VC

CR EN
NGIN
NE TEST SE
ET UP
P
1CYLIN
1 NDR, 4STROK
4 KE, DIIESEL WITH
H EGR
(Com
mputerizzed)

Produ
uct Code
2
234

Instrucction man
nual

Contents

1 Des
scription 5 Installattions 9 Ex
xperiments
2 Spe
ecifications 6 Commis
ssioning 10 Components used
3 Ins
stallation req
quirements 7 Software 11 Calculations
s
4 Pac
cking slip 8 Troubles
shooting 12 Wiring &Wa
arranty
Apex Innovations

Description
The setup consists of single cylinder, four stroke, VCR (Variable Compression Ratio)
Diesel engine connected to eddy current type dynamometer for loading. The
compression ratio can be changed without stopping the engine and without altering
the combustion chamber geometry by specially designed tilting cylinder block
arrangement. Setup is provided with necessary instruments for combustion pressure
and crank-angle measurements. These signals are interfaced to computer through
engine indicator for Pθ−PV diagrams. Provision is also made for interfacing airflow,
fuel flow, temperatures and load measurement. The set up has stand-alone panel
box consisting of air box, two fuel tanks for blend test, manometer, fuel measuring
unit, transmitters for air and fuel flow measurements, process indicator and engine
indicator. Rotameters are provided for cooling water and calorimeter water flow
measurement.
The setup enables study of VCR engine performance with EGR for brake power,
indicated power, frictional power, BMEP, IMEP, brake thermal efficiency, indicated
thermal efficiency, Mechanical efficiency, volumetric efficiency, specific fuel
consumption, A/F ratio and heat balance. Labview based Engine Performance
Analysis software package “ICEngineSoft” is provided for on line performance
evaluation.
A computerized Diesel injection pressure measurement is optionally provided.

DYNAMOMETER ENGINE

Schematic arrangement

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Specifications
Product VCR Engine test setup 1 cylinder, 4 stroke, Diesel with
EGR (Computerized)
Product code 234
Engine Make Kirloskar, Type 1 cylinder, 4 stroke Diesel, water
cooled, power 3.5 kW at 1500 rpm, stroke 110 mm,
bore 87.5 mm. 661 cc, CR 17.5, Modified to VCR engine
CR range 12 to 18
Dynamometer Type eddy current, water cooled with loading unit
Propeller shaft With universal joints
Air box M S fabricated with orifice meter and manometer
Fuel tank Capacity 15 lit with glass fuel metering column
Calorimeter Type Pipe in pipe
EGR Water cooled, ss 304, Range 0-15%
Piezo sensor Range 5000 PSI, with low noise cable
Crank angle sensor Resolution 1 Deg, Speed 5500 RPM with TDC pulse.
Data acquisition device NI USB-6210, 16-bit, 250kS/s.
Piezo powering unit Make-Apex, Model AX-409.
Digital milivoltmeter Range 0-200mV, panel mounted
Temperature sensor Type RTD, PT100 and Thermocouple, Type K
Temperature RTD PT100, Range 0–100oC,3 Nos; Thermocouple, Range 0‐1200
transmitter oC, 2 Nos

Load indicator Digital, Range 0-50 Kg, Supply 230VAC

Load sensor Load cell, type strain gauge, range 0-50 Kg
Fuel flow transmitter DP transmitter, Range 0-500 mm WC
Air flow transmitter Pressure transmitter, Range (-) 250 mm WC
Software “ICEngineSoft” Engine performance analysis software
Rotameter Engine cooling 40-400 LPH; Calorimeter 25-250 LPH
Pump Type Monoblock
Overall dimensions W 2000 x D 2500 x H 1500 mm
Optional Computerized Diesel injection pressure measurement

Shipping details
Gross volume 2.02m3, Gross weight 744kg, Net weight 639kg

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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 (3 Nos.)
Water supply
Continuous, clean and soft water supply@ 1000 LPH, at 10 m. head. Provide tap with
1” BSP size connection
Computer
Typical configuration as follows:
Computer with OS Windows 8 or higher, RAM Min 4 GB, DVD drive, high speed USB
port, Monitor with pixel setting 1200x900,
Space
3300Lx3200Wx1700H in mm (Refer foundation drawings)
Drain
Provide suitable drain arrangement (Drain PVC pipe 75 mm/2.5” size)
Exhaust
Provide suitable exhaust arrangement (Exhaust GI/MS pipe 32 NB/1.25” size)
Foundation
Refer the document “Site Utilities” under Solutions tab on our
websitewww.apexinnovations.co.in
Fuel, oil
Diesel@10 lit.
Oil @ 3.5 lit. (20W40)

