P6550 Technical-Documentation Eng

Bell Piston Prover DN400 Page 1
EHRLER PRÜFTECHNIK PNO

ENGINEERING GMBH 6550
Technical Documentation Chapter 1
Overview V1.00
1 Bell Piston Prover DN400 with nozzle system

System no.: 6550-001; 6550-002; 6550-003
Year of 2013
construction:
Customer: Nitech srl
Ehrler Prüftechnik Customer service:

Engineering GmbH Phone: (0049) 07932 / 60666-0
Wilhelm-Hachtel-Straße 8 Fax: (0049) 07932 / 60666-11
D-97996 Niederstetten Email: info@ep-e.com
This documentation is intended for our customers and may not be copied or disclosed to
third parties without prior written consent of EP Prüftechnik Engineering GmbH.
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 All rights with Ehrler Prüftechnik Engineering GmbH. Any right of disposal, like the right of copying and transfer with us.
Overview V1.00
1.1 Table of content:
1 BELL PISTON PROVER DN400 WITH NOZZLE SYSTEM................................................... 1-1

1.1 TABLE OF CONTENT: .......................................................................................................... 1-2
1.2 VERSION MANAGEMENT:..................................................................................................... 1-5
2 SAFETY MEASURES ............................................................................................................. 2-1
2.1 USED SYMBOLS ................................................................................................................. 2-1
2.2 PROPER OPERATION OF THE CONSTRUCTION....................................................................... 2-2
2.2.1 Admissible media / materials / limit value.................................................................... 2-2
2.2.2 Inadmissible modes of operation ................................................................................. 2-2
2.2.3 Manipulation ................................................................................................................ 2-2
2.3 REMAINING RISK ................................................................................................................ 2-3
2.4 SAFETY DEVICES ............................................................................................................... 2-4
2.4.1 General information ..................................................................................................... 2-4
2.5 SOURCES OF DANGER ON THE SYSTEM ............................................................................... 2-5
2.6 OBLIGATIONS OF THE OPERATOR ........................................................................................ 2-5
2.7 OPERATING AND WORKING INSTRUCTIONS........................................................................... 2-6
2.7.1 Instructions for system operation ................................................................................ 2-6
2.7.2 Instructions for electrical equipment ............................................................................ 2-7
2.7.3 Instructions for cleaning............................................................................................... 2-7
3 TRANSPORT AND INSTALLATION ...................................................................................... 3-1
3.1 TRANSPORT AND STORAGE................................................................................................. 3-1
3.1.1 Dimensions and weight ............................................................................................... 3-1
3.1.2 Instructions and protection measures for transport ..................................................... 3-2
3.1.3 Protection of the electrical / electronic equipment ....................................................... 3-2
3.1.4 Conditions for storage and transport ........................................................................... 3-2
3.2 INSTALLATION, ENERGY- AN MEDIA SUPPLY.......................................................................... 3-3
3.2.1 Ground conditions ....................................................................................................... 3-3
3.2.2 Electrical connection.................................................................................................... 3-3
3.2.3 Pneumatic connection ................................................................................................. 3-4
3.2.4 Test medium ................................................................................................................ 3-4
3.3 ENVIRONMENTAL CONDITIONS DURING OPERATION .............................................................. 3-5
3.4 DISPOSAL .......................................................................................................................... 3-5
4 OPERATING INSTRUCTIONS ............................................................................................... 4-1
4.1 BELL PISTON PROVER DN400 WITH NOZZLE SYSTEM .......................................................... 4-1
4.1.1 Workpiece description - Test specimen description .................................................... 4-1
4.1.2 Destination and Purpose - Scope of testing ................................................................ 4-1
4.2 SYSTEM DESCRIPTION ........................................................................................................ 4-2
4.2.1 Bell-Piston-Prover........................................................................................................ 4-2
4.2.2 Nozzle system ............................................................................................................. 4-3
4.3 GENERAL OPERATION ........................................................................................................ 4-4
4.3.1 Switching on the system .............................................................................................. 4-4
4.3.2 Switching off the system .............................................................................................. 4-5
4.3.3 Troubleshooting ........................................................................................................... 4-5
4.3.4 System Control ............................................................................................................ 4-6
4.3.5 Overview System seen from the front ......................................................................... 4-6
4.3.6 Operating elements ..................................................................................................... 4-7
4.3.7 Subassemblies – The main components - Operating functions ................................ 4-10
4.4 PERFORMANCE DATA OF THE SYSTEM ............................................................................... 4-12
4.4.1 Measurement / Control variable ................................................................................ 4-12
4.4.2 Nozzle stepping ......................................................................................................... 4-14

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Overview V1.00
4.5 TECHNOLOGY DIAGRAM.................................................................................................... 4-15

