ENGINE TEST SET UP 3CYLINDR, 4STROKE, PETROL. Product Code 231. Instruction manual. Contents

Similar documents
ENGINE TEST SET UP 1CYLINDR, 4STROKE, PETROL

ENGINE TEST SET UP 4CYLINDR, 4STROKE, DIESEL TURBO. Product Code 227. Instruction manual

ENGINE TEST SET UP 3 CYLINDR, 4 STROKE, PETROL. Product Code 230. Instruction manual. Contents

APPENDIX 1 COMPONENTS USED IN ENGINE SETUP

RESEARCH ENGINE TEST SET UP

2 CYLIND APEX. Contents. 1 Description 2 Specifications. 9 Theory. Im238. Page 1

Computerized VCR Single Cylinder Diesel Engine Test Set up

SINGLE CYLINDER FOUR STROKE PETROL ENGINE TEST RIG WITH EDDY CURRENT DYNAMOMETER

SHREE RAMCHANDRA EDUCATION SOCIETY S LONIKAND, PUNE DEPARTMENT OF MECHANICAL ENGINEERING LAB MANUAL. Applied Thermodynamics (ATD) Semester-IV

CHAPTER 4 VARIABLE COMPRESSION RATIO ENGINE WITH DATA ACQUISITION SYSTEM

Instruction Manual PN-Z PACKED PLUNGER PUMP. This Manual should be made available to person responsible for installation, maintenance and operation.

SERVICE SOLUTIONS For Engine setups

LABORATORY MANUAL I. C. ENGINES & GAS TURBINES (ME-317-E)

Instruction Manual PN-K PACKED PLUNGER PUMP. This Manual should be made available to person responsible for installation, maintenance and operation.

The Vario motor-driven pump series from ProMinent Adaptable to a wide range of applications VARIO METERING PUMP

SHRI SHANKARACHARYA INSTITUTE OF PROFESSIONAL MANAGEMENT AND TECHNOLOGY LAB MANUAL INTERNAL COMBUSTION ENGINES MECHANICAL ENGINEERING DEPARTMENT

DEWATERING PUMP. Instruction, Installation, Operation and Maintenance Manual. A Mark of Quality. ISO 9001 Certified Company

CHAPTER-3 EXPERIMENTAL SETUP. The experimental set up is made with necessary. instrumentations to evaluate the performance, emission and

Ni-HARD SUBMERSIBLE PUMP

THERMAL ENGINEERING LAB MANUAL

AT 2303 AUTOMOTIVE POLLUTION AND CONTROL Automobile Engineering Question Bank

DELUGE VALVE DATA SHEET

MODULATING SERVICE ELECTRIC ACTUATORS OPERATION AND MAINTENANCE MANUAL COMMERCIAL AND INDUSTRIAL VALVES AND AUTOMATION

Operating Manual Model- P282 Digiflow Controller

AN ANALYSIS OF EFFECT OF VARIABLE COMPRESSION RATIO IN C.I. ENGINE USING TURBOCHARGER

Eco-Propel TM Variable Speed Pump Kit Instruction and Operation Manual, p/n Revision 0

HORIZONTAL SPLIT CASING PUMP

OPERATION & MAINTENANCE MANUAL POLDER PUMP. A Mark of Quality

PROCESS PUMPS (INDIA) PVT LTD

MODEL 905V OPERATING INSTRUCTIONS

PowerLink GW series Eddy Current Dynamometer User Manual

Eco-Propel TM Variable Speed Pump Kit Instruction and Operation Manual, P/N: , Revision 1

INLINE Flow sensor for hazardous area II 1 G/D - II 2 D - II 3 GD - I M1

PROCESS PUMPS (INDIA) PVT LTD

TILLOTSON LTD., CLASH INDUSTRIAL ESTATE, TRALEE, CO. KERRY, IRELAND PHONE: FAX:

CBC-300 Series & CBC-300C Series Dual Channel Adjust Clutch/Brake Controls

DA 150 EFI. Electronic Fuel Injected Engines OWNER S MANUAL

AMB100L-im-issue INSTRUCTION MANUAL 240V DIESEL MINI BOWSER AMB100L AMB100L

HALLMARK INDUSTRIES INC

Electro-Pneumatic Positioner Series 830/831-WP/EX. Operation & Maintenance Manual

2. Discuss the effects of the following operating variables on detonation

VQ400M SERIES CLASS A COMBINATION VALVES PRODUCT HANDBOOK APPLICATION

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.


