efficiency (О·m): Mechanical efficiency is the ratio of brake horse power (delivered power) to the indicated horsepower (power provided to the piston). пЃЁ m пЂЅ BrakePower / IndicatedP ower and Frictional power = Indicated power вЂ“ 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) 21-01-2014 Im226.docx Page 14 Apex Innovations Indicated thermal efficiency = B/A Brake thermal efficiency = C/A Mechanical efficiency = C/B Volumetric efficiency (О·v): 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 вЂћbreathingвЂџ 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: О·v (%) = пЃЁ v (%) пЂЅ Mass of air consumed -------------------------------------------------------------------------mass of flow of air to fill swept volume at atmospheric conditions AirFlow ( Kg / Hr) п‚ґ 100 пЃ° / 4 п‚ґ D L(m ) п‚ґ N ( RPM ) / n п‚ґ NoofCyl п‚ґ AirDen( Kg / m 3 ) п‚ґ 60 2 3 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. AitFlow ( Kg / Hr) пЂЅ Cd п‚ґ пЃ° / 4 п‚ґ D 2 п‚ґ 2 g п‚ґ hwater п‚ґ Wden / Aden п‚ґ Aden п‚ґ 3600 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 21-01-2014 Im226.docx Page 15 Apex Innovations 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). BMEP (bar ) пЂЅ BrakePower ( KW ) п‚ґ 60 L п‚ґ A п‚ґ ( N / n) п‚ґ NoOfCyl п‚ґ 100 IMEP (bar ) пЂЅ IndicatedP ower ( KW ) п‚ґ 60 L п‚ґ A п‚ґ ( N / n) п‚ґ NoOfCyl п‚ґ 100 Similarly, the friction means effective pressure (FMEP) can be defined as FMEP= IMEP вЂ“ 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. 21-01-2014 Im226.docx Page 16 Apex Innovations 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 = в€ЏDN (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: 21-01-2014 Im226.docx Page 17 Apex Innovations The figure shows crank-slider mechanism. The piston pin position is given by x пЂЅ r cos пЃ± пЂ« l cos пЃ¦ From figure r sin пЃ± пЂЅ l sin пЃ¦ and recalling cos пЃ¦ пЂЅ 1 пЂ sin пЃ» 2 пЃЅ пЃ¦ 2 x пЂЅ r пѓ¦пѓ§ cos пЃ± пЂ« l r 1 пЂ пЂЁr l пЂ© sin 2 пЃ± пѓ¶пѓ· пѓЁ пѓё The binomial theorem can be used to expand the square root term: пЃ› пЃ» пЃќпЃЅ x пЂЅ r cos пЃ± пЂ« l / r 1 пЂ 1 (r / l ) 2 sin 2 пЃ± пЂ 1 8 (r / l ) 4 sin 4 пЃ± пЂ« ... 2 вЂ¦.1 The powers of sin пЃ± can be expressed as equivalent multiple angles: sin 2 пЃ± пЂЅ 1 / 2 пЂ 1 / 2 cos 2пЃ± sin 4 пЃ± пЂЅ 3 / 8 пЂ 1 / 2 cos 2пЃ± пЂ« 1 / 8 cos 4пЃ± вЂ¦вЂ¦.2 Substituting the results from equation 2 in to equation 1 gives пЃ› пЃ» пЃќпЃЅ x пЂЅ r cos пЃ± пЂ« l / r 1 пЂ 1 (r / l ) 2 пЂЁ1 / 2 пЂ 1 / 2 cos 2пЃ± пЂ© пЂ 1 8 (r / l ) 4 пЂЁ3 / 8 пЂ 1 / 2 cos 2пЃ± пЂ« 1 / 8 cos 4пЃ± пЂ© пЂ« ... 2 2 The geometry of the engine is such that пЂЁr / l пЂ© is invariably less than 0.1, in which case it is acceptable to neglect the пЂЁr / l пЂ©4 terms, as inspection of above equation shows that these terms will be at least an order of magnitude smaller than пЂЁr / l пЂ©2 terms. The approximate position of piston pin end is thus: пЃ» пЃ› пЃќпЃЅ x пЂЅ r cos пЃ± пЂ« l / r 1 пЂ 1 (r / l ) 2 пЂЁ1 / 2 пЂ 1 / 2 cos 2пЃ± пЂ© 2 Where r =crankshaft throw and l = connecting rod length. Calculate x using above equation; then (l пЂ« r пЂ x) shall give distance traversed by piston from its top most position at any angle пЃ± 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 вЂњmotorвЂќ 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. 