4.6 OPERATING MODES.......................................................................................................... 4-16
4.6.1 Operating mode: Bell-piston mode with pressure ..................................................... 4-16
4.6.2 Operating mode: Bell-piston mode with vacuum ....................................................... 4-16
4.6.3 Operating mode: Nozzle mode with vacuum............................................................. 4-16
4.6.4 Operating mode: Calibration mode of bell-piston prover with nozzles ...................... 4-17
4.6.5 Diagnostic mode ........................................................................................................ 4-17
4.6.6 Calibration ................................................................................................................. 4-17
4.7 MAINTENANCE ................................................................................................................. 4-18
4.7.1 Daily ........................................................................................................................... 4-19
4.7.2 Weekly ....................................................................................................................... 4-19
4.7.3 Monthly ...................................................................................................................... 4-19
4.7.4 Every 6 months .......................................................................................................... 4-20
4.7.5 Yearly......................................................................................................................... 4-20
4.7.6 Important maintenance cycle / on demand ............................................................... 4-20
4.7.7 Recalibration: ............................................................................................................. 4-20
5 SUBASSEMBLY / COMPONENT DESCRIPTION ................................................................. 5-1
5.1 BG 1000 TEST BENCH SETUP - BASE FRAME:...................................................................... 5-1
5.1.1 Range of functions ....................................................................................................... 5-1
5.1.2 The main components ................................................................................................. 5-1
5.1.3 Wear parts ................................................................................................................... 5-1
5.1.4 Spare parts .................................................................................................................. 5-1
5.2 BG 2000 MECHANICAL CONSTRUCTION BELL PISTON / ......................................................... 5-2
NOZZLE BLOCK 1 / NOZZLE BLOCK 2: ............................................................................................... 5-2
5.2.3 Wear parts ................................................................................................................... 5-8
5.2.4 Spare parts .................................................................................................................. 5-8
5.3 BG 3000 PNEUMATICS - VALVES - FLAPS - CONTROL ELEMENTS: ........................................ 5-9
5.3.3 Wear parts ................................................................................................................. 5-10
5.3.4 Spare parts ................................................................................................................ 5-10
5.4 BG 4000 ELECTRIC - SUPPLY - CONTROL: ........................................................................ 5-11
5.4.1 Range of functions ..................................................................................................... 5-11
5.4.2 The main components ............................................................................................... 5-11
5.4.3 Wear parts ................................................................................................................. 5-12
5.4.4 Spare parts ................................................................................................................ 5-12
5.5 BG 5000 MEASUREMENT TECHNOLOGY - SENSORS - INTERFACE MODULES:....................... 5-13
5.5.3 Wear parts ................................................................................................................. 5-17
5.5.4 Spare parts ................................................................................................................ 5-17
5.6 BG 6000 TEST-PC - HARDWARE - AD-CONVERTER: ......................................................... 5-18
5.6.3 Wear parts ................................................................................................................. 5-19
5.6.4 Spare parts ................................................................................................................ 5-19
5.7 BG 7000 SOFTWARE: ...................................................................................................... 5-20
5.8 BG 8000 PRESSURE SUPPLY - COMPRESSOR: .................................................................. 5-21
5.8.3 Wear parts ................................................................................................................. 5-23
5.8.4 Spare parts ................................................................................................................ 5-23
5.9 BG 8100 VACUUM SUPPLY - VACUUM PUMP:..................................................................... 5-24

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Overview V1.00

5.9.3 Wear parts ................................................................................................................. 5-24
5.9.4 Spare parts ................................................................................................................ 5-24
5.10 BG 9000 DOCUMENTATION: ............................................................................................. 5-25
6 APPENDIX ............................................................................................................................... 6-I
6.1 BG 1000 – TEST-BENCH SETUP – BASE FRAME.................................................................... 6-I
6.1.1 Drawings ....................................................................................................................... 6-I
6.1.2 Data sheets (see separate folder) ................................................................................ 6-I
6.2 BG 2000 - TEST SETUP - ADAPTION - CHANGE PARTS - PIPING ............................................ 6-II
6.2.1 Drawings ...................................................................................................................... 6-II
6.2.2 Data sheets (see separate folder) ............................................................................... 6-II
6.3 BG 3000 - PNEUMATICS - VALVES - FLAPS - CONTROL VALVES ........................................... 6-III
6.3.1 Pneumatic plan ........................................................................................................... 6-III
6.3.2 Data sheets (see separate folder) .............................................................................. 6-III
6.4 BG 4000 - ELECTRICS - SUPPLY - CONTROL ...................................................................... 6-IV
6.4.1 Electric diagram .......................................................................................................... 6-IV
6.4.2 Data sheets (see separate folder) .............................................................................. 6-IV
6.5 BG 5000 - MEASUREMENT TECHNIQUE - SENSORS - ........................................................... 6-V
INTERFACE ASSEMBLY GROUP ........................................................................................................ 6-V
6.5.1 Technology diagram .................................................................................................... 6-V
6.5.2 Data sheets (see separate folder) ............................................................................... 6-V
6.6 BG 6000 – TEST-PC - CONTROL - HARDWARE - AD-CONVERTER ....................................... 6-VI
6.6.1 Data sheets (see separate folder) .............................................................................. 6-VI
6.7 BG 7000 - SOFTWARE ..................................................................................................... 6-VII
6.7.1 Data sheets (see separate folder) ............................................................................. 6-VII
6.8 BG 8000 – MEDIA SUPPLY - PRESSURE SUPPLY .............................................................. 6-VIII
6.8.1 Data sheets (see separate folder) ............................................................................ 6-VIII
6.9 BG 8100 – MEDIA SUPPLY - VACUUM SUPPLY .................................................................... 6-IX
6.9.1 Data sheets (see separate folder) .............................................................................. 6-IX
6.10 BG 9000 - DOCUMENTATION .............................................................................................. 6-X
6.10.1 Declaration of conformity ......................................................................................... 6-X
6.10.2 Calibration protocol in original version .................................................................... 6-X
6.10.3 Protocol Electrical measuring .................................................................................. 6-X
6.10.4 Spare parts- and wear parts list .............................................................................. 6-X

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Overview V1.00
1.2 Version management:

Version Date Author Comment
1.00 02.05.2013 PE Creation

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Safety Measures V1.00
2 Safety Measures
2.1 Used Symbols
The following warning symbols for safe working to prevent danger for life and limb are
used in this operating manual and, if needed, on the machine.
Note these instructions and be very cautious!
Danger of crushing
Danger from electric current or voltage
Attention: Danger spot
Attention: High noise level! Wear ear protection!
Maintenance
Information symbol
is used for additional information
Attention: Risk of bursting
Attention: Wear eye protection
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2.2 Proper operation of the construction

2.2.1 Admissible media / materials / limit value
The test bench is designed for the operation with the following media:
• Compressed air (max. 6 bars over pressure)

• Atmospheric air (atmospheric absorbed with vacuum pump)
Any other use or use beyond such as the usage of other products than intended
as well as the handling with hazardous substances or harmful materials is not
intended.
The operator assumes the liability for all damages resulting from non-
compliance.
To the intended use also belongs the compliance of the described procedure by
the maintenance in this operation manual.
2.2.2 Inadmissible modes of operation

The operation of the system is inadmissible
• using equipment modified by the operator
• using other products then intended
• using other media than intended
• using other sensors than intended
• using other hoses than intended
• using other piping than intended
• using other safety devices than intended
• using modified safety valves for pressure reduction
• using other bursting disks than intended
2.2.3 Manipulation
To operate the system it is not allowed to remove, to bypass or to put the safety
devices out of operation. Furthermore it is not allowed to modify the software
used for system control without consulting Ehrler Prüftechnik. This applies also
for modifications on the operating system of the computer or on the software.