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Packing slip
Total no. of boxes: 9, Volume: 2.02 m3, Gross weight: 744 kg. Net wt. 639 kg
Box Engine set up assembly Gross weight: 444kg
3
No.1/9 Size W1600xD670xH1120 mm; Volume:1.20m Net weight: 444kg
1 Engine test setup assembly Engine + 1 No.
Dynamometer
Box Engine panel box Gross weight: 75kg
3
No.2/9 Size W990xD475xH500 mm; Volume:0.24m Net weight: 52kg
1 Engine panel box assembly 1 No.
Transmitter panel, Fuel pipe, Fuel DP
transmitter, Air transmitter, NI USB 6210, power
supply and wiring, Manometer with PU tube.
Box Engine panel box structure Gross weight: 46kg
No.3/9 Size W800xD475xH500 mm; Volume:0.19m3 Net weight: 25kg
1 Structure assembly consisting of 1 No.
Rotameters with piping (2)
Dynamometer loading unit clamp (1)
Box Calorimeter Gross weight: 28kg
3
No.4/9 Size W725xD250xH325 mm; Volume: 0.06m Net weight: 15kg
1 Calorimeter 1 No.
2 Calorimeter support structure with pad 1 No.
Box Exhaust pipe Gross weight: 16kg
3
No.5/9 Size W900xD200xH200 mm; Volume: 0.04m Net weight: 10kg
1 Exhaust pipe 1 No.
Box Pump Gross weight: 14kg
No.6/9 Size W300xD225xH300 mm; Volume:0.02m3 Net weight: 7kg
1 Pump 1 No.
Box Battery Gross weight: 25kg
No.7/9 Size W150xD225xH250 mm; Volume:0.01m3 Net weight: 17kg
1 Battery 1 No.
Box Engine piping Gross weight: 58Kg
No.8/9 Size W1250xD450xH350mm; Volume: 0.20m3 Net weight: 41kg
1 Piping set (14 pieces) 1 No.
Engine water inlet and outlet, Dynamometer
water inlet and outlet, Calorimeter water inlet

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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 Fuel Glass tube 2Nos (one spare) 1 No.
3 Funnel for fuel fill 1 No.
4 Wiring PVC channel set (4 pieces) 1 No.
5 Starting kick/Handle 1 No.
6 Exhaust extension pipe with socket 1 No.
7 Pump bracket 1 No.
8 Air box connection 1 No.
9 Calorimeter exhaust outlet flange 1 No.
Box Engine wiring Gross weight: 38kg
No.9/9 Size W500xD400xH300 mm; Volume:0.06m3 Net weight: 18kg
1 Piezo powering unit 1 No.
2 Load indicator 1 No.
3 Digital voltmeter 1 No.
4 Dynamometer loading unit 1 No.
5 Pressure gauge 1 No.
6 Wiring set 1 No.
7 Load cell with nut bolt 1 No.
8 Crank angle sensor 1 No.
9 Temperature sensors (5) 1 No.
10 Piezo sensor 1/2Nos.
11 Low noise cable 1/2Nos.
12 Data acquisition device and driver CD 1 No.
13 Apex Enginesoft DVD CD 1 No.
14 Set of loose nut bolts 1 No.
15 Tool kit 1 No.
16 Dash board box for Engine starter with charger 1 No.
17 Fuel caps(2), Teflon tape(2) & Gasket shellac(1) 1 No.
18 Set of instruction manuals consisting of: 1 No.
Instruction manual CD (Apex)
DP transmitter
Dynamometer (AG10/TM15)
Sheet Kirloskar engine maint.
Sheet Calibration for Piezo sensor and load cell

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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 Crank angle sensor, and Load cellare fitted on the dynamometer and
Piezo sensor is fitted on the engine. The dynamometer body is clamped with its
base by locking flat which is to be removed. 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 and Calorimeter structure from Calorimeter box. Remove
calorimeter from the structure, reverse the structure and put it near engine. Fit
calorimeter over the structure.

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• Collect the Engine Panel Box. It is fitted with Manometer, Fuel DP transmitter, Air
transmitter, Orifice for air metering, Transmitter panel(fitted with Power supply
and five Temperature transmitters). NI-6210 USB interface with cable for
computer.
• Check all terminal connections, component mounting and wiring screws
• Fit the Engine panel box assembly on the Panel box structure with four bolts.

• Collect Piezo powering unit (Ax409), Dynamometer loading unit (AX155), Load
indicator (SV8)and Digital voltmeter (SMP35) from “Engine wiring” box.

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• Remove the covers ofPiezo powering unit and 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 Piezo powering unit (AX409) and put its clamps. Connect Electric supply
cables and a 9 pin connector at Output
• Fit load indicator (SV8) and put its clamps. Connect 6 wires at respective
terminals.
• Fit Voltmeter (Meco) and put its clamps. Connect 4 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.