OPERATION & MAINTENANCE MANUAL PORTABLE SUBMERSIBLE PUMP

LEVEL AND FLOW MEASUREMENT WS131 FLOW METER USER MANUAL.

OPERATIONAL MANUAL EMBC-8025 INTELLIGENT BATTERY CHARGER. Version 1.5

WARNING: Read these instructions before using the machine GENERATOR MODEL NO: IG3500F PART NO: OPERATION & MAINTENANCE INSTRUCTIONS

X4 Installation and Operation Manual - POWER FLAME INCORPORATED

A Member of the. Integrated Metering Technologies

FAIRCHILD T5420 DIGITAL-PNEUMATIC TRANSDUCER Installation, Operation and Maintenance Instructions

Integrated Flow Control Module for Slurries and Chemicals LFC-7000

DA 120 EFI. Electronic Fuel Injected Engines OWNER S MANUAL

Troubleshooting the Transmission Hydraulic System

TABLE OF CONTENTS. 8.3 Online Sensor Specifications. Series TS (Models TS1, TSP, TSH, TSL,TSF, TSB1, TSB2) According to Electromatic factory procedure

Parts Manual V100G Vacuum Machine Part #E (SERIAL #1G G )

Ford Meter Box Test Bench Installation Instructions

TITAN FLOW CONTROL, INC.

2-Way Motorized Valves

Introduction. System Components

Mustang. Installation Manual

MicroCoat. System Operating Manual MC2000 Series. MC785, MC785-WF Spray Valves. US: UK: Mexico:

SP5 INSTALLATION AND SETUP MANUAL

Chapter 1 Internal Combustion Engines

Operating and Installation Instructions

OPEN/CLOSE SERVICE ELECTRIC ACTUATORS OPERATION AND MAINTENANCE MANUAL COMMERCIAL AND INDUSTRIAL VALVES AND AUTOMATION

TECHNICAL BULLETIN. Logix 510si Series Digital Positioner. Experience In Motion FCD LGENTB /09

Air-Assist Service Jack Max. Capacity: 10 Tons

Installation and Maintenance Manual Duplex Pressure Powered Pump Package Unit with Insulation Jacket and Condensate Recovery Meter PPPPU-D

RESISTIVITY MONITOR/CONTROLLERS

CHAPTER -3 EXPERIMENTAL SETUP AND TEST PROCEDURE

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION (Autonomous) Summer 15 EXAMINATION Subject Code: Model Answer Page No: 1/18

Digital Pressure Regulator Sentronic PLUS Series 614

OPERATION MANUAL Common for All models Bobbin Sensor (Weft End Detection) DP150 - L2 BP150 - L2-12V BP150 - L2-24V (PNP/NPN)

Pneumatic Positioner RTX - Series USER S MANUAL. ROTEX P/P Ver. 0.1 Dated: MAY / 2009 REV 01: SEP/2010 Page 1 of 16

HIGH PRESSURE SPRAY GUNS &ACCESSORIES

Solar Thermal. Grant Solar Pump Station Installation & Servicing Instructions

HOT WASHER MODEL NO: KING 125 OPERATION & MAINTENANCE INSTRUCTIONS PART NO: LS1009

ProMinent Beta Solenoid Diaphragm Metering Pumps

DSL-240 MkIII Single Pass Dust Monitor Measures mg/m 3 using DDP

Classic Instruments. Installation Manual

Stewart-Warner Electronic Tachometer 54.07

Instruction Manual. Series E7 Metering Pumps. For file reference, please record the following data:

User s Guide. EZ-Bar Livestock Scale WEIGH BARS AND DIGITAL INDICATOR. WB-40 Weigh Bars TS-700 WB Digital Indicator. Guide version 1.