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2.3 Remaining risk

The system is designed according to the state-of-the-art and it is reliable.
However there can be danger to the user or third parties and impairments to the
system or other properties in case of improper use.
Despite all precautions there is the following residual risk:
Emission of pressured air (up to 6 bars) when bursting of a hose or a pipe at the
test bench and accordingly to loosening of a hose- or pipefitting.
Direct contact with the vacuum inside the system may lead to injuries.
The operation of the construction with the diagnostic mode is just allowed by
authorized persons ⇒ the readjusting respectively switching of individual valves
can cause substantial damage at the operating persons and the entire site.
There is a possibility, that also after switching off the main control switch some
components in the electric control cabinet or the test bench are energized with
electrical potential. This can be identified in the circuit diagram or by special
marking (yellow electrical-outlet, wires in a yellow hose).

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2.4 Safety devices

To protect the operating personnel, the environment and the system, the system is
equipped with the following safety devices:
2.4.1 General information
No. Description
1. EMERGENCY STOP CONTROL on the control unit at the table
2. EMERGENCY STOP CONTROL at electric control cabinet of the vacuum pump
3. EMERGENCY STOP CONTROL at compressor
4. Relief pressure valve at compressor
5. Differential pressure switch on the piston
6. Earth Leakage Circuit Breaker in electric control cabinet

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2.5 Sources of danger on the system

Emission of pressured air (up to 6 bars) when bursting of a hose or a pipe at the
test bench and accordingly to loosening of a hose- or pipefitting.
Direct contact with the vacuum inside the system may lead to injuries.
Direct contact with live parts may lead to serious injuries.
2.6 Obligations of the operator

Danger of accidents!
The operator is obliged only to operate the system if it is in proper and safe
condition.
• Only trained personnel may operate the system
• Check regularly that the personnel is working in a safety- and hazard-
conscious way in compliance with the operating instructions
• Check regularly that the safety devices are working properly
Observe the operating instructions at all stages of life of the system

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2.7 Operating and working instructions

2.7.1 Instructions for system operation
Basic safety Please observe the instructions below. Failure to observe

instructions these instructions can cause danger to life and limb!
Instructions
1 Errors or damages detected on the machine immediately have to be reported to
the responsible superior. The operation of the test bench has to be interrupted
until the damage is eliminated.
2 Before work is performed on the machine:
• Ensure that the working area is adequately secured (safety chains, warning
signs).
• Inform the operating personnel and appoint a supervisor.
• Depressurize (air) the system.
• Observe the instructions for residual risk.
3 Do not change or modify the machine. This also applies for the installation and
the settings of the safety equipment.
4 Spare parts have to comply with the technical requirements of the manufacturer.
Installation of parts that are no original parts may lead to danger for persons and
machinery. In this case, every liability of the manufacturer is excluded.
5 Properly dispose of all waste and harmful substances such as lubricants or
cleaning agents that can no longer be used.

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2.7.2 Instructions for electrical equipment
Work on electrical parts / subassemblies may only be carried out by qualified

electricians in accordance with the electrical engineering regulations.
5 safety rules
1. Switch off the main switch.
2. Lock the main switch and protect against switching on.
3. Check the absence of voltage.
4. Earthen and short-circuit the workplace.
5. Cover neighboring live parts.
Defective electrical parts may be live and can cause serious injuries.
Defects detected on electrical systems/subassemblies/operating equipment
immediately have to be eliminated. If there is a serious risk of danger, the
system, the subassembly or the operating equipment may not be used any
longer.
2.7.3 Instructions for cleaning

The machine has to be switched off and protected against unintentional
switching on before cleaning. The medias (compressed air, vacuum and
power supply) have to be depressurized respectively de-energized!

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Transport and installation V1.00
3 Transport and installation
3.1 Transport and storage
3.1.1 Dimensions and weight
Bell Piston:
Dimensions (Length x Width x Height) 1000x1000x3600 mm
Weight approx. 1000 kg
SP1:
Compressor:
Cooler and fan:

Vacuum pump with frame and electrical control cabinet:

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3.1.2 Instructions and protection measures for transport

For transporting by truck or by rail, the system has to be secured using tensioning straps
or wedges to avoid falling or slipping.
During transport it is not allowed to store any objects on, in or at the system.
Protect the system against soiling and humidity and inadmissible temperatures.
Please consult Ehrler Prüftechnik for other transport methods.
3.1.3 Protection of the electrical / electronic equipment

For external transport, the PC has to be demounted and separately packed in an ESD-
safe way.
3.1.4 Conditions for storage and transport

For storing the system note the following points:
• Only in covered, closed spaces
• Protect against temperature and humidity variations
• Protect against dust and moisture
• Storage temperature: 10° – 40° Celsius
• Relative humidity: 10 –70 %

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3.2 Installation, energy- an media supply

3.2.1 Ground conditions
The floor has to be even and horizontal. The system has to be placed firmly on the ground
and has to be fixed on the points provided.
3.2.2 Electrical connection

The connection may only be done by specialized personnel. The local
regulations and laws have to be observed.
Check the existing mains voltage and frequency for compliance with the indicated values.
SP1:
Electrical supply 400 V / 50 Hz
Input fuse 32 A
Connection Ceekon-plug 16 A
Vacuum pump with electric control cabinet:

Input fuse 32 A
Compressor:
Input fuse 32 A

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3.2.3 Pneumatic connection
Compressed air supply max. 8 bars
Operating pressure for valves 6 bars, internal regulated
3.2.4 Test medium

Compressed air max. 6 bars over pressure; 710 Nl/min
Vacuum max. 150 hPa abs.; 100 m³/h

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3.3 Environmental conditions during operation
Observe the following points for system operation:

• Dry environment without increased exposure to dust.
In case of permanent increased exposure to dust, the filter elements will be soiled.
In case of humid air, there will be condensation water in the system.
• Temperature: 15° – 25° Celsius additional confinement
Important:
Avoid large temperature variations during system operation.
Avoid direct sunlight.
Pay attention to constant media temperatures; on the same temperature level as

the surrounding area if possible.
Avoid too high temperature gradients of the environment (temperature variations

have got a negative effect on the repeatability of the measured values and
extend the setting time).
Avoid wetting of the test bench with water or other media.
3.4 Disposal
Dispose of the test bench in accordance with the environmental regulations.