21-01-2014 Im226.docx Page 18 Apex Innovations Calculations п‚· Brake power (kw): 2пЃ°NT 60 x1000 2пЃ°N (WxR ) пЂЅ 60000 0.785 xRPMx (Wx9.81) xArmlength пЂЅ 60000 TxN BHP пЂЅ 75x60 BP пЂЅ п‚· Brake mean effective pressure (bar): BMEP пЂЅ BPx 60 пЃ° / 4 xD xLx( N / n) xNoOfCylx100 2 n = 2 for 4 stroke n = 1 for 2 stroke п‚· Indicated power (kw) :From PV diagram ..m3 X scale (volume) 1cm = Y scale (pressure) 1cm = Area of PV diagram = ..bar ..cm2 workdone / cycle / cyl ( Nm) пЂЅ AreaofPVdi agram п‚ґ Xscalefact or п‚ґ Yscalefact or п‚ґ100000 workdone / cycle / cyl п‚ґ ( N / n) п‚ґ NoOfCyl IP пЂЅ 60 п‚ґ 1000 п‚· Indicated mean effective pressure (bar): IMEP пЂЅ IPx 60 пЃ° / 4 xD xLx( N / n) xNoOfCylx100 2 п‚· Frictional power (kw): п‚· Brake specific fuel consumption (Kg/kwh): FP пЂЅ IP пЂ BP FHP пЂЅ IHP пЂ BHP BHP пЂЅ IHP пЂ FHP BSFC пЂЅ п‚· FuelflowIn kg / hr BP Brake Thermal Efficiency (%): BThEff пЂЅ 21-01-2014 BP п‚ґ 3600 п‚ґ 100 FuelFlowIn Kg / hr п‚ґ CalVal Im226.docx Page 19 Apex Innovations IThEff п‚ґ MechEff BHP OR 100 FuelHP BThEff пЂЅ п‚· п‚· Indicated Thermal Efficiency (%): IThEff пЂЅ IP п‚ґ 3600 п‚ґ 100 FuelFlowIn Kg / hr п‚ґ CalVal IThEff пЂЅ BThEff п‚ґ 100 MechEff Mechanical Efficiency (%): MechEff пЂЅ п‚· BP п‚ґ 100 IP Air flow (Kg/hr): AirFlow пЂЅ Cd п‚ґ пЃ° / 4 п‚ґ d 2 2 gh п‚ґ (Wden / Aden ) п‚ґ 3600 п‚ґ Aden п‚· Volumetric Efficiency (%): VolEff пЂЅ пЂЅ п‚· AirFlow п‚ґ 100 пЃ° / 4 п‚ґ D п‚ґ Stroke п‚ґ ( N / n) п‚ґ 60 п‚ґ NoOfCyl п‚ґ Aden 2 Air fuel ratio: A/ F пЂЅ п‚· AirFlow п‚ґ 100 Theoretica lAirFlow AirFlow FuelFlow Heat Balance (KJ/h): a) HeatSuppli edbyFuel пЂЅ FuelFlow п‚ґ CalVal b) HeatEquivalentToUsefulWork пЂЅ BP п‚ґ 3600 HeatEquivalentToUsefulWork п‚ґ 100 HeatSuppli edByFuel C) HeatInJack etCoolingW ater пЂЅ F 3 п‚ґ C PW п‚ґ (T 2 пЂ T1) HeatEquivalentToUsefulWorkIn% пЂЅ HeatInJack etCoolingW aterIn% пЂЅ HeatInJack etCoolingW ater п‚ґ 100 HeatSuppli edByFuel d) Heat in Exhaust (Calculate CPex value): C P ex пЂЅ F 4 п‚ґ C PW п‚ґ (T 4 пЂ T 3) ..KJ / Kg 0 k ( F1 пЂ« F 2) п‚ґ (T 5 пЂ T 6) 21-01-2014 Im226.docx Page 20 Apex Innovations Where, Cpex Specific heat of exhaust gas kJ/kg0K Cpw Specific heat of water kJ/kg0K F1 F2 F4 T3 T4 T5 T6 Fuel consumption Air consumption Calorimeter water flow Calorimeter water inlet temperature Calorimeter water outlet temperature Exhaust gas to calorimeter inlet temp. Exhaust gas from calorimeter outlet temp. kg/hr kg/hr kg/hr 0 K 0 K 0 K 0 K HeatInExha ust( KJ / h) пЂЅ ( F1 пЂ« F 2) п‚ґ C P ex п‚ґ (T 5 пЂ Tamb) HeatInExha ust п‚ґ 100 HeatInExha ust % пЂЅ HeatSuppli edByFuel e) Heat to radiation and unaccounted (%) пЂЅ HeatSuppli edByFuel (100%) пЂ {( HeatEquivalentToUsefulWork (%) пЂ« HeatInJack etCoolingW ater (%) пЂ« HeatToExha ust (%)} 21-01-2014 Im226.docx Page 21 Apex Innovations Experiments 1 Study of engine performance (Manual mode, With turbocharger ) Object To study the performance of 4 cylinder, 4 stroke, Turbo charged, CRDI Diesel engine connected to eddy current dynamometer in manual mode Procedure п‚· Ensure cooling water circulation for eddy current dynamometer, piezo sensor, engine cooling and calorimeter. п‚· Start the set up and run the engine at no load for 4-5 minutes. п‚· Gradually increase throttle to full open condition and load the engine simultaneously maintaining engine speed at @ 4000 RPM. п‚· Wait for steady state (for @ 3 minutes) and collect the reading as per Observations provided in вЂњCal226вЂќ worksheet in вЂњEngine.xlsвЂќ. п‚· Gradually increase the load to decrease the speed in steps of @500 RPM up to @ 2000 RPM and repeat the observations. п‚· Fill up the observations in вЂњCal226вЂќ worksheet to get the results and performance plots. 