INSTALLATION MANUAL FOR JABIRU 5100 AIRCRAFT ENGINE

Items Vehicles with 4G63 engine Vehicles with 4D56 engine. Type 4-speed full automatic 4-speed full automatic. 2nd rd

Hand Expansion Valves Built Stronger to Last Longer Sizes: 6mm (¼ ) to 305mm (4 )

OWNER S MANUAL AUTOMATIC DISCHARGE PUMP CONTROLLER

ENGINE LUBRICATION & COOLING SYSTEMS SECTIONLC CONTENTS. ENGINE LUBRICATION SYSTEM...2 Precautions...2

Owners Manual: - Pumps

99 Washington Street Melrose, MA Fax TestEquipmentDepot.com. Instruction Manual. Model 1672 Triple Output Power Supply

GYANMANJARI INSTITUTE OF TECHNOLOGY (GMIT) SUBJECT: ELEMENTS OF MECHANICAL ENGINEERING Assignment Ch 1

FPD1000-HP SERIES HIGH PRESSURE Positive Displacement Flowmeters

DEMA 258BD-200C and 258BT-200C DRAIN MASTER Jr. INSTALLATION INSTRUCTION SHEET

Electric Stone Hearth Oven

SPECIALISTS IN PRESSURE, TEMPERATURE, LEVEL, FLOW, GAS DETECTION, CALIBARATION & FLUID POWER INSTRUMENTATION

Instruction Manual. * We reserve the right to amend specification without prior notice.

PROCESS PUMPS (INDIA) PVT LTD

CX-SERIES ADVANCED BATTERY CHARGER

Experiment (4): Flow measurement

Transcription:

ENGINE TEST SET UP 3CYLINDR, 4STROKE, PETROL Product Code 231 Instruction manual Contents 1 Description 2 Specifications 3 Installation requirements 4 Packing slip 5 Installations 6 Commissioning 7 Troubleshooting 8 Experiments 9 Components used 10 Calculations 11Warranty 01-08-2018 Im231 Page 1

Description The setup consists of three cylinder, four stroke, Petrol engine connected to Eddy dynamometer for engine loading. The setup has stand-alone type independent panel box consisting of air box, fuel tank, manometer, fuel measuring unit, digital speed indicator and digital temperature indicator. Engine jacket cooling water inlet, outlet and calorimeter temperature is displayed on temperature indicator. Rotameters are provided for cooling water and calorimeter flow measurement. The setup enables study of engine for brake power, BMEP, brake thermal efficiency, volumetric efficiency, specific fuel consumption, air fuel ratio and heat balance. Set up is supplied with MS Excel program for Engine Performance Analysis. Fuel F1 F2 Air F3 F4 Wt T2 T1 N T3 T4 T5 DYNAMOMETER ENGINE Schematic arrangement (Performance evaluation) 01-08-2018 Im231 Page 2

Specifications Product Engine test setup 3 cylinder,4 stroke, Petrol Product code 231 Engine Make Maruti, Model Maruti 800, Type 3 Cylinder, 4 Stroke, Petrol (MPFI), water cooled, Power 27.6Kw at 5000 rpm, Torque 59 NM at 2500rpm,stroke 72 mm, bore 66.5mm, 796 cc, CR 9.2 Dynamometer Type Eddy current, water cooled (Arm length 210 mm) Dynamometer Variable speed engine, Range 0-5000rpm with speed controller sensor Propeller shaft With universal joints Air box M S fabricated with orifice meter and manometer (Orifice dia 35 mm) Fuel tank Capacity 15 lit with glass fuel metering column Calorimeter Type Pipe in pipe Temperature sensor Thermocouple, Type K Temperature Digital, multi channel with selector switch indicator Speed indicator Digital with non contact type speed sensor Load sensor Load cell, type strain gauge, range 0-50 Kg Load indicator Digital, Range 0-50 Kg, Supply 230VAC Rotameter Engine cooling 100-1000 LPH; Calorimeter 25-250 LPH Pump Type Centrifugal Monoblock Overall dimensions W 2000 x D 2750 x H 1750 mm Shipping details Gross volume 2.54m 3, Gross weight 860kg, Net weight 684kg 01-08-2018 Im231 Page 3

Installationrequirements Electric supply Provide 230 +/- 10 VAC, 50 Hz, single phase electric supply with proper earthing. (Neutral Earth voltage less than 5 VAC). Separate UPS for computer 5A three pin socket with switch (2 Nos.), 15A three pin socket with switch (1 No), Water supply Continuous, clean and soft water supply@ 4000 LPH, at 10 m. head. Provide tap with 1.25 BSP size connection Space 3500Lx4000Wx2000H in mm (Refer foundation drawings) Drain Provide suitable drain arrangement (Drain pipe PVC 75 mm/ 2.50 size) Exhaust Provide suitable exhaust arrangement (Exhaust GI/MS pipe 1.50 BSP size) Foundation Refer the document Site Utilities under Solutions tab on our website www.apexinnovations.co.in Fuel, oil Petrol@10 lit. Oil @ 3.5 lit. (20W40) 01-08-2018 Im231 Page 4