• 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 pipeat the outlet of calorimeter. Insert additional pipe
in between and take the exhaust out of the room. At the end put Exhaust muffler.
• Connect EGR to exhaust outlet pipe and air inlet manifold.
• Remove Pump packed in wooden box placed inside “Engine piping”. Fit Pump
bracketto 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.

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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 hosebetween the
outlet pipe and engine body. The Outlet pipe is to 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.
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) RTD T1/T3 at the inlet water at pump outlet. (ii) RTD T2 at the Engine
outlet water on the engine head. (iii) RTD T4 at the calorimeter water outlet. (iv)

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Thermocouple T5 at the Exhaust inlet of calorimeter and (v) Thermocouple T6 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
LNE terminals to the transmitter panel at supply 230V. Connect its 3 pin (F)
connector to Dynamometer loading unit at Supply. Connect male 3 pin connectorto
Elelctric supply available at the site. Route the cable through wiring channel.
• Connect cablefrom Crank angle sensor, 4 pin round (F), to CA of Piezo powering
unit.
• Connect cable from Load cell, 4 pin round (F), to Load on transmitter panel.
• Remove black cap on piezo sensor andconnect piezo cable to the sensor. Connect
other end of the piezo cable to Piezo powering unit at PZ1.
• Connect dynamometer supply cable, 3 pin(M), to Output VDC of dynamometer
loading unit.
• Take out USB cable from NIUSB 6210 from Engine Panel and connect to Computer.
The cable is short in length. A spare cable of extra length is also supplied.

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Commissioning
• Remove top cover on the rocker box of the engine. Fill lubrication oil (SAE20W40
or equivalent) in the rocker box. About 3.5 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. You may fill
two different fuels, for testing the fuels. Fill Diesel 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 Diesel is filled. Note the
Fuel in the glass fuel pipe. Remove complete air from the fuel pipe between Engine
panel and Engine setup.
• Air removal from fuel DP:Remove air bubbles from the fuel line connecting to
Fuel DP transmitter. For removing the air loosen the Air vent on the fuel DP
transmitter and allow some fuel to come out from it and then tighten it gently.

• 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 Piezo powering unit,
load indicator and voltmeter are ON.
• TDC adjustment:
o Keep the Decompression lever on the rocker box in vertical position
and rotate the flywheel slowly in clockwise direction (Viewed from
dynamometer end) till the CA mark on the flywheel matches with the
reference pointer provided on the engine body. This rotation
movement should be unidirectional.

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o Check if the TDC light on the Piezo powering unit is lit. If not adjust the
crank angle sensor as follows:
o Loosen the four screws on the flange provided for clamping the
crankangle sensor on the mounting bracket.
o Ensure that crank angle sensor body is free to rotate about its axis.
Rotate the sensor body slowly till the TDC light on the piezo powering
unit glows. Ensure that the flywheel is adjusted for CA mark as
explained above.
o Clamp the four screws on the flange.

• By using multipoint selector switch on the engine panel confirm that all voltage
values are properly displayed. Convert the voltage values in to respective
temperature reading using parameter chart pasted on the panel. 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 vlues on the
load indicator are changing.
• Compression Ratio adjustment:
o Slightly loosen 6 Allen bolts provided for clamping the tilting block.
o Loosen the lock nut on the adjuster and rotate the adjuster so that the
compression ratio is set to “maximum”. Refer the marking on the CR
indicator.
o Lock the adjuster by the lock nut.
o Tighten all the 6 Allen bolts gently.

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o You may measure and note the centre distance between two pivot pins
of the CR indicator. After changing the compression ratio the
difference (∆) can be used to know new CR.

• Switch on the pump after providing electric supply to it and ensure water
circulation through engine, calorimeter and dynamometer.
• Keep the Load knob on the dynamometer loading unit at minimum position.
• Engine starting:
o Ensure that all foundation bolts, propeller shaft bolts and Allen bolts of
tilting block (of VCR arrangement) are properly tightened.
o Keep the Decompression lever (Decomp lever) in vertical position.
Ensure that Engine stop lever is free and can be pulled towards engine
cranking side for stopping the engine.
o For first start after installation, loosen the fuel inlet pipe to the injector
o Crank the engine slowly till fuel starts dribbling out from the loosened
nut. Then tighten the nut.
o Rotate the handle 5-6 rotations manually in clockwise direction (viewed
from engine side) by right hand. When the flywheel has gathered
sufficient momentum make the decompression lever horizontal by left
hand while cranking the engine and keep on cranking for additional 2-3
rotations.
o The handle will release automatically and come out, however do not
leave handle.

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o Repeat above steps if it does not start at first instance. Engine starting
needs some practice. If engine does not start you may check valve
setting as explained below.
o To Stop the engine pull Engine stop lever.

