SITE UTILITIES

For Engine setups

The document describes requirements of site utilities for engine set ups purchased from Apex Innovations

General Foundation block Engine exhaust Electric supply

Computer Water supply Drain Water

Contents in the document subject to change without notice

APEX INNOVATIONS PVT. LTD.

E9/1, MIDC, Kupwad, Sangli - 416436 (MS) India Telefax: +91 233 2644098/2644398 Email: support@apexinnovations.co.in Web: www.apexinnovations.co.in

Site utilitiesEngine setups

General
Decide the location and working space considering permanent location of the setups. Temporary location and foundation is not advisable as shifting of the setups, later on, is a tedious task.

Following are the space/layout diagrams and photographs of Engine test setups. Note photos are clicked from working front. Dynamometer is on working front side and engine is on the back side.

Single cylinder engine set up

Multi cylinder engine set up

Space/Layout diagram

Space/Layout diagram

Photograph

Photograph

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Foundation block
Following photographs show foundation blocks with necessary dimensions. Maintain foundation block height to 150 mm as there is rigid piping between Engine Panel Box and Engine Set up. Also maintain width of the foundation block as water drain pipe location is just touching the block.

Anti-vibration mounts instead of foundation block are not recommended. Foundation bolts of size M16 or 5/8 BSW, 250 mm long (8 nos) 50 mm threading length are required. Dig a pit as suitable to for size of the foundation block. Engine setup Foundation Block size LxW mm Depth (Black soil /rocky soil) mm Single cylinder 1700 X 700 800-900 / 600-700 Multi cylinder 1900 X 850 600-700 / 500-600

Put a rectangular grid mesh box in the pit using 6 mm ms rods with 150 mm pitch or 8 mm ms rods with 200 mm pitch.

Grid mesh box

Foundation bolt

Following are two methods for preparing foundation block

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A) Foundation block with integrated foundation bolts

Prepare a Template from ms flat or plywood for

foundation holes. Prepare Support Box of height 150 mm for

template using wood / plywood & battens.

Fit the foundation bolts to the template ensuring

threaded portion 50 mm above the template.

Place the foundation bolt + template assembly on

the Support box and place support box on the pit.

Pour the concrete in the pit. Ensure that the

foundation bolts distances are maintained.

Next day remove the template and support box.

Plaster the sidewalls and top of the foundation block. Allow foundation block curing for 8 days.

Put round or rectangular supports on the

foundation block. Ensure that base frame bottom is above the top of the foundation bolts. Slide the setup over the supports to align the base frame holes with foundation bolts. Then remove the supports.

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B) Foundation block with pockets for foundation bolts

Put vertical round/square/rectangular pieces at a pitch distance of foundations bolts. The size of the pocket should be about 125-150 mm.

Pour the concrete in to the pit. Ensure that the

block height above the ground level is 150 mm.

Next day remove the side plates and pieces

inserted for pockets. Plaster the sidewalls and top of the foundation block. Allow foundation block curing for 8 days.

Insert the foundation bolts in the pockets. Put the

engine set up on the foundation block. Fit the foundation bolts to the engine set up frame from bottom. Fill-up the pockets with concrete slurry and allow

for 3-4 days curing. Do not tighten the nuts of the foundation bolts before curing period is over.

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Note that the foundation block height should be 150 mm. As there is rigid water piping between Engine panel and base frame, extra height foundation block also needs support block for engine panel.

Following picture shows Engine panel box with support block due to extra

foundation block height

Extra height foundation (Not recommended)

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Engine exhaust
Engine exhaust connection should be taken out of the lab by shortest straight route. Avoid bends. Institute has to arrange necessary exhaust piping. Following are the exhaust pipe line sizes. Engine setup Exhaust line size Single cylinder 1.25 BSP Multi cylinder 1.50 BSP

Single cylinder engine set up

Multi cylinder engine set up

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Electric supply
The setups need single phase electric supply with proper earthing. The typical supply voltages should be PhaseNeutral: 220V-240 V; Phase-Earth: 220V-240V; Neutral-Earth: 0-5V Max. This should not exceed 5V. Electrical supply to be arranged on the back wall. The distance between Engine panel and electric supply board should not exceed 2 m. For single cylinder engine setups provide supply board with min. 2 Nos, 5 A, 3 pin plugs with switches For multicylinder engine setups provide supply board with min. 1No, 15 A, 3 pin plug with switch. For computerized set ups provide separate UPS or stabilized electric supply for computer (5 A, single phase 3 pin plug with switch) For computerized petrol engine set ups provide special earthing near the foundation block to avoid sparking noise. (Prepare a pit of 0.3 m x 0.3 m x 0.5 m size. Put a copper plate of @ 150 mm X150 mm x 3 mm thk. Connect the plate to base frame by copper wire. Fill the pit using coal and salt. Consult Electricians.)

Computer
Provide computer of standard configuration with DVD drive (for computerized engine test set up). The computer should have minimum 2GB RAM and USB port for communication. The computer may need to be formatted before installing engine testing software. Separate cabin for computer is not recommended. The computer needs to be near Engine panel Box.

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Water supply
Following are pipe line sizes and water quantity requirements. Engine setup Dynamometer Water line size Water quantity Single cylinder Eddy current 1 BSP @2000 LPH Multi cylinder Eddy current 1.25 BSP @4000 LPH Single OR Multi cylinder Hydraulic 1.25 BSP @4000 LPH

Water supply from overhead tank with positive head is preferred. Avoid water recirculation as the inlet water will continuously heat up and steady state shall not be achieved Engine set up is supplied with water pump. If water supply is from existing pump, for avoiding flow fluctuations, the pump supplied with the set up shall be bypassed.

Drain Water
The Dynamometer cooling outlet water, Engine cooling outlet water and Calorimeter cooling outlet water is collected in a 75 mm PVC pipe. The institute has to arrange 75 mm PVC pipe for taking this drain water outside the lab.

Contents in the document subject to change without notice

APEX INNOVATIONS PVT. LTD.

E9/1, MIDC, Kupwad, Sangli - 416436 (MS) India Telefax: +91 233 2644098/2644398 Email: support@apexinnovations.co.in Web: www.apexinnovations.co.in