Observe the national regulations on waste disposal.
When the test bench is scrapped at the end of its operating life, the different
subassemblies and the individual parts have to be disposed of accordingly.
Call an authorized and certified company for the collection and the disposal of the
material in order to ensure that the materials are disposed of according to the
regulations in force for the disposal of solid industrial waste.
Give priority to recycle the materials.

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Operating Instructions V1.00
4 Operating Instructions
4.1 Bell Piston Prover DN400 with nozzle system
4.1.1 Workpiece description - Test specimen description
This test bench is designed for the calibration of Flow-Measurement-Systems. The test-
samples which are tested / calibrated are e.g. gas meter, LFE, MFM, critical driven
nozzles, etc.
The test-sample adaption is not included in the scope of delivery by Ehrler Prüftechnik.
Therefore there are 2 Triclamp-connections (AD=50,5 mm) provided for cutting site.
4.1.2 Destination and Purpose - Scope of testing
The Flow-Measurement-Test-Bench is calibrating flow-meters with air. With the Bell

Piston there can a volume flow from 16 l/h up to 10.000 l/h (40l/h till 4.000 l/h with PTB
measuring) be adjusted, with the nozzle system a volume flow between 16 l/h and 56.000
l/h with different nozzle combinations can be regulated.
The media temperature has to be kept at room temperature. Upon the test bench 3 test
samples can simultaneously (in row) be tested respectively calibrated.
The room temperature where the measuring system (Bell-Piston-Prover,

SP1, heat-exchanger) is setup must be constant. Also the Bell-Piston-
Prover must be adjusted to this room temperature. Therefore the room
temperature must be constant already for the 3 days before the measuring
to correspond to the room temperature while measuring, to avoid a
temperature drift.
The tempering (room temperature/media temperature) of the system while

measuring has to take place corresponding to PTB test-code volume 29
and must absolutely be followed for stable measuring results.
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4.2 System description

4.2.1 Bell-Piston-Prover
The Bell Piston Prover is a primary standard to account for the quantity medium volume
flow (l/h) of flowing gas with gauge pressures of up to 6 bars. This Bell Piston Prover is a
calibration device as per German Patent no. 102 28 025 / US Patent 7263900 / European
Patent 03 760 640.7.
For the calibration of gas meters, fundamental equipment of the calibration chain were
jointly developed with PTB. To be able to accurately present medium volume flows, a new
bell piston prover device with a spindle stepper motor was developed and has already
been successfully tested. The piston device allows to generate flow rates of very good
reproducibility and to calibrate devices under test generating a continuous flow rate
themselves, such as sonic nozzles, which are often also used as transfer standards.
The bell piston is situated in a pressure-proof container and is moved at its upper end via
step motor and a ball screw spindle with spindle nut. The bell body is sealed both outside
and inside on the guide bars via double seals. Any potential leakage can be detected by
measuring pressure between the seals. The system consists of an upper and a lower
chamber connected with each other by means of a pipeline featuring a check valve.
Compared to a conventional piston device, this design has its advantage in that it arrives
at the unit of length by using outer diameter values. These outer diameter values can be
measured at considerably lower rates of uncertainty than is the case with inside diameter
values.
With an outer bell diameter of approximately 380 mm and a stroke of 720 mm, the
maximally displaced volume amounts to approximately 80 liters. The range of realization
is between QV = 40 l/h and 4.000 l/h, measuring time is at least 1 min. For measuring at
lower levels of uncertainty, flow rates between 16l/h and 40l/h and also between 4.000
und 10.000l/h are possible.
Temperature adjustment is ensured by having the test air flow, for a certain period of time
before the actual measuring, through the entire system, i.e. through the upper chamber,
through the connecting pipe into the lower chamber, past the standing piston and, finally,
through the device under test. The measurement setup is designed for calibration of a
single specimen. It is not useful to calibrate more than one unit in a row in such a high
accuracy system.
• Operating pressure: max 6bar overpressure/ gauge pressure

• Volume flow: 40 l/h up to 4.000 l/h with PTB flow-calibration
• Measuring time (typically): 20 sec to 30 min
• Test medium: air
• Outer dimensions: approx. (L x W x H 1.025 x 1.025 x 3.300 mm)
• Bell diameter: approx. 380 mm
• Maximum stroke: approx. 790 mm
• Displaced volume: approx. 80l with 720mm stroke
• Setting of flow rate: via manual choke valves and manual pressure valve