Packing slip Total no. of boxes: 10, Volume: 2.54 m 3, Gross wt.: 860 kg. Net wt. 684 kg Case No.1/10 Engine Set up Assembly Size W1700xD800xH1200 mm; Volume:1.63m3 Gross weight: 475kg Net weight: 475kg 1 Engine test setup assembly Engine + 1 No. Dynamometer + Base frame Box No.2/10 Engine panel box Size W990xD475xH500 mm; Volume:0.24m 3 Gross weight: 78kg Net weight: 50kg 1 Engine panel box assembly 1 No. Manometer with PU tube. Box No.3/10 Engine panel box structure Size W800xD475xH500 mm; Volume:0.19m 3 Gross weight: 56kg Net weight: 31kg 1 Engine panel box structure assembly 1 No. Rotameters with piping (2) Dynamometer loading unit clamp (1) Box No.4/10 Calorimeter Size W650xD275xH325 mm; Volume:0.06m 3 Gross weight: 45kg Net weight: 22kg 1 Calorimeter assembly 1 No. Box No.5/10 Exhaust pipe Size W900xD200xH250 mm; Volume:0.05m 3 Gross weight: 17kg Net weight: 9kg 1 Exhaust pipe 1 No. Box No.6/10 Pump Size W525xD325xH425mm; Volume:0.07m 3 Gross weight: 42kg Net weight: 23kg 1 Pump 1 No. Box No.7/10 Battery Size W150xD225xH250 mm; Volume:0.01m 3 Gross weight: 25kg Net weight: 17kg 1 Battery 1 No. Box No.8/10 Dash board Size W500xD400xH300 mm; Volume:0.06m 3 Gross weight: 32kg Net weight: 20kg 1 Dash board panel with support structure 1 No. 2 Fuel throttle body with cable 1 No. Box No.9/10 Engine wiring Size W500xD400xH300 mm; Volume:0.06m 3 Gross weight: 30kg Net weight: 12kg 1 Temperature indicator 1 No. 01-08-2018 Im231 Page 5

2 Load indicator 1 No. 3 RPM Indicator 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 RPM sensor 1 No. 9 Temperature sensor (5) 1 No. 10 Set of loose nut bolts 1 No. 11 Tool kit 1 No. 12 Fuel caps(2), Teflon tape(2) & Gasket shellac(1) 1 No. 13 Set of instruction manuals consisting of: 1 No. Instruction manual CD (Apex)Dynamometer Calibration sheets for load cell Box No.10/1 Engine piping Size W1250xD450xH350mm; Volume: 0.20m 3 Gross weight: 60kg Net weight: 25kg 0 1 Piping set (14 pieces) Engine water inlet and outlet, Dynamometer water inlet and outlet, Calorimeter water inlet 1 No. 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) 2 Water supply pipe 1.25 hose 1 No. 3 Load cell bracket 1 set 4 Fuel measuring unit 2Nos (one spare) 1 No. 5 Wiring channel set 1 No. 6 Engine air connection pipe 1 No. 7 Fuel filter assembly 1 No. 8 Exhaust extension pipe with socket and bend 1 No. 9 Pump bracket 1 No. 10 Air box connection 1 No. 11 Calorimeter exhaust outlet flange 1 No. 01-08-2018 Im231 Page 6

Installation Unpack the box(es) received and ensure that all material is received as per packing slip. In case of short supply or breakage contact Apex Innovations / your supplier for further actions. Remove the packings, paper boxes, wrappers from the components. Refer the various photographs below and note locations of different components. Install Engine setup assembly on the foundation and tighten the foundation bolts. Note that RPM sensor, and Load cell are fitted on the dynamometer and Temperature sensors is fitted on the engine. The dynamometer body is clamped with its jack bolts below the dynamometer which is to be lowered. There are jack bolts below the dynamometer which are raised upwards to restrict the swiveling motion. These bolts to be lowered to allow free motion of the body of the dynamometer. Keep Engine panel box structure near Engine setup assembly. Two rotameters are fitted in the panel box structure. Inside the rotameters plastic rods are inserted to arrest the movement of respective floats. These rods are to be removed. Note the C type clamp provided for clamping the dynamometer loading unit. Collect the Calorimeter from Calorimeter box. Fit calorimeter over the base frame. Collect the Engine Panel Box. It is fitted with, Manometer. Orifice for air metering. Check all terminal connections, component mounting and wiring screws. Fit the Engine panel box assembly on the Panel box structure with four bolts. 01-08-2018 Im231 Page 7

