IC Engine Manual
IC Engine Manual
IC Engine Manual
Instruction manual
Contents
1 Description
6 Commissioning
11 Components used
2 Specifications
7 Software
12 components manuals
3 Installation requirements
8 Troubleshooting
13 Warranty
4 Packing slip
9 Theory
5 Installation
10 Experiments
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 PPV diagrams. Provision is also made for interfacing airflow,
fuel flow, temperatures and load measurement.
box consisting of air box, two fuel tanks for duel fuel 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 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 EnginesoftLV is provided for on line performance evaluation.
A computerized Diesel injection pressure measurement is optionally provided.
Schematic arrangement
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Specifications
Product VCR Engine test setup 1 cylinder, 4 stroke, Diesel
(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
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-Cuadra, Model AX-409.
Digital milivoltmeter Range 0-200mV, panel mounted
Temperature sensor Type RTD, PT100 and Thermocouple, Type K
Temperature Type two wire, Input RTD PT100, Range 0100 Deg C,
transmitter Output
420
mA
and
Type
two
wire,
Input
Shipping details
Gross volume 2.46m3, Gross weight 808kg, Net weight 528kg
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Installation requirements
Electric supply
Provide 230 +/- 10 VAC, 50 Hz, single phase electric supply with proper earthing.
(Neutral Earth voltage less than 5 VAC)
5A, three pin socket with switch (2 Nos.)
Water supply
Continuous, clean and soft water supply @ 1000 LPH, at 10 m. head. Provide valve
with 1 BSP hose terminal connection
Computer
IBM compatible with standard configuration. Typical configuration as follows:
CPU: Pentium 300 GHz, RAM: Min. 512 MB, CD ROM drive, USB Port.
OS: Windows XP + SP2.
Monitor: Screen resolution 1280x1024.
Space
L3300 mm x W3200 mm x H1700 mm (Refer foundation drawings)
Drain
Provide suitable drain extension arrangement (Drain pipe 65 NB/2.5 size)
Exhaust
Provide suitable exhaust extension arrangement (Exhaust pipe 32 NB/1.25 size)
Foundation
Refer foundation drawings Foundation234(1) and Foundation234(2)
Fuel, oil
Diesel@10 lit.
Lubrication 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
No.1/9
Engine
test
setup
assembly
Engine
Dynamometer
Box
No.2/9
1 No.
Transmitter
panel,
Fuel
pipe,
Fuel
DP
No.3/9
Calorimeter
No.4/9
Calorimeter
1 No.
1 No.
Box
Exhaust pipe
No.5/9
Exhaust pipe
Box
Pump
No.6/9
Pump
Box
Battery
No.7/9
Battery
1 No.
Box
Engine piping
No.8/9
1 No.
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and
outlet,
Air
hose
pipe,
Pump
suction
1 No.
1 No.
1 No.
Starting kick/Handle
1 No.
1 No.
Pump bracket
1 No.
1 No.
1 No.
Box
Engine wiring
No.9/9
1 No.
Load indicator
1 No.
Digital voltmeter
1 No.
1 No.
Pressure gauge
1 No.
Wiring set
1 No.
1 No.
1 No.
1 No.
10
Piezo sensor
1/2Nos.
11
1/2Nos.
12
1 No.
13
1 No.
14
1 No.
15
Tool kit
1 No.
16
1 No.
17
1 No.
18
1 No.
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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 cell are 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.
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 Fuel pipe (Glass), Manometer, Fuel
DP transmitter, Air transmitter, Orifice for air metering, Transmitter panel(fitted
with Power supply and five Temperature
Collect Piezo powering unit (Ax409), Dynamometer loading unit (AX155), Load
indicator (PIC152), Digital voltmeter (SMP35) from Engine wiring box.
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Remove the covers of
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 (PIC152) and put its clamps. Connect 8 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 pipe at the outlet of calorimeter. Insert additional pipe
in between and take the exhaust out of the room. At the end put Exhaust muffler.
Remove Pump packed in wooden box placed inside Engine piping. Fit Pump
bracket to the Engine panel structure and fit pump on it.
Collect the piping pieces form Engine piping box. Clean the pipes internally to
remove any dust and particles. Complete the piping as follows:
o Assemble the PVC drain pipes (3 components) as per the marking done. Put
it between Engine panel and Engine set up assembly.
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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 hose between 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.
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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 L
N E terminals to the transmitter panel at supply 230V. Connect its 3 pin (F)
connector to Dynamometer loading unit at Supply. Connect male 3 pin connector
to Elelctric supply available at the site. Route the cable through wiring channel.
Connect cable from 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 and connect 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.
pointer
provided
on
the
engine
body.
This
rotation
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Check if the TDC light on the Piezo powering unit is lit. If not adjust the
crank angle sensor as follows:
Loosen the four screws on the flange provided for clamping the
crankangle sensor on the mounting bracket.
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.
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.
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.
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.
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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.
For first start after installation, loosen the fuel inlet pipe to the injector
Crank the engine slowly till fuel starts dribbling out from the loosened
nut. Then tighten the nut.
The handle will release automatically and come out, however do not
leave handle.
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.
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Keep water circulation on, Set @ 300 lph and 100 lph flow rates for engine cooling
and calorimeter respectively.
Start the engine and allow it to run for 5 minutes in idling condition. Confirm that
engine speed is displayed on 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 rocker
is 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 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 CA and other as T. CA marking is to be used for
crankangle sensor adjustment for PO diagram).