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4.2.2 Nozzle system

The nozzle calibration system consists of two separate nozzle blocks, each is equipped
with 7 critical nozzles. The two sonic nozzle calibration systems in this application are
used for flow calibration of flow measuring systems.
The systems are designed for use with atmospheric air, the calibration of the sonic
nozzles at PTB will be done by atmospheric pressure. The systems as offered here allow
measuring accuracies for air flow rates of 0,25% (except for 16l/h – 0,3%). Measuring
accuracy depends on temperature.
The two sonic nozzle systems each consist of seven standard nozzle sections in a nozzle
block of appropriate nominal diameter. Each system configuration includes the inlet paths
as well as the nozzle fixtures. Integrated in the nozzle block are the coupling holes with
screw thread for absolute pressure (P) and temperature (T).
The nozzles can be easily replaced and changed, making the systems easily adjustable to
different volumetric flow rates respectively mass flow rates. Switching valves and process
connections are realized via screwed tube and pipe couplings. This is made for maximum
leak tightness and quick serviceability. Nozzle sections are entered into the circuit via
pneumatically controlled valves which will eliminates thermal impact on the directional
valves.
For collection and recording of measuring data, assessment and display of measuring
data, both systems jointly use a PC with National Instruments hardware for measuring
data collection and recording running with LabView operating software. This PC is
integrated in the control panel of the Bell Piston Prover System. The vacuum pump of the
Bell Piston system serves as vacuum supply for both systems.
Nozzle block 1:
• 7-fold nozzle block with pneumatically controlled valves for entering nozzles into the
circuit
• Grading of nozzles in nozzle block 1: 16 / 32 / 64 / 128 / 256 / 512 / 1.024 l/h
• Measuring uncertainty of PTB calibration of nozzles: ≤0,15 % (k=2) (except for 16l/h –
0,2%)
• Measuring uncertainty of overall system: ≤0,25 % (k=2) for operation with atmospheric
air intake (except for 16l/h – 0,3 %)
• Test medium: air; inert gases
• Outer dimensions: approx. L x W x H 350 x 350 x 156mm
Nozzle block 2:
• 7-fold nozzle block with pneumatically controlled valves to enter nozzles into circuit
• Grading of nozzles: 2 / 4 / 8 / 10 / 10 / 10 / 10 m³/h
• Measuring uncertainty of PTB calibration of nozzles: ≤0,15 % (k=2)
• Measuring uncertainty of overall system: ≤0,25 % (k=2) for operation with atmospheric
air intake
• Test medium: air; inert gases
• Outer dimensions: approx. L x W x H 755 x 680 x 250 mm

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4.3 General operation

For operation of the construction note Chapter 2 “Safety-Measures”!
The System is operated via key buttons, a keyboard and a mouse.
4.3.1 Switching on the system

Switch on the test bench in the following order:
Activity Consequence / Comment
Ensure the supply with compressed air,
vacuum and electrical energy.
Switch on the test bench via the main The test bench is supplied with energy. The
switch. computer is booting and loading the
operating system.
Register for the operating system entering You are entering the Windows desktop.
your user name and the corresponding
password.
Start the test bench software by double- As soon as the test bench software has
clicking the icon on the desktop (see booted correctly, the main window is
instruction 1 for further possibilities). displayed. Here you are requested to login.
Switch on the test bench pressing „System The test bench hardware is activated and
ON“. the button "System ON" is illuminated
(instruction 2).
Log in to the test bench software. You are now entering the main
measurement screen.
Start your tests.
Instruction 1:
The software may also be started automatically using the Windows Autostart
function. Furthermore the software can also be started using the Windows
taskbar.
Instruction 2:
The button "System ON" has to be illuminated. If the program is started
correctly, you can start your tests. Some of the functions are password-
protected.

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4.3.2 Switching off the system

Precaution!
The hard disk of your computer can be damaged and data may get lost, if
you did not exit the program and the computer was not shutdown before
switching off.
Switch off the test bench in the following order:

Activity Consequence / Comment
Exit the program. You are on the Windows desktop.
Press „System OFF“ The test bench hardware is deactivated.
Shut down the Computer. Shut down the Computer with the Windows
shut down option and wait until the test PC
is completely shutdown!
Put the main switch in position OFF. Turn off the test bench via the main switch
at the electric control cabinet.
4.3.3 Troubleshooting
Error Activity
Emergency stop Eliminate danger
Restart the test bench and the program
Unexpected interruption of the power Remove error

supply Acknowledge the error message, if
necessary
Restart the test bench and the program
Error messages see Chapter 5 BG 7000 Software

erview_eng.doc
4.3.4 System Control

The test bench is controlled by a PC with appropriate data-entry-hardware from NI. The
software is created in LabVIEW (version 7.0 or higher) using the operating system MS
Windows 7.
For settings and service the software has got a graphical user interface and is operated by
a keyboard and a mouse. The user interface is in English language. See Chapter 4 BG
7000 Software for details.
4.3.5 Overview System seen from the front
Figure 3-1: Front of the test bench

erview_eng.doc
4.3.6 Operating elements

Emergency stop
“System ON“
“System OFF“
Figure 3-2: Operating elements on the table of the SP1
Main switch at the electric control cabinet
Figure 3-3: Operating elements at the SP1 electric control cabinet (back)

erview_eng.doc
Figure 3-4: Operating elements calibration stiffener wall
Figure 3-5: Operating elements stiffener wall

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“System ON“
Emergency Stop
“System OFF“
Main switch
Figure 3-6: Operating elements vacuum-pump electric-control-cabinet
Emergency Stop
Control Panel
Switch Air-dryer
Block valve
Figure 3-7: Operating elements Compressor

erview_eng.doc
4.3.7 Subassemblies – The main components - Operating functions
BG 1000-Test bench setup-Base frame:

• Welded base frame
• Aluminum profile frame
Description see Chapter 5.1
BG 2000-Test setup-Adaption-Piping:
• Bell Piston
• Nozzle system (2 Nozzle-blocks with 7 nozzles each)
• Piping
BG 3000-Pneumatics-Valves-Flaps-Control elements:
• Maintenance unit
• Valve block
• Shift valves
• Adjustment valves
• Control valves
• Compressed-air conditioning
BG 4000-Electrics-Supply-Control:
• Electric control cabinet
• Operating elements
• Wiring
BG 5000-Measurement technology-Sensors-Interface components:

• Sensors
• Measuring elements
• DKD / DAkkS Calibration
• Measuring Bell-Piston
BG 6000-Test PC-Hardware-Analog converter:

• Test PC
• NI Data logging card

erview_eng.doc
BG 7000 Software:
• Test-bench software
BG 8000 Media supply-Pressure supply:

• Compressor for Pressure supply
BG 8100 Media supply-Vacuum supply:

• Vacuum pump for Vacuum supply
BG 9000 Documentation:
• Operating Instruction
• Electric-Plan
• Pneumatic-Plan
• Calibration protocols
• Declaration of conformity
• Drawings
• Data sheets
• Calibration
• Putting into operation
Description see Chapter 6 - Appendix

erview_eng.doc
4.4 Performance data of the system

4.4.1 Measurement / Control variable
Technical data Bell-Piston:

Adjustable control variables From To Uncertainty
Volume Flow [l/h] 16 10.000 ≤0,15% (k=2) for the

range between 40 l/h up
to 4.000 l/h with PTB
calibration
Inlet pressure [bar] 0,2 6 ±0,01 bar
Measured variable From To Uncertainty
Inlet absolute pressure PAIN [hPa] 600 7.000 ±0,1% of value
Inlet temperature TIN [°C] 0 50 1/3 Cl.B
Inlet humidity [%] 0 100 ±3 % FS
Outlet temperature bell piston [°C] 0 50 1/3 Cl.B