Collect Temperature indicator (ESD), Dynamometer loading unit (AX155), Load indicator (SV8), and RPM indicator (RC100A) from Engine wiring box. Remove the covers of Dynamometer loading unit and confirm that all components inside are at proper location and tightly fitted. Remove any packing material inside dynamometer loading unit. Confirm smooth working of loading knob on its front. The cover of the dynamometer loading unit is to be fitted after inserting the unit in the Engine panel support structure. Fit the Temperature indicator (ESD) and put its clamps. Fit load indicator (SV8 series) and put its clamps. Connect 6 wires at respective terminals. Fit RPM indicator (RC100A) and put its clamps. Connect 5 wires at the back terminals. Fit Dynamometer loading unit in the Engine panel structure after removing C clamp. Fit its cover and then fit the C clamp. 01-08-2018 Im231 Page 8

Remove the Exhaust pipe packed in wooden box placed inside Engine piping box and connect it between calorimeter exhaust inlet and engine exhaust outlet. Connect Exhaust extension pipe at the outlet of calorimeter. Insert additional pipe in between and take the exhaust out of the room. At the end put Exhaust muffler. Remove Pump packed in wooden box placed inside Engine piping. Fit Pump bracket to the Engine panel structure and fit pump on it. Collect the piping pieces form Engine piping box. Clean the pipes internally to remove any dust and particles. Complete the piping as follows: o Assemble the PVC drain pipes (3 components) as per the marking done. Put it between Engine panel and Engine set up assembly. o Connect Engine water inlet from engine cooling rotameter to water inlet on engine body. Separate Engine water inlet hose pipe with clamps is provided for connecting the engine side end of the pipe. o Connect Engine water outlet. Connect Engine water outlet hose between the outlet pipe and engine body. The Outlet pipe is bolted on the base frame and the water outlet drains in drain pipe. o Fit Pump outlet at the delivery side of the pump. Connect Rotameter inlet hose pipes to the pump outlet. o Connect Dynamometer water inlet from Pump inlet to dynamometer. o Connect Dynamometer water outlet from dynamometer to drain pipe. o Connect Calorimeter inlet from rotameter to calorimeter. o Connect Calorimeter water outlet to drain. o Fit Strainer and hose nipple at the pump inlet and connect Water supply hose pipe. Connect this hose pipe to site water supply. 01-08-2018 Im231 Page 9

o Fit Air box connection to air box and connect Air hose pipe from air box to engine. o The fuel pipe is put on engine and its one end is connected to fuel filter. Connect the other end in the engine panel at the brass hose tee in the fuel line. The fuel line is to be routed through the wiring channels. Fit Pressure gauge on dynamometer inlet pipe. Fit wiring PVC channel set. Collect the wiring set from Sensors bag and fit 5 temp sensors at respective places. (i) Thermocouple T1 at the inlet water at pump outlet. (ii) Thermocouple T2 at the Engine outlet water on the engine head. (iii) Thermocouple T3 at the calorimeter water outlet. (iv) Thermocouple T4 at the Exhaust inlet of calorimeter and (v) Thermocouple T5 at the exhaust outlet of calorimeter. Route the wiring from PVC wiring channels. Collect Electric supply cable packed in packing (named as Sensors) and connect L N E terminals to the transmitter panel at supply 230V. Connect its 3 pin (F) connector to Dynamometer loading unit at Supply. Connect male 3 pin connector to Electric supply available at the site. Route the cable through wiring channel. Connect cable from RPM sensor, to RPM indicator. Connect cable from Load cell, to Load indicator panel. Connect dynamometer supply cable, 3 pin (M), to Output VDC of dynamometer loading unit. 01-08-2018 Im231 Page 10