• Keep water circulation on, Set @ 200 lph and 75lph 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 Piezo powering unit.
• Rotate the knob on dynamometer loading unit and gradually load the engine.
Ensure that the load on the load indicator gradually increases.
• Load the engine up to 12 kg allow it to run for 5 minutes.
• Ensure that voltages displayed for all 5 temperature sensors are logically correct.
• Stop the engine after releasing the load.
• Switch off the pump
• For software installation on the computer proceed to Software section
Engine Valve setting:
This peocedure to be followed only if engine does not start or pressure crankangle
diagram shows some pressure values at the start of suction.)
• Open the cover on the rocker box. Rotate the flywheel slowly and observe the
rocker movement. The cranking side rocker is for inlet air and flywheel side
rockeris for exhaust air. The “Engine fuel pump side end” of each rocker is pushed
up by the valve rods below. Due to this the front end (injector side end) goes down

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to open the respective valves (Inlet/exhaust). For alternate rotation of flywheel at

TDC position, both rockers move simultaneously.
• Adjust the TDC mark marked as T on the flywheel with the pointer. (Note there are
two marks one marked as ‘E’ and other as ‘T’. ‘E’ marking is to be used for
crankangle sensor adjustment for PO diagram). Ensure that when we bring the
flywheel near these markings both rockers should move i.e. piston is at the start of
new cycle.
• Refer the valve timing diagram on the engine panel. The Inlet valve should open
4.5 degree before TDC and exhaust valve should close 4.5 deg after TDC. Make a
marking of @ 16 mm (4.5 degree) on both sides of TDC mark.
• Rotate the flywheel in anticlockwise direction for 60 degrees and slowly rotate in
clockwise direction up to the first mark before TDC (Here the inlet valve should
open. Exhaust valve is already in open position i.e. rocker is in operated position).
Adjust the Tappet clearance by using ring spanner no. 18 such that the clearance if
any is removed and rocker just starts opening the inlet valve.
• Further rotate the flywheel in clockwise direction to next marking of 4.5 degrees
after TDC. At this position the exhaust valve should fully close. Adjust the tappet
clearance so that there is no clearance in exhaust rocker. (Note: The decomp lever
should be in horizontal position)
• Ensure that inlet valve opens at 4.5 degree BTDC and exhaust valve closes 4.5
degree ATDC.
Programming of load indicator
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 the 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.
• Piezo Sensor Handling:
o While engine is running ensure cooling water circulation for combustion
pressure sensor / engine jacket.
o Diaphragm of the sensor is delicate part. Avoid scratches or hammering.

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o A long sleeve is provided inside the hole drilled for piezo sensor. This sleeve
is protecting the surface of the diaphragm. While removing the sensor, this
sleeve may come out with the sensor and fall down or loose during handling.
o Status of the sensor is indicated on the Piezo powering unit. Damages to the
electronic parts of the sensor or loose connection are indicated as "open" or
"Short" status on Piezo powering unit.

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Software
Computer requirement
Typical configuration as follows:
Computer with OS Windows 8 or higher, RAM Min 4 GB, DVD drive, high speed USB
port, Monitor with pixel setting 1200x900,
Refer ICEngineSoft DVD supplied with the setup. Follow the instructions and
instal the software.

For instructions related to software refer help provided in the software.

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Troubleshooting
Note: 1 For component specific problems refer components’ manual
2 For wiring problems refer drawing “Wiring234”.
Problems Possible causes / remedies
Engine does not start • Insufficient fuel
• Air trapped in fuel line: Remove fuel. To remove air
trapped in the fuel pipe connected to injector loosen the
nut near the injector and crank the engine.
• Clogged injector: Remove injector and check the fuel
injection spray while engine is manually cranked.
• Improper valve setting: The valve setting procedure is
described below.
• VCR setting low: Set VCR to 17-18
• Fuel injection point disturbed: Set to company setting
• Dynamometer loaded: Switch off dynamometer
Dynamometer does • Faulty/ loose wiring from dynamometer loading unit to
not load the engine dynamometer
• NoDC voltage at the outlet of dynamometer loading unit.
Check DLU for loose connection
• No free movement of dynamometer body due to raised
jack bolts below dynamometer body
• Water inlet outlet hoses connecting dynamometer body
below the dynamometer may be very hard.
Faulty air flow • Air hose leakage at connections between air box and
engine.
Faulty fuel flow • Air trap in pressure signal line to fuel transmitter
• Improper closing of fuel cock.
Software does not • Faulty or wrong USB port
work • Virus in computer
• Loose connections, improper earthing
Faulty indicated • TDC setting disturbed. Readjust TDC setting(refer
power commissioning).
• Check configuration data
Faulty pressure crank • Improper earthing
angle diagram • Adjust Plot reference for cylinder pressure in setup
constants such that suction stroke pressure just matches
the zero line.