TOUTBPP
Temperature bell piston TBPP [°C] 0 50 1/3 Cl.B
Differential pressure bell piston to [hPa] 0 60 ±0,1% of value

inlet test piece PDBPP
Inlet absolute pressure test piece 1 [hPa] 600 7.000 ±0,1% of value
PATP1
Inlet temperature test piece 1 TTP1 [°C] 0 50 1/3 Cl.B
PATP2
PATP3
Ambient absolute pressure PAAMB [hPa] 800 1.200 ±0,1% of value
Ambient temperature TAMB [°C] 0 50 1/3 Cl.B
Ambient humidity HAMB [%] 0 100 ±3 % FS

The accuracies given only apply to thermally steady states with air

erview_eng.doc
Technical Data Nozzle system:

Adjustable control variables From To Uncertainty
Volume Flow, realized with 14 pcs. [l/h] 16 50.000 ≤0,25% (k=2) of overall
sonic nozzles system
Measured variable From To Uncertainty
Absolut pressure upstream nozzle [hPa] 800 1.200 ±0,1% of value

block 1 PANOZIN1
Temperature upstream nozzle block [°C] 0 50 1/3 Cl.B

1 TNOZIN1
Humidity upstream nozzle block 1 [%] 0 100 ±3 % FS

HNOZ1
Absolut pressure downstream nozzle [hPa] 0 1.200 ±0,25% FS

block 1 PANOZOUT1
Absolut pressure upstream nozzle [hPa] 800 1.200 ±0,1% of value

block 2 PANOZIN2
Temperature upstream nozzle block [°C] 0 50 1/3 Cl.B

2 TNOZIN2
Humidity upstream nozzle block 2 [%] 0 100 ±3 % FS

HNOZ2
Absolut pressure downstream nozzle [hPa] 0 1.200 ±0,25% FS

block 2 PANOZOUT2
The accuracies given only apply to thermally steady states with air

erview_eng.doc
4.4.2 Nozzle stepping
Nozzle block 1:
Description Flow rate [l/h]
Nozzle 1 16
Nozzle 2 32
Nozzle 3 64
Nozzle 4 128
Nozzle 5 256
Nozzle 6 512
Nozzle 7 1.024
Nozzle block 2:
Description Flow rate [l/h]
Nozzle 1 2.000
Nozzle 2 4.000
Nozzle 3 8.000
Nozzle 4 10.000
Nozzle 5 10.000
Nozzle 6 10.000
Nozzle 7 10.000

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4.5 Technology diagram

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4.6 Operating modes

The following operation modes exist:
• Bell-piston mode with pressure
• Bell-piston mode with vacuum
• Nozzle mode with vacuum
• Calibration mode of bell-piston-prover with nozzles
• Diagnostic mode
4.6.1 Operating mode: Bell-piston mode with pressure

- V101 / V105 / V108 / V110 / V111 / V112 closed
- V100 / V102 / V103 / V106 open
- Purging the piston-unit with compressed-air until temperature stability is reached
- Closing V102
- Create flow rate with the piston
- Show current flow rate
4.6.2 Operating mode: Bell-piston mode with vacuum

- V100 / V105 / V106 / V110 / V111 / V112 closed
- V101 / V102 / V103 / V108 open
- Switching on vacuum pump
- Wait for running-in and tempering time
- Create flow rate with the piston
- Adjust the piston speed until the pressure in front of the unit-under-test is stable
4.6.3 Operating mode: Nozzle mode with vacuum

- V100 / V101 / V103 / V106 / V108 closed
- V102 / V105 / V110 / V111 / V112 open
- Pilot the needed nozzles respectively nozzle combination (V201 till 207
and V301 till 307)
- Start measurement
- Generate the average date across the test time and display it

erview_eng.doc
4.6.4 Operating mode: Calibration mode of bell-piston prover with nozzles

- V100 / V105 / V106 / V108 closed
- V101 / V102 / V103 / V110 / V111 / V112 open
- Pilot the needed nozzles respectively nozzle combination (V201 till 207
and V301 till 307)
- Adjust the piston speed until the pressure in front of the unit-under-test is stable
- Comparing displayed Qv nozzles with Qv piston via the operator
4.6.5 Diagnostic mode

In the diagnostic mode the operator has the possibility over a diagnostic screen to set all
relevant digital outputs (e.g. valves), display the status of the digital inputs, pilot analog
outputs and display analog inputs
The diagnostic mode is password-protected and only for operators with appropriate
permission available.
4.6.6 Calibration
Modifications on the calibration values (coefficients) of the sensors or
measuring elements directly result in different measured values.
Only modify values on consulting Ehrler Prüftechnik in advance!
After modifying values, recheck them once again.
Back up to the file “AnalogIO.ini” before you adjust any sensors.