Commissioning Remove oil cap fitted on the on the top of the engine and fill lubrication oil (SAE20W40 or equivalent). About 4.5 lit oil is needed. To reach most of the oil to oil sump, it is necessary to wait for about 5 minutes, after filling the oil. Check the oil level by the dip stick provided in the crank case. Two fuel tanks are provided on the top portion of the engine panel. Fill Petrol in one of the fuel tanks or both tanks. Use Fuel funnel for filling. Put fuel caps on the fuel tanks. Open the Fuel cock at the outlet of the fuel tank in which petrol is filled. Note the Fuel in the glass fuel pipe. Remove complete air from the fuel pipe between Engine panel and Engine setup. Fill water in the manometer up to 0 mark level. Ensure that Jack bolts under dynamometer are lowered for free movement of the dynamometer body. Switch on electric supply of the panel box and ensure that temperature indicator, load indicator and RPM indicator are ON. By using multipoint selector switch temperature indicator on engine panel confirm that all temperature values are properly displayed. The values displayed should show around ambient temperatures. Confirm the load value on the load indicator is zero. Rotate the dynamometer body so that the nylon bush is pressing the load cell. Ensure that the load values on the load indicator are changing. Engine starting: o Ensure that all foundation bolts, propeller shaft bolts are properly tightened. Keep water circulation on, Set @ 1000 lph and 250 lph flow rates for engine cooling and calorimeter respectively. Start the engine and allow it to run for 5 minutes in idling condition. Confirm that engine speed is displayed on RPM indicator. Gradually increase throttle to full open condition and load the engine (by knob on DLU) simultaneously maintaining engine speed at @ 2500-3000 RPM. Check load & RPM reading on the indicator. Load the engine up to 15-20 kg allow it to run for 5 minutes Ensure displayed all 5 temperature sensors are logically correct. Stop the engine after releasing the load. Switch off the pump. 01-08-2018 Im231 Page 11

Programming of load indicator (SV8 series) If the load indicator shows error in load indication or if the program is disturbed inadvertently it may need reprogramming/recalibration. Follow following steps. Refer Load indicator documents in components manual and understand the programming steps and key operations. Calibration: If recalibration is needed fit the load cell on flat platform from bottom side. On top surface of the load cell fix a flat sheet for placing which will hold the weights up to 50 kg. (Capacity of load cell) Precautions Use clean and filtered water; any suspended particle may clog the piping. Circulate dynamometer and engine cooling water for some time after shutting down the engine. 01-08-2018 Im231 Page 12

Troubleshooting Note: For component specific problems refer components manual Problems Possible causes / remedies Engine does not start Water circulation pump not switched on Discharged Battery Check Engine wiring connector Air trapped in fuel line Engine EARTH cable Low Battery voltage: Recharge battery Engine preloaded: Switch off dynamometer loading unit or adjust load to minimum Dynamometer does Loose connection from DLU to dynamometer not load the engine Proximity for speed feedback not connected Improper gap between speed feedback proximity and rotating object. Gap should be 5-8 mm. Engine not steady Improper gap of speed feedback proximity sensor after loading connected to DLU. Gap should be 5-8 mm. Faulty air flow Air hose leakage at connections with air-box and with engine. Faulty fuel flow Improper closing of fuel cock. Faulty speed Improper gap between speed sensor and rotating indication object. Gap should be 5-8 mm. Faulty load indication Excessively raised dynamometer jack bolts Damaged load cell due to overstressing Incorrect Check the connection between thermocouple and temperature temperature indicator/transmitter. Note that yellow indication cable of thermocouple is positive and red is negative. Open or damaged temperature sensor 01-08-2018 Im231 Page 13

Experiments 1 STUDY OF ENGINE PERFORMANCE (MANUAL MODE) OBJECT To study the performance of 3 cylinder, 4 stroke, petrol engine connected to dynamometer in manual mode PROCEDURE Fill up the observations in Cal231 worksheet to get the results and performance plots. Ensure that all the nut bolts of engine, dynamometer, propeller shaft, base frame are properly tightened. Ensure that sufficient lubrication oil is present in the engine sump tank. This can be checked by marking on the level stick Ensure sufficient fuel in fuel tank. Remove air in fuel line, if any. Switch on electric supply and ensure that RPM Indicator, Load indicator, Temperature Indicator and DLU (Dynamometer loading unit), are switched on. Start water pump. Adjust the flow rate of "Rotameter (Engine)" to 900-1000 LPH and "Rotameter (Calorimeter)" to 200-250 LPH by manipulating respective globe valves provided at the rotameter inlet. Ensure that water is flowing through dynamometer at a pressure of @ 1 to 2 Kg/cm2.(For Hydraulic dynamometer at a pressure of @ 1.5 to 2 Kg/cm2) Keep the dynamometer loading knob at minimum position.change the Fuel cock position from "Measuring" to "Tank". Start the engine by starter keys switch and allow it to run at idling condition for 4-5 minutes. Ensure that Speed, Temperatures and Manometer reading are correctly displayed on the engine panel. Gradually increase throttle to full open condition and load the engine (by DLU knob) simultaneously maintaining engine speed at @ 2000-2500 RPM. Check load & RPM reading on the indicator. Wait for steady state (for @ 3 minutes) and ensure that RPM & Load is constant during this period. Change the Fuel cock position from "Tank" to "Measuring". Note the time required for 100 ml fuel in seconds by using stopwatch. Turn fuel cock from Measuring to Tank 01-08-2018 Im231 Page 14