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• If peak pressure is just after TDC, TDC setting disturbed,

readjust
• If peak pressure shifts randomly with respect to TDC,
coupling of crank angle sensor may be loose
Faulty speed • Broken coupling of crank angle sensor
indication
Incorrect • Check the connection between thermocouple, RTD,
temperature transmitters, Digital voltmeter. Note that yellow cable of
indication thermocouple is positive and red is negative.
• Open or damaged temperature sensor

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Experiments

1 Study of VCR engine performance (Computerized mode)

Object
To study the performance of 1 cylinder, 4 stroke, Diesel engine connected to eddy
current dynamometer in computerized mode.
Adjustment of the compression ratio
• Slightly loosen the 6 nos. vertical Allen (socket headed)bolts provided on both
sides of the tilting cylinder block.
• Loosen the lock nut of the Adjuster and rotate the Adjuster by using spanner
for tilting the cylinder block.
• Adjust the desired compression ratio by referring the scale provided on the CR
indicator (near the Adjuster)
• Tighten the lock nut of the Adjuster.
• Gently tighten the vertical Allen bolts (6 nos.).

Procedure
• Ensure that all the nut bolts of engine, dynamometer, propller 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(Use SAE20W40 or equivalent
make any company market available)
• Ensure sufficient fuel in fuel tank. Remove air in fuel line, if any.
• Switch on electric supply and ensure that PPU (Piezo powering unit), DLU
(Dynamometer loading unit), Load indicator and Voltmeter are switched on.
• Start Computer and open "ICEngineSoft" (Double click "ICEngineSoft" icon on
the desktop) Click File | Configure | Product.
• Select “VCR Diesel Engine” in Select file.
• Otherwise click “Load Default” select “VCR Diesel Engine”. Check configuration
values & system constants with the values displayed on engine setup panel or
refer Configuration Data below. Click on "Save & Apply" after the changes
corrections, if any
• Start water pump. Adjust the flow rate of "Rotameter (Engine)" to 200-300
LPH and "Rotameter (Calorimeter)" to 75-100 LPH by manipulating respective
globe valves provided at the rotameter inlet. Ensure that water is flowing
through dynamometer at a pressure of @ 0.5 to 1 Kg/cm2.
• Keep the DLU knob at minimum position.
• Change the Fuel cock position from "Measuring" to "Tank"

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• Start the engine by hand cranking and allow it to run at idling condition for 4-
5 minutes.
• Click on "Mode" (Mode on is indicated by respective green light glow) in
ICEngineSoft
• Click on " Measurement " (Measurement on is indicated by respective green
light glow)
• Note: Switching ON Measurement button will Start measuring, computing the
data, and display of results in form of calculated values, graphs, tables. User
will not be allowed to start measurement unless a configuration is loaded.
Switching OFF measurement will stop measuring.
• Ensure that Speed, Temperatures and Manometer reading are correctly
displayed on the computer. These readings should tally with those displayed
on the engine panel.
• Increase the load on the engine by rotating knob on the DLU and confirm the
load reading on the indicator and computer are same.
• Adjust DLU knob and to set 0.5 kg load on Load Indicator. Wait for @ 3 mins
to ensure steady state operation. Change the Fuel cock position from "Tank"
to "Measuring". Click "Log on" on. The fuel metering is ON for next 60
seconds. During first 30 seconds enter engine water flow, calorimeter jacket
cooling water flow in LPH. Click OK after recording fuel reading. Enter the file
name under which the records to be stored. The first reading data is now
saved. Change the Fuel cock position from "Measuring" to "Tank".
• Adjust DLU knob and to set 3 kg load on Load Indicator. Wait for 3 mins.
ensure that load is constant during this period. Change the Fuel cock position
from "Tank" to "Measuring". Click "Log on" on. The fuel metering is ON for
next 60 seconds. During first 30 seconds enter engine water flow, calorimeter
jacket cooling water flow in LPH. Click OK after recording fuel reading. The
second reading data is now saved. Change the Fuel cock position from
"Measuring" to "Tank".
• Repeat above step for various loads e.g. 6,9,12,15,18 kg (For VCR engine do
not exceed 12 kg load)
• After finishing all the readings remove the load on the engine by DLU, Click
"Scan Stop" on PC.
• Stop the engine by pressing engine stop lever. Allow the water to circulate for
about 5 minutes for engine cooling and then Stop the pump.
• Click "File Open" on PC, Select the File under which the readings are stored
and click "OK". On all the screens the first reading (of 0.5kg) is shown. To

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view next readings click "Next Data". The results are displayed on all the three
screens.
• Report Printing: Click “Report” tab for generating Performance Report,
Combustion Report. Enter File name in “Report File”. Select the Report
Requirements viz. Result Data, Observation Data, Graph Only OR Graph and
Table. (Note: If “Graph and Table” option is selected under Combustion
Report, the size of the output file for printing becomes too big. However it can
be viewed in Excel) Click: File| Data| Close. After printing & checking. Click
"Exit" and then Shut Down the computer.