If you do so, you can restore the old status if necessary.

erview_eng.doc
4.7 Maintenance
Warning!
Improper maintenance
This fact can result in injuries and damage to property.
• Maintenance of the test bench may only be carried out by authorized
personnel.
Danger!
Electrical voltage resp. over- or underpressure.
This fact can result in injuries and damage to property.
• Maintenance work on electrical parts / subassemblies may only be carried
out by trained electricians according to the 5 electrotechnical safety
regulations.
• Before starting maintenance and cleaning work, switch off the test bench
and protect against unintentional switching on.
• Depressurize all media circuits!
Observe the instructions for servicing and maintenance given in the

operating manuals of the purchased parts!
The most important maintenance tasks:
Before maintenance and servicing close hand valves and depressurize

the whole construction (all media circuits)!
The references for maintenance and servicing have to be followed!

erview_eng.doc
4.7.1 Daily
Maintenance point Activity
Check measurement technology for Check the measured values
plausibility
4.7.2 Weekly
All machine areas Clean with suction air and cleaning rap
Observe the safety measures
Check main switch Press main switch (•)
Check emergency stop Press emergency stop
Check FI-circuit breaker Press test button (•)
Hoses and Cables Check for wear
Exchange in case of wear
Hoses / Piping Check for damage / leakage
Tubing / fittings media circuits Check for damage / leakage
Gaskets of the construction Check for wear and damage
Exchange if necessary
Silencers for exit air Check for soiling
Clean or exchange, if necessary
Construction must be pressureless!
Filters Check for soiling
Clean or exchange, if necessary
Construction must be pressureless!
(•) Quit the testing procedure and shut down the Computer before!
4.7.3 Monthly
Electrical connections and cables Check for damage
Fans of electric control cabinets Check for function

erview_eng.doc
4.7.4 Every 6 months

Pneumatic Check for tightness
Piping / Fitting Media circuit Optical control for leakage
Pneumatic hoses Check for tightness / damages
Mechanical parts in general Check screws for tightness / retighten
Construction must be electroless and
pressureless!
Mechanical parts in general Check covering panels for tightness
Electric parts in general Check cables for tightness and damages
Electrical screw connections Check screws for tightness / retighten
Construction must be electroless!
4.7.5 Yearly
Sensors / Measuring elements Yearly Calibration
4.7.6 Important maintenance cycle / on demand

Maintenance unit for compressed air / Drain condensation water
compressed air regulator control valves Housing must be pressureless therefore!
Maintenance unit for compressed air / Clean filter cartridge and filter lining
compressed air regulator control valves Housing must be pressureless therefore!
4.7.7 Recalibration:
We recommend a yearly recalibration of all sensors and measuring elements.

erview_eng.doc
Subassembly description V1.00
5 Subassembly / component description

5.1 BG 1000 Test bench setup - Base frame:
5.1.1 Range of functions
The test bench SP1 is for the inclusion of the measuring technology, the piping as well as
the electric and pneumatic supply.
This test bench consists of a welded base frame and a construction of aluminum profiles
of the test bench for the installation of all components.
5.1.2 The main components
Figure 5-1: SP1 Front

5.1.3 Wear parts
See wear parts list in Appendix
5.1.4 Spare parts

See spare parts list in Appendix
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Overview_eng.doc
5.2 BG 2000 Mechanical construction bell piston /

nozzle block 1 / nozzle block 2:
This subassembly describes the construction of the bell piston, the nozzle blocks, the
piping of the test bench and the connection for the unit-under-test adaption.
Motor
Spindle
Air entrance Bell Piston Prover
Ball valve
Connecting line
Ball valve
Air exit Bell Piston Prover
Figure 5-2: Bell-Piston

Overview_eng.doc
Temperature sensor Pressure sensor connection nozzle with fitting Valve before nozzles
Figure 5-3: Nozzle block 1

Overview_eng.doc
Block valves after nozzles Connection pressure sensor Collector
Figure 5-4: Distributing block after nozzle block 1

Overview_eng.doc
Nozzle with fitting Connection pressure sensor Temperature sensor Valve before nozzles
Figure 5-5: Nozzle block 2

Overview_eng.doc
Block valves after nozzles Connection pressure sensor Collector to Vacuum pump
Figure 5-6: Distributing block after nozzle block 2

Overview_eng.doc
Calibration connections Test-piece connections

pressure sensors pressure, frequency, temperature
Figure 5-7: Calibration stiffener wall for Pressure sensors

Overview_eng.doc
Entrance pressure regulator Manometer compressed air Flow regulator

compressed air
Figure 5-8: Pressure regulator and flow regulator
5.2.3 Wear parts

See wear parts list in appendix
5.2.4 Spare parts

See spare parts list in appendix

Overview_eng.doc
5.3 BG 3000 Pneumatics - Valves - Flaps - Control elements:

This subassembly consists of the compressed air preparation and the pneumatic supply.
Manual main valve Filter regulator Electric main valve Pressure switch
Figure 5-9: Maintenance unit
Before maintenance and servicing works close hand valves and depres-
surize the system (all media circuits)!
Consider the references for maintenance and servicing!

Overview_eng.doc
Bus knot Ethernet connection Power supply Switching valves
Figure 5-10: Valve cluster
5.3.3 Wear parts

5.3.4 Spare parts


Overview_eng.doc
5.4 BG 4000 Electric - Supply - Control:

The electric of the test bench consists of the electric control cabinet and the electric
supply of all components.
There is possibly still voltage on some of the components in the electric

control cabinet or in the test bench even after switching off the main
switch. For voltage see circuit diagram or look for special marking (yellow
sockets or cables in yellow hose).
Frequency converter
heat exchanger
Motor controller
Contactors
Terminal blocks
Temperature signal
converter
Terminal
DIG I/O Power supply
Figure 5-11: Electric control cabinet SP1

Overview_eng.doc
FC Terminal block Contactors power supply main switch
Figure 5-12: Electric control cabinet Vacuum pump
5.4.3 Wear parts

5.4.4 Spare parts


Overview_eng.doc
5.5 BG 5000 Measurement technology - Sensors - Interface

modules:
The measurement technology describes the different sensors.
PA_TP2 PA_PIS1_EX PA_TP1 PA_TP3
Figure 5-13: Absolut pressure sensors
PA_NOZIN1 PA_NOZOUT1 PA_NOZIN2 PA_NOZOUT2
Figure 5-14: Absolut pressure sensors nozzles

Overview_eng.doc
PA_AMB
Figure 5-15: Absolut pressure sensors ambient

Overview_eng.doc
PD_LINE DPS01
Figure 5-16: Differential pressure sensors and Differential pressure switch

Overview_eng.doc
T_AMB / H_AMB
Figure 5-17: Temperature- and humidity combined sensor ambient
T_NOZIN1 T_NOZIN2
Figure 5-18: Temperature sensors nozzle block 1 and 2
H_NOZIN1 H_NOZIN2
Figure 5-19: Humidity sensors nozzle block 1 and 2