21-01-2014 Im226.docx Page 22 Apex Innovations 2 Study of engine performance with turbocharger (Computerized mode) Object To study the performance of 4 cylinder, 4 stroke, Turbo charged, Diesel engine connected to eddy current dynamometer in computerized mode. Procedure п‚· Ensure cooling water circulation for eddy current dynamometer, piezo sensor, engine cooling and calorimeter. п‚· Start the set up and run the engine at no load for 4-5 minutes. п‚· Switch on the computer and run вЂњEnginesoftвЂќ. Confirm that the Enginesoft configuration data is as given below. п‚· Gradually increase throttle to full open condition and load the engine simultaneously maintaining engine speed at @ 4000 RPM. п‚· Wait for steady state (for @ 3 minutes) and log the data in the вЂњEnginesoftвЂќ. п‚· Gradually increase the load to decrease the speed in steps of @500 RPM up to @ 2000 rpm maximum and repeat the data logging for each observation. п‚· View the results and performance plots in вЂњEnginesoftвЂќ. Enginesoft Configuration data Set up constants: No of PO cycles Fuel read time Fuel factor Orifice diameter Dynamometer arm length Engine and set up details: Engine power Engine max speed Cylinder bore Stroke length Connecting rod length Compression ratio Stoke type No. of cylinders Speed type Cooling type Dynamometer type Indicator used type Data acquisition device Calorimeter used Theoretical constants: Fuel density Calorific value Orifice coefficient of discharge Sp heat of exhaust gas Max sp heat of exhaust gas Min sp heat of exhaust gas Specific heat of water Water density Ambient temperature Sensor range Exhaust gas temp. trans. (Engine) Air flow transmitter 21-01-2014 : : : : : 10 60 sec 0.096 kg/Volt 48 mm 400 mm : : : : : : : : : : : : : : 55 Kw 4000 RPM 69.6mm 82mm 141 mm 17.6:1 Four Four Variable Water Eddy current Cylinder pressure USB-6210 Pipe in pipe : : : : : : : : : 830 kg/m^3 42000 kJ/kg 0.60 1.00 kJ/kg-K 1.25 kJ/kg-K 1.00 kJ/kg-K 4.186 kJ/kg-K 1000 kg/m^3 300C : 0-1200 C : 0-200 mm WC Im226.docx Page 23 Apex Innovations Fuel flow DP transmitter Load cell Cylinder pressure transducer 21-01-2014 : 0-500 mm WC : 0-50 kg : 0-345.5 bar Im226.docx Page 24 Apex Innovations Software Refer separate instruction manual supplied with software CD 21-01-2014 Im226.docx Page 25 Apex Innovations components 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 Make Pvt. Ltd. Flow Rate Max. Packing/Gaskets Measuring tube Float Cover Accuracy Range ability Scale length Max. Temp. Connection PG-1 to 21 Eureka Industrial Equipments 4000 to 40000 Lph Neoprene Borosilicate glass 316SS Glass +/-2% full flow 10:1 175-200mm. 2000C 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. Fig.1 Edge 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 п‚· Shut off the flow. п‚· Remove the front and rear covers. п‚· 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 21-01-2014 Im226.docx Page 26 Apex Innovations 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. п‚· Put the glands first in their position and then put the packing on the tube. п‚· Insert the tube in its place. п‚· Push the glands downwards and upwards respectively and fix them with the gland adjusting screws. п‚· 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. п‚· Fix the scale, considering the remark given in the test report. п‚· Fix the front and rear covers. Troubleshooting Problem Leakage on glands Showing high/low flow rate than expected Showing correct reading initially but starts showing high reading after few days Showing correct reading initially but starts showing high reading after some months. Fluctuation