Configuration data
Set Parameters (Default values)
Engine
Engine parameters
Power (KW): 3.5 Stroke type: 4
Max Speed (rpm): 1500 Number of Cylinder: 1
Cylinder Bore (mm): 87.5 Speed Type: Constant
Stroke Length (mm):110 Cooling Type: Water
Connecting Rod Length (mm): 234 Fuel Type: Diesel
Compression Ratio: 18 Compression Type: VCR
Swept Volume (cc): 661.5 Engine Name: VCR Diesel Engine

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Sensors
Sensors Available Sensors Selected

(T1) Jacket Water Inlet temp. trans. (degC)

(T2) Jacket Water outlet temp. trans. (degC)
(T3) Calorimeter water in temp. trans. (degC)
(T4) Calorimeter water out temp. trans. (degC)
(T5) Exhaust Gas temp. trans. (Engine) (degC)
(T6) Exhaust Gas temp. trans. (cal) (degC)

(F7) Air Flow Transmitter (mmWC)

(F8)Fuel Flow Transmitter (mmWC)

(F9) Load Cell (kg)

(P10)Cylinder Pressure Transducer (bars)

(P11) Diesel Pressure Transducer (bars)

(R12) Engine rpm Sensor

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Combustion
Combustion Parameters Combustion Parameters
Number Of Cycles: 10 Speed Scan Interval (msec): 2000
Pulses Per Revolution: 360 Fuel Line Pressure Reference: Auto
Cylinder Pressure Smoothing: 2 Cylinder Pressure Reference: Auto
Adiabatic Index: 1.41 Polytrophic Index: Auto
X-axis Scale Style: [(-ve) to (+ve)] TDC Adjustment (deg): Man
Fuel Injection /Spark angle(deg. Before TDC):23
Noise Reduction Parameters
Avg& Interpolate Segment: NO

De-Noise the Signal: Yes

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Performance
Fuel Parameters Constant Parameters
Fuel Pipe Diameter(mm): 12.4 Water Density (kg/m^3): 1000
Fuel Measuring Interval(Sec): 60 Specific Heat of Water (kj/kg.K): 4.200
Calorific Value of Fuel (kj/kg): 42000
Fuel Density (kg/m^3): 830 Specific Heat of Gas (kj/kg.K): 1
Ambient Temperature (degC): 27
Setup Parameters Air Density (kg/m^3): 1.174

Orifice Diameter(mm): 20
Orifice Coefficient of Discharge: 0.6
Dynamometer Arm Length(mm): 185

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2 Study of VCR engine performance (Manual mode)

Object
To study the performance of 1 cylinder, 4 stroke, Diesel engine connected to eddy
current dynamometer in manual mode
Adjustment of the compression ratio
• Refer Expt no. 1 and adjust VCR for desired compression ratio.

Procedure
• Ensure cooling water circulation for eddy current dynamometer and piezo
sensor, engine and calorimeter.
• Start the set up and run the engine at no load for 4-5 minutes.
• Gradually increase the load on the engine by rotating dynamometer loading
unit.
• Wait for steady state (for @ 3 minutes) and collect the reading as per
Observationsprovided in “Cal234” worksheet in “Engine.xls”.
• Gradually decrease the load.
• Fill up the observations in “Cal234” worksheet to get the results and
performance plots.

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3 Study of Pressure volume plot and indicated power

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

Procedure
• Run the engine set up at any load and store the observation in a data file or
use previously stored data file in “Enginesoft” for indicated power calculation.
• Export the data file in ms excel worksheet. The pressure crank angle and
volume data is available in excel.
• Refer “IP_cal” worksheet in “Engine.xls”. The sample worksheet shows
pressure crank angle plot, pressure volume plot and indicated power
calculation. The worksheet is for single cylinder four stroke engine with 180
observations per revolution.
• Copy the pressure readings from exported data file in to the IP
_cal worksheet at the respective crank angle.
• Observe the Pressure crank angle diagram, pressure volume diagram and
indicated power value. (The calculations are explained in theory part).

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4 Maximum power test at different compression ratio

Object
To study the maximum power generated by VCR engine at various compression
ratios.
Adjustment of the compression ratio
• Adjust the compression ratio as explained in experiment no.1

Performance test
• Ensure cooling water circulation for eddy current 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 till the engine is fully loaded. (As load is increased further the
speed drops significantly.)
• Note the reading as per Observations provided in “Cal234” worksheet in
“Engine.xls”.
• Gradually decrease the load.
• Change the compression ratio for next observation and repeat above steps.
• Fill up the observations in “Cal234” worksheet to get the results and
performance plots.