Overview_eng.doc
H_PIS1_EX T_PIS1_EX PA_PIS1_EX
Figure 5-20: Sensors entrance Bell Piston Prover
T_PIS2_EX
Figure 5-21: Temperature sensor exit Bell Piston Prover
5.5.3 Wear parts

5.5.4 Spare parts


Overview_eng.doc
5.6 BG 6000 Test-PC - Hardware - AD-converter:

This subassembly consists of the test PC and the associated hardware.
Filter elements On-Off switch Status LEDs USB Ports DVD Rom
Figure 5-22: PC Front
Main switch Keyboard/Mouse Monitor NI-Measurement data logging
Figure 5-23: PC back

Overview_eng.doc
5.6.3 Wear parts

5.6.4 Spare parts


Overview_eng.doc
5.7 BG 7000 Software:

Covers the entirely test program for controlling the test bench and data logging.
In the following the software description:

See Appendix.

Overview_eng.doc
5.8 BG 8000 Pressure supply - Compressor:

This subassembly ensures the pressure- and flow supply of the test bench.
PCV Fine filter Refrigerant type dryer Accumulator Control unit
Figure 5-24: Compressor
Before maintenance and servicing works close hand valves and

depressurize the system (all media circuits)!
Consider the references for maintenance and servicing!
Follow the information for servicing and maintenance in the handbooks

from the purchased parts!

Overview_eng.doc
Motor Air entrance Air exit Cooler
Figure 5-25: Heat exchanger (Air cooler)

Overview_eng.doc
5.8.3 Wear parts

5.8.4 Spare parts


Overview_eng.doc
5.9 BG 8100 Vacuum supply - Vacuum pump:

This subassembly describes the vacuum- and vacuum-flow creation of the test bench.
Electric control cabinet
Motor
Intake fitting
Pump housing
Exhaust
Figure 5-26: Vacuum pump
5.9.3 Wear parts

5.9.4 Spare parts


Overview_eng.doc
5.10 BG 9000 Documentation:
Declaration of conformity, protocols and other documents:

See chapter 6 – Appendix BG9000 Documentation

Overview_eng.doc
Bell Piston Prover DN400 Appendix I
ENGINEERING GmbH 6550
Appendix V1.00
6 Appendix
6.1 BG 1000 – Test-bench setup – Base frame
6.1.1 Drawings
6.1.2 Data sheets (see separate folder)

Overview_eng.doc
Bell Piston Prover DN400 Appendix II
Appendix V1.00
6.2 BG 2000 - Test setup - Adaption - Change parts - Piping
6.2.1 Drawings

Overview_eng.doc
Bell Piston Prover DN400 Appendix III
Appendix V1.00
6.3 BG 3000 - Pneumatics - Valves - Flaps - Control valves
6.3.1 Pneumatic plan

Overview_eng.doc
Bell Piston Prover DN400 Appendix IV
Appendix V1.00
6.4 BG 4000 - Electrics - Supply - Control
6.4.1 Electric diagram

Overview_eng.doc
Bell Piston Prover DN400 Appendix V
Appendix V1.00
6.5 BG 5000 - Measurement technique - Sensors -

Interface assembly group
6.5.1 Technology diagram

Overview_eng.doc
Bell Piston Prover DN400 Appendix VI
Appendix V1.00
6.6 BG 6000 – Test-PC - Control - Hardware - AD-converter

Overview_eng.doc
Bell Piston Prover DN400 Appendix VII
Appendix V1.00
6.7 BG 7000 - Software

Overview_eng.doc
Bell Piston Prover DN400 Appendix VIII
Appendix V1.00
6.8 BG 8000 – Media supply - Pressure supply

Overview_eng.doc
Bell Piston Prover DN400 Appendix IX
Appendix V1.00
6.9 BG 8100 – Media supply - Vacuum supply

Overview_eng.doc
Bell Piston Prover DN400 Appendix X
Appendix V1.00
6.10 BG 9000 - Documentation
6.10.1 Declaration of conformity
6.10.2 Calibration protocol in original version
6.10.3 Protocol Electrical measuring
6.10.4 Spare parts- and wear parts list

Overview_eng.doc

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Bell Piston Prover DN400 Page 1

EHRLER PRÜFTECHNIK PNO

1 Bell Piston Prover DN400 with nozzle system

Ehrler Prüftechnik Customer service:

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1.1 Table of content:

1 BELL PISTON PROVER DN400 WITH NOZZLE SYSTEM................................................... 1-1

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4.5 TECHNOLOGY DIAGRAM.................................................................................................... 4-15

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5.9.1 Range of functions ..................................................................................................... 5-24

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1.2 Version management:

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Safety Measures V1.00

2.1 Used Symbols

Note these instructions and be very cautious!

Danger from electric current or voltage

Attention: Danger spot

Attention: High noise level! Wear ear protection!

Attention: Risk of bursting

Attention: Wear eye protection

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Safety Measures V1.00

2.2 Proper operation of the construction

• Compressed air (max. 6 bars over pressure)

2.2.2 Inadmissible modes of operation

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Safety Measures V1.00

2.3 Remaining risk

Despite all precautions there is the following residual risk:

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Safety Measures V1.00

2.4 Safety devices

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Safety Measures V1.00

2.5 Sources of danger on the system

Direct contact with live parts may lead to serious injuries.

2.6 Obligations of the operator

Observe the operating instructions at all stages of life of the system

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Safety Measures V1.00

2.7 Operating and working instructions

Basic safety Please observe the instructions below. Failure to observe

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Safety Measures V1.00

2.7.2 Instructions for electrical equipment

Work on electrical parts / subassemblies may only be carried out by qualified

2.7.3 Instructions for cleaning

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Transport and installation V1.00

3 Transport and installation

3.1 Transport and storage

3.1.1 Dimensions and weight

Weight approx. 1000 kg

Weight approx. 600 kg

Weight approx. 250 kg

Cooler and fan:

Vacuum pump with frame and electrical control cabinet:

Weight approx. 120 kg

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Transport and installation V1.00

3.1.2 Instructions and protection measures for transport