of float Frequent breakage of glass tube Check Replace gland packing Consult manufacturers Replace float Incase of gases, check also leakage Clean the rotameter by suitable solvent or soft brush Maintain operating pressure as mentioned in test report. Use loflometer to accommodate correct flow rate. Maintain operating pressure below pressure rating of the tube. Check piping layout. ManufacturerвЂ™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 вЂ“ 411 038. Email: eureka.equip@gems.vsnl.net.in 21-01-2014 Im226.docx Page 27 Apex Innovations Air flow transmitter 21-01-2014 Im226.docx Page 28 Apex Innovations 21-01-2014 Im226.docx Page 29 Apex Innovations ManufacturerвЂ™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 21-01-2014 Wika Instruments India Pvt. Ltd. Plot No. 40, GatNo. 94+100, high Cliff Ind. Estate, Village Kesnand, Pune 412207 Im226.docx Page 30 Apex Innovations 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 Model Type Capacity Mounting thread Full scale output (mV/V) Tolerance on output (FSO) Zero balance (FSO) Non-linearity (FSO) Hysteresis (FSO) Non-repeatability Creep (FSO) in 30 min Operating temperature range Rated excitation Maximum excitation Bridge resistance Insulation resistance Span / 0C (of load) Zero / 0C (of FSO) Combined error (FSO) Safe overload (FSO) Ultimate overload (FSO) Protection class Overall dimensions Weight ManufacturerвЂ™s address Sensortronics 60001 вЂћSвЂџ Beam, Universal 0 вЂ“ 50Kg M10 x 1.25mm 3.00 +/-0.25% +/-0.1mV/V <+/-0.025% <+/-0.020% <+/-0.010% <+/-0.020% -200C to +700C 10V AC/DC 15V AC/DC 350 Ohms (Nominal) >1000 Meg ohm @ 50VDC +/-0.001% +/-0.002% <+/-0.025% 150% 300% IP 67 51 L x 20 W x 76 H mm 380 gm 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 вЂ“ 600 096. E-mail: KBS@SANMARGROUP.com 21-01-2014 Im226.docx Page 31 Apex Innovations Waaree Pressure gauge Introduction Pressures gauges are suitable for use with air, oil, water or compatible gases. The phosphor bronze bourdon tube is housed within a rugged SS case. The aluminum dial and pointer are protected by an impact resistant polycarbonate window. Accuracy is +/- 3-2-3% per ASME grade B. Brass back connection is ВјвЂќ male NPT. Technical specifications Make Code Pressure gauge Liquid filled Internals part Housing Range Connection Accuracy Media Bourdon tube Dial/pointer Wetted parts Temperature range Mounting Overall dimensions Weight Waaree Instruments PW2.5GNNNS9 0-2.5 ВјвЂќB 2.5вЂќ diameter Glycerin Brass SS 0 вЂ“ 2.5 and 0 вЂ“ 7 Kg/cm2 ВјвЂќ center back +/-3-2-3% per ASME grade B. Clean, no corrosive liquid Phosphor bronze Aluminum dial with black enameled pointer Phosphor bronze bourdon tube with brass stem -10 to 800C Panel mounting 70diameter x 55mmL 140 gm ManufacturerвЂ™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. Waaree Instruments Ltd. 10, Damji Shamji Industrial Complex, Off Mahakali Caves Road, Andheri (E), Mumbai вЂ“ 400 093. E-mail: waaree@waaree.com Web: www.waaree.com 21-01-2014 Im226.docx Page 32 Apex Innovations Encoder Technical specifications Make Model Supply voltage Output PPR Outlet Cable type Encoder Diameter Shaft size Weight Kubeler 8.3700.1321.0360 5-30VDC Push pull (AA,BB,OO) 360 axial Dia. 37, Dia.6mm x length12mm 120 gm ManufacturerвЂ™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 вЂ“ Germany Indian supplier: Rajdeep Automation Pvt. Ltd. Survey No. 143, 3rd floor, Sinhgad Road, Vadgaon Dhayari, Pune вЂ“ 411 041. 