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5 BSFC and brake thermal efficiency test at different CR

Object
To study the BSFC and brake thermal efficiency of VCR engine at various
compression ratios.
Adjustment of the compression ratio
• Adjust the compression ratio as explained in experiment no.1

Performance test
• Ensure cooling water circulation for eddy current 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 @80% of load (Refer experiment 3 for full load observed at
the set compression ratio).
• Note the reading as per Observationsprovided in “Cal234” worksheet in
“Engine.xls”.
• Gradually decrease the load.
• Change the compression ratio for next observation and repeat above steps.
Fill up the observations in “Cal234” worksheet to get the results and performance
plots.

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6 Study of valve timing diagram

Object
To study valve timing diagram

Valve Timing Diagram

Engine Kirloskar (TV1) 1Cylinder, 4Stroke, Diesel

1 TDC 5
3

Compression

Expansion
Induction
1 Inlet valve opens before TDC : 4.5 0
Exhaust

2 Inlet valve closes after BDC : 35.5 0

3 Fuel injection starts before TDC : 23 0
4 Exhaust valve opens before BDC : 35.5 0
0
5 Exhaust valve closes after TDC : 4.5

2 4

BDC

Procedure
• Switch off the electric supply of the panel box
• Open the cover on the engine head to see the rocker arms.
• Lift up the decompression lever.
• Note the TDC mark provided on the flywheel. (Also refer the valve timing
diagram).
• Slowly rotate the flywheel in clockwise direction looking from dynamometer side.
Identify inlet valve and exhaust valve rocker arms
• Observe the movement of rocker arms and understand the valve opening and
closing.
To observe fuel injection it is necessary to remove fuel injector.

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Components used
Components Details
Engine Make Kirloskar, Type 1 cylinder, 4 stroke Diesel,
water cooled, Model TV1, stroke 110 mm, bore 87.5
mm. 661 cc, CR 17.5, Modified to VCR engine CR
range 12 to 18
Dynamometer Make Technomech, model TMEC10, 10BHP@1500-
5000 RPM, without load cell with instruction manual
Dynamometer Loading Make Apex, Model AX-155. Type constant speed,
unit Supply 230V AC.
Propeller shaft Make Hindustan Hardy Spicer, Model 1260, Type A
Manometer Make Apex, Model MX-104, Range 100-0-100 mm,
Type U tube, Conn. 1/4`` BSP hose back side,
Mounting panel
Fuel measuring unit Make Apex, Glass, Model:FF0.012
EGR Water cooled, SS, Range 0-15%
Piezo sensor Make PCB Piezotronics, Model S111A22, Range 5000
psi, Diaphragm stainless steel type & hermetic
sealed
White coaxial teflon Make PCB piezotronics, Model 002C20, Length 20 ft,
cable Connections one end BNC plug and other end 10-32
micro
Crank angle sensor Make Kubler, Model
8.KIS40.1361.0360Clamping/Synchro flange,
6x12.5mm shaft, IP64Logic level: RS422; Supply=
5VDCSquare wave O/P: A, A’, B, B’, 0, 0’Incr/turn:
360 PPR, Termination: 2m long axial cable
Data acquisition device NI USB-6210 Bus Powered M Series Multifunction
DAQ Device, NI DAQmx driver Software
Piezo powering unit Make-Apex, Model AX-409.
Temperature sensor Make Radix Type K, Ungrounded, Sheath
Dia.6mmX110mmL, SS316, Connection 1/4"BSP (M)
adjustable compression fitting
Temperature sensor Make Radix, Type Pt100, Sheath Dia.6mmX110mmL,
SS316, Connection 1/4"BSP(M) adjustable
compression fitting

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Temperature transmitter Make ABUSTEK, Model : Fr Block, Input :