Note all temperatures, load, speed, manometer reading and Rotameter flow rates. Refer observation table in excel sheet. Gradually decrease the load to the increase speed in steps of @500 RPM up to @ 4000 rpm maximum and repeat Repeat observations for various speeds e.g. 2500,3000,3500,4000 RPM. After finishing all the observations decrease the load on the engine by DLU. Stop the engine by pressing engine stop starter keys. Allow the water to circulate for about 5 minutes for engine cooling and then stop the pump. Fill up the observations in Cal231 worksheet to get the results and performance plots 01-08-2018 Im231 Page 15

2 Maximum power test OBJECT To study the maximum power generated by engine. PERFORMANCE TEST Ensure cooling water circulation for dynamometer and 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 knob on dynamometer till the engine is fully loaded. (As load is increased further the speed drops significantly.) Note the reading as per Observationsprovided in Cal231 worksheet in Engine.xls. Gradually decrease the load. Change the compression ratio for next observation and repeat above steps. Fill up the observations in Cal231 worksheet to get the results and performance plots. 01-08-2018 Im231 Page 16

3 BSFC and brake thermal efficiency test OBJECT To study the BSFC and brake thermal efficiency PERFORMANCE TEST Ensure cooling water circulation for dynamometer and 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 knob on dynamometer loading unit to @100% of load (Refer experiment 3 for full load) Note the reading as per Observations provided in Cal231 worksheet in Engine.xls. Gradually decrease the load. Fill up the observations in Cal231 worksheet to get the results and performance plots. 01-08-2018 Im231 Page 17

4 Study of Morse test OBJECT To study Morse test PROCEDURE Ensure cooling water circulation for dynamometer, 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 from dynamometer loading unit. Increase the engine throttle to any desired position and simultaneously load the engine to obtain desired speed for which frictional power is to be calculated. Wait for few minutes till steady state is achieved. Note Engine speed and load. Cut off the fuel supply of cylinder no. 1 by pushing the push button "Cyl1" from Morse test panel. The engine speed shall decrease. Now decrease the load on dynamometer and bring back engine speed to the original. Wait for steady state (for @ 3 minutes) and collect the reading Repeat the same for "Cyl2" and "Cyl3". Fill up the readings is the Observationsprovided in Cal231 worksheet in Engine.xls. Gradually decrease the load and throttle and Stop the engine. 01-08-2018 Im231 Page 18

Components used Components Details Engine Make Maruti, Model Maruti 800, Type 3 Cylinder, 4 Stroke, Petrol (MPFI), water cooled, Power 27.6Kw at 5000 rpm, Torque 59 NM at 2500rpm,stroke 72 mm, bore 66.5mm, 796 cc,cr 9.2 Dynamometer Make Technomech, Model TME100, Type Eddy current 100BHP@4500RPM. Dynamometer controller Make Technomech, Model TM-92E, Supply 230V AC,Variable speed Engine, Input PNP pulse from rpm sensor 0-30mV from load cell, Range 0-5000rpm. 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:FF0.090 Temperature sensor Make Radix Type K, Ungrounded, Sheath Dia.6mmX110mmL, SS316, Connection 1/4"BSP (M) adjustable compression fitting Temperature Make ESD, model ESD 9043, 230VAC, Input indicator Thermocouple, 6 point,range 0-1200deg.C. Speed indicator Make Selectron, model RC 100A, Range 6000, 85 to 270VAC/DC with Photoelectric sensor, NPN (5-30 volt DC) Load sensor Make SensotronicsSanmar Ltd., Model 60001,Type S beam, Universal, Capacity 0-50 kg Load indicator Make Selectron, model PIC152-B-2, 85 to 270VAC, retransmission output 4-20 ma Rotameter Make Eureka Model PG 5, Range 25-250 lph, Connection ¾ BSP vertical, screwed, Packing neoprene Rotameter Make Eureka, Model PG 9, Range 100-1000 lph, 01-08-2018 Im231 Page 19