21-01-2014 Im226.docx Page 33 Apex Innovations 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 Make Model Range, FS (5V output) Useful range (10V output) Maximum pressure Resolution Sensitivity Resonant frequency Rise time Discharge time constant Linearity (zero based BSL) Output impedance Acceleration sensitivity Temperature coefficient Temperature range Vibration Shock Sealing Excitation (Constant current) Voltage to current regulator Sensing geometry Sensing element Housing material Diaphragm Electrical connector Mounting thread Weight Cable model Hydraulic pressure transducer With built in amplifier PCB Piezotronics, INC. M108A02 10000 psi 20000 psi 50000 psi 0.4 psi 0.5 mV/psi 300 kHz 2 пЃs 1000 s 2% 100 ohms 0.01 psi/g 0.03 %/0F -100 to +250 0F 2000 g peak 20000 g peak Hermetic welded 2 to 20 mA +18 to 28 VDC Compression Quartz C-300 C-300 10-32 coaxial jack M10 x 0.1pitch 12 gm 002C20 white coaxial cable Technical specifications Sensor name Make Model Range, FS (5V output) Dynamic pressure transducer With built in amplifier PCB Piezotronics, INC. M111A22 5000 psi 21-01-2014 Im226.docx Page 34 Apex Innovations Useful range (10V output) Maximum pressure Resolution Sensitivity Resonant frequency Rise time Discharge time constant Low frequency response (-5%) Linearity (Best straight line) Output polarity Output impedance Output bias Acceleration sensitivity Temperature coefficient Temperature range Flash temperature Vibration / Shock Ground isolation Excitation (Constant current) Voltage to current regulator Sensing geometry Sensing element Housing material Diaphragm Sealing Electric connector Mounting thread Weight (with clamp nut) Cable model 10000 psi 15000 psi 0.1 psi 1 mV/psi 400 kHz 2 пЃs 500 s 0.001 Hz 2% Positive 100 ohms 8-14 volt 0.002 psi/g 0.03 %/0F -100 to +275 0F 3000 0F 2000 / 20000 g peak No (2) 2 to 20 mA +18 to 28 VDC Compression Quartz 17.4 SS Invar Welded hermetic 10-32 coaxial jack M7 x 0.75 pitch 6 gm 002C20 white coaxial cable 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. п‚· 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. п‚· 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 0.010вЂќ thick can be effective. General electric RTV type 106 silicone rubbers are recommended. 21-01-2014 Im226.docx Page 35 Apex Innovations 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 вЂ“ 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. п‚· 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. п‚· Low Frequency Response п‚· The discharge time constant of the sensor. п‚· If AC вЂ“ coupled at the power unit, the coupling time constant. Depending upon the sensorвЂџs 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 systemвЂџs discharge time constant. Troubleshooting Problem No signal Sensor damaged or ceases to operate Check п‚· Remove sensor and clean by dampened cloth п‚· 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 вЂњXducerвЂќ 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. ManufacturerвЂ™s address 21-01-2014 Im226.docx Page 36 Apex Innovations 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. 