Thermocouple (K), Range : 0 To 1200ºC, Output : 4-
20 mA, Powersupply : 24 V DC, Dimension : 44 X 25
MM, , Precalibrated to 1200 Deg C
Temperature transmitter Make ABUSTEK, Model : Fr Block, Input : PT-100,
Range : 0 To 100ºC, Output : 4-20 mA, Powersupply
: 24 V DC, Dimension : 44 X 25 MM, , Precalibrated
to 100 Deg C
Load sensor Make Sensotronics Sanmar Ltd., Model 60001,Type
S beam, Universal, Capacity 0-50 kg
Load indicator Make ABUS, model SV8-DC10, 85 to 270VAC,
retransmission output 4-20 mA
Power supply Make Meanwell, model NES-15-24, O/P 24 V, 0.7 A
Digital voltmeter Make Meco, 3.1/2 digit LED display, range 0-20
VDC, supply 230VAC, model SMP35S
Fuel flow transmitter Make Yokogawa, Model EJA110E-JMS5J-912NN,
Calibration range 0-500 mm H2O, Output linear
Air flow transmitter Make WIKA, Model SL-1-A-MQA-ND-ZA4Z-ZZZ,
output 4-20 mA, supply 10-30 Vdc, conn.
1/2"NPT(M), Range (-)25 - 0 mbar.
Rotameter Make Eureka Model PG 5, Range 25-250 lph,
Connection ¾” BSP vertical, screwed, Packing
neoprene
Rotameter Make Eureka Model PG 6, Range 40-400 lph,
Connection ¾” BSP vertical, screwed, Packing
neoprene
Pump Make Kirloskar, Model Mini 18S, HP 0.5, Size 1” x 1”,
Single ph 230 V AC

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Calculations

Brake power (kw)

2πNT
BP =
60 x1000
2πN (WxR)
=
60000
0.785 xRPMx(Wx9.81) xArmlength
=
60000
TxN
BHP =
75x 60

Brake means effective pressure (bar)

BPx 60
BMEP =
π / 4 xD xLx ( N / n) xNoOfCylx100
2

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

Indicated power From PV diagram (kw)

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

Area of PV diagram = ..cm2

workdone / cycle / cyl ( Nm ) = AreaofPVdi agram × Xscalefact or × Yscalefact or × 100000
workdone / cycle / cyl × ( N / n) × NoOfCyl
IP =
60 × 1000

Indicated mean effective pressure (bar)

IPx60
IMEP =
π / 4 xD xLx( N / n) xNoOfCylx100
2

Frictional power (kw)

FP = IP − BP
FHP = IHP − BHP
BHP = IHP − FHP

Brake specific fuel consumption (Kg/kwh)

FuelflowIn kg / hr
BSFC =
BP

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Brake Thermal Efficiency (%)

BP × 3600 × 100
BThEff =
FuelFlowInKg / hr × CalVal
IThEff × MechEff BHP
BThEff = OR
100 FuelHP

Indicated Thermal Efficiency (%)

IP × 3600 × 100
IThEff =
FuelFlowInKg / hr × CalVal
BThEff × 100
IThEff =
MechEff

Mechanical Efficiency (%)

BP × 100
MechEff =
IP

Air flow (Kg/hr)

AirFlow = Cd × π / 4 × d 2 2 gh × (Wden / Aden ) X3600 X Aden

Volumetric Efficiency

AirFlow × 100
VolEff =
Theoretica lAirFlow
AirFlow × 100
=
π / 4 × D × Stroke × ( N / n) × 60 × NoOfCyl × Aden
2

Air fuel ratio

AirFlow
A/ F =
FuelFlow

Heat Balance (KJ/h)

a) HeatSuppli edbyFuel = FuelFlow × CalVal
b) HeatEquiva lentToUsef ulWork = BP × 3600
HeatEquivalentToUsefulWork × 100
HeatEquivalentToUsefulWorkIn% =
HeatSuppliedByFuel
C) HeatInJacketCoolingWater = F 3 × C PW × (T 2 − T1)
Where F3 is rate of Jacket cooling water, T2 is jacket water outlet temperature and
T1 is jacket water inlet temperature.

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HeatInJacketCoolingWater × 100
HeatInJacketCoolingWaterIn% =
HeatSuppliedByFuel
d) Heat in Exhaust (Calculate CPex value):

F 4 × C P w × (T 4 − T 3)
C P ex = ..KJ / Kg 0 k
( F1 + F 2) × (T 5 − T 6)
Where,
Cpex Specific heat of exhaust gas kJ/kg0K

Cpw Specific heat of water kJ/kg0K

F1 Fuel consumption kg/hr

F2 Air consumption kg/hr
F4 Calorimeter water flow kg/hr
0
T3 Calorimeter water inlet temperature K
0
T4 Calorimeter water outlet temperature K
0
T5 Exhaust gas to calorimeter inlet temp. K
T6 Exhaust gas from calorimeter outlet temp. 0K
HeatInExha ust ( KJ / h ) = ( F1 + F 2) × C P ex × (T 5 − Tamb )
HeatInExhaust × 100
HeatInExhaust % =
HeatSuppliedByFuel
e) Heat to radiation and unaccounted (%)
= HeatSuppliedByFuel (100%) − {( HeatEquivalentToUsefulWork (%) +
HeatInJacketCoolingWater (%) + HeatToExhaust (%)}

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x Innovatio
ons

Wiiring diag
gram

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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:[email protected]: www.apexinnovations.co.in

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