Connection 1 BSP vertical, screwed, Packing neoprene Pump Make Kirloskar, Model GMC1.542, Head 20m., HP 1.5, Single phase, Size 32x25 Type Centrifugal monoblock Battery Make Exide, Model EM 35R (MF), 12 V DC Contact relay Make Leone, Model P40FC 2C, Supply 240V AC, AC240V 5900 ohms, Contact 30A, 250VAC 01-08-2018 Im231 Page 20

Calculations Brake power (kw) 2NT BP 60x1000 2N ( WxR) 60000 0.785xRPMx ( Wx9.81) xarmlength 60000 TxN BHP 75x60 Brake means effective pressure (bar) BPx60 BMEP 2 / 4xD xlx( N / n) xnoofcylx 100 n = 2 for 4 stroke n = 1 for 2 stroke Indicated power From PV diagram (kw) X scale (volume) 1cm =..m 3 Y scale (pressure) 1cm =..bar Area of PV diagram =..cm 2 workdone / cycle / cyl( Nm) AreaofPVdiagram Xscalefact or Yscalefact or 100000 workdone / cycle / cyl ( N / n) NoOfCyl IP 601000 Indicated mean effective pressure (bar) IPx60 IMEP 2 / 4xD xlx( N / n) xnoofcylx 100 Frictional power (kw) FP IP BP FHP IHP BHP BHP IHP FHP Brake specific fuel consumption (Kg/kwh) FuelflowIn kg/ hr BSFC BP Brake Thermal Efficiency (%) BP 3600100 BThEff FuelFlowIn Kg / hr CalVal 01-08-2018 Im231 Page 21

BThEff IThEff MechEff 100 OR BHP FuelHP Indicated Thermal Efficiency (%) IP 3600100 IThEff FuelFlowIn Kg / hr CalVal BThEff 100 IThEff MechEff Mechanical Efficiency (%) BP 100 MechEff IP Air flow (Kg/hr) 2 AirFlow Cd / 4 d 2gh ( Wden / Aden ) X3600 X Aden Volumetric Efficiency AirFlow 100 VolEff TheoreticalAirFlow AirFlow 100 2 / 4 D Stroke ( N / n) 60 NoOfCyl Aden Air fuel ratio AirFlow A/ F FuelFlow Heat Balance (KJ/h) a) HeatSuppli edbyfuel FuelFlow CalVal b) HeatEquiva lenttousefulwork BP 3600 HeatEquivalentToUsefulWork 100 HeatEquivalentToUsefulWorkIn % HeatSuppliedByFuel C) HeatInJack etcoolingwater F3CPW ( T2 T1) Where F3 is rate of Jacket cooling water, T2 is jacket water outlet temperature and T1 is jacket water inlet temperature. HeatInJacketCoolingWater 100 HeatInJacketCoolingWaterIn % HeatSuppliedByFuel d) Heat in Exhaust (Calculate C P ex value): F4CPw ( T 4 T3) 0 CPex.. KJ / Kg k ( F1 F2) ( T5 T6) Where, C p ex Specific heat of exhaust gas kj/kg 0 K 01-08-2018 Im231 Page 22

C pw Specific heat of water kj/kg 0 K F1 Fuel consumption kg/hr F2 Air consumption kg/hr F4 Calorimeter water flow kg/hr T3 Calorimeter water inlet temperature 0 K T4 Calorimeter water outlet temperature 0 K T5 Exhaust gas to calorimeter inlet temp. 0 K T6 Exhaust gas from calorimeter outlet temp. 0 K HeatInExha ust( KJ / h) ( F1 F2) CPex ( T5 Tamb) HeatInExhaust 100 HeatInExhaust % HeatSuppliedByFuel e) Heat to radiation and unaccounted (%) HeatSuppliedByFuel (100%) {( HeatEquivalentToUsefulWork (%) HeatInJacketCoolingWater (%) HeatToExhaust (%)} 01-08-2018 Im231 Page 23

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.inweb: www.apexinnovations-ind.com 01-08-2018 Im231 Page 24