21-01-2014 Im226.docx Page 37 Apex Innovations 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 Make End flanges both side Water inlet Minimum kPa Pressure lbf/in2 Air gap mm Torque Nm Hot coil voltage max. Continuous current amps Cold resistance ohms Speed max. Load Bolt size Weight AG10 Saj Test Plant Pvt. Ltd. Cardon shaft model 1260 type A 1.6bar 160 23 0.77/0.63 11.5 60 5.0 9.8 10000rpm 3.5kg M12 x 1.75 130kg Model Make End flanges both side Water inlet Minimum kPa Pressure lbf/in2 Air gap mm Torque Nm Hot coil voltage max. Continuous current amps Cold resistance ohms Speed max. Load Bolt size Weight AG20 Saj Test Plant Pvt. Ltd. Cardon shaft model 1260 type A 1.6bar 160 23 0.88/0.72 11.5 60 5.0 9.8 10000rpm 5.0Kg M12 x 1.75 220Kg Model Make End flanges both side Water inlet Minimum kPa Pressure lbf/in2 Air gap mm Torque Nm AG80 Saj Test Plant Pvt. Ltd. Cardon shaft model 1260 type A 1.0bar 100 14.5 1.047/0.855 11.5 Technical specifications Technical specifications 21-01-2014 Im226.docx Page 38 Apex Innovations Hot coil voltage max. Continuous current amps Cold resistance ohms Speed max. Load Bolt size Weight 75 5.0 12.8 9000rpm 40kg M16 x 2.00 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 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 Calibration of dynamometer not coming in accuracy limit Vibrations to dynamometer Abnormal noise Loss plate temperature high Bearing temperature high 21-01-2014 Check п‚· Remove the obstruction for the free movement of casing п‚· Calibrate the weights from authorized source. п‚· Maintain constant water flow п‚· Clean & lubricate properly with grease п‚· Bearings clean & refit properly п‚· Load cell link tighten properly п‚· Clean & refit trunnion bearings п‚· Dynamometer foundation bolts tighten properly п‚· Arrest engine vibrations п‚· Cardon shaft cover secure properly п‚· Align guard properly п‚· Replace rotor if warped п‚· Replace main bearing п‚· Check correct water flow п‚· De-scale with suitable solution п‚· Clear off water passages п‚· Grease with proper brand п‚· Remove excess grease & avoid over Im226.docx Page 39 Apex Innovations п‚· п‚· п‚· п‚· п‚· п‚· Dynamometer not rotating Water leakages at various locations п‚· п‚· п‚· п‚· п‚· п‚· grease Use specified grease and do not mix two types of grease Clear the drain Replace the bearings Replace shaft & coupling Replace bearings Replace rotor / loss plates after checking Replace casing вЂћoвЂџ rings Loss plates bolts tighten properly Replace loss plate вЂћoвЂџ rings Casing plugs tighten properly Replace pipe вЂћoвЂџ 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 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 вЂњZEROвЂќ if necessary adjust the control equipment until вЂњZEROвЂќ 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: Torque( Nm) xSpeed ( Radians / sec .) inS .I .units 1000 Torque(lbfft ) xSpeed ( Radians / sec .) Power (hp) = in.imperialun its 550 Power (kW) = 3. The dynamometer will be calibrated in either Imperial or S.I. units or MKS as specified. Power = WN k Where N = Shaft speed in rev/min W = Torque (Indicated on torque indicator) K = Constant dependant on units of power and torque ManufacturerвЂ™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. 21-01-2014 Im226.docx Page 40 Apex Innovations 72-76, Mundhwa, Pune Cantonment, Pune вЂ“ 411 036. Email:sajdyno@vsnl.com 21-01-2014 Im226.docx Page 41 Apex Innovations 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-DMS5A92NN Make Yokogawa Output signal 4 вЂ“ 20mA DC with digital communication (Linear) Measurement span 1 to 100kPa (100 to 10000mmH2O) Calibration range 0 вЂ“ 200, 0 вЂ“ 500 mmH2O Wetted parts material Body вЂ“ SCS14A, Capsule вЂ“ 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 вЂћOвЂџ rings Buna-N Supply 10 to 24VDC Process temperature limit -40 to 120 0C Housing Weather proof Weight 3.9Kg ManufacturerвЂ™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. 21-01-2014 Indian supplier: Yokogawa Blue Star Ltd. 40/4 Lavelle Road, Bangalore вЂ“ 560 001. Im226.docx Page 42