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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 (PIC152N)
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.
Wiring:
o
From load cell white wire is connected to terminal no. 4 as +ve input
mV and green wire at terminal no. 5 as -ve input mV.
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)
Programming of Level 0
(To enter or exit program mode press both arrow key together for 3 seconds)
1 Up Arrow :- Upward movement
2 Down Arrow :- Downward movement
3 Squre + Up arrow :- Increase value.
4 Squre + Down Arrow :- Decrease value.
Press both arrow keys together for 3 seconds. Indicator display shows "ID" and "0".
Press Square + Up/ Down key so that the indicator will display "LUL, 0 "
Press Up key select "INP"
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Press Square + Up key together select "AU".
Press Up key and set as follows
A] RESL (Resolution)----------------------------------- 0.1
B] FtC (Filter time constant)--------------------------1
C] dSCL (Display value scalling point Low-------0.0
D] ISCL (Input value scalling point Low)-----------1.10 (mV input from load cell when
the load is 0 kg.)
E] dSCH ( Display value scalling point high)-----50.0 (max range of load indicator)
F] ISCH ( Input value scalling point High)------------32.00 to 38.00 ( mV input from
load cell when the load is 50 kg.)
G] RSCL (Reverse scalling)----------------------------- NO
H] SPHL (Set point high Limit) ------------------------ 50
I ] SPLL (Set point Low Limit ---------------------------0.0
J] LOCY (Lck code) ---------------------------------------0
K] rst (Reset) -------------------------------------------------No
Programming of Level 3
Press both arrow keys together for 3 seconds. Indicator displays ID" and "0".
Press Square + Up/ Down key so that the indicator displays "LUL, 3 "
Press Up key and set as follows
L] MANL (Manual) ------------------------------ Off
M] A - LO (Lower Limit) ------------------------0
N] A - HI ( Upper Limit)------------------------- 50 (max.capacity off 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.
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
CPU: Pentium 300 GHz, RAM: Min. 512 MB, CD ROM drive, USB Port.
OS: Windows XP + SP2.
Monitor: Screen resolution 1280x1024.
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Troubleshooting
Note: 1 For component specific problems refer components manual
2 For wiring problems refer drawing Wiring234.
Problems
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.
Dynamometer does
not load the engine
work
Virus in computer
Loose connections, improper earthing
Faulty indicated
power
Improper earthing
angle diagram
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TDC, coupling of crank angle sensor may be loose
Faulty speed
indication
Incorrect
temperature
indication
cable
of
thermocouple
is
positive
and
red
is
negative.
Open or damaged temperature sensor
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Theory
Terminology
Engine Cylinder diameter (bore) (D): The nominal inner diameter of the
working cylinder.
Piston area (A): The area of a circle of diameter equal to engine
cylinder diameter (bore). A / 4 D
Engine Stroke length (L): The nominal distance through which a working
piston moves between two successive reversals of its direction of motion.
Dead center: The position of the working piston and the moving parts, which
are mechanically connected to it at the moment when the direction of the piston
motion is reversed (at either end point of the stroke).
Bottom dead center (BDC): Dead center when the piston is nearest to
the crankshaft. Sometimes it is also called outer dead center (ODC).
Top dead center (TDC): Dead center when the position is farthest from the
crankshaft. Sometimes it is also called inner dead center (IDC).
Swept volume (VS): The nominal volume generated by the working piston
when travelling from one dead center to next one, calculated as the product of
piston area and stroke. The capacity described by engine manufacturers in cc
is the swept volume of the engine. Vs A L / 4 D L
2
Clearance volume (VC): The nominal volume of the space on the combustion side
of the piston at top dead center.
Cylinder volume: The sum of swept volume and clearance volume.
V Vs Vc
Compression ratio (CR): The numerical value of the cylinder volume divided
by the numerical value of clearance volume. CR
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V / Vc
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Bore
D
Cylinder head
Suction valve
Intake or suction manifold
Exhaust valve
Exhaust manifold
Clearance volume.Vc
Cylinder volumeV
Stroke volume.Vs
Crank pin
Crank
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when the exhaust valve closes some exhaust gas residuals will be left; these will
dilute the next charge.
the
compression
stroke;
ignition
should
again
occur
before
TDC.
Simultaneously under side of the piston is drawing in a charge through a springloaded non-return inlet valve.
2. Power stroke: The burning mixture raises the temperature and pressure in the
cylinder, and forces the piston down. The downward motion of the piston also
compresses the charge in the crankcase. As the piston approaches the end of its
stroke the exhaust port is uncovered and blowdown occurs. When the piston is at
BDC the transfer port is also uncovered, and the compressed charge in the
crankcase expands into the cylinder. Some of the remaining exhaust gases are
displaced by the fresh charge; because of the flow mechanism this is called loop
scavenging'. As the piston travels up the cylinder, the piston closes the first
transfer port, and then the exhaust port is closed.
Performance of I.C.Engines
Indicated thermal efficiency (t): Indicated thermal efficiency is the ratio of
energy in the indicated power to the fuel energy.
BrakePower ( KW ) 3600
100
FuelFlow ( Kg / Hr) CalorificV alue( KJ / Kg )
Mechanical efficiency (m): Mechanical efficiency is the ratio of brake horse power
(delivered power) to the indicated horsepower (power provided to the piston).
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and Frictional power = Indicated power Brake power
Following figure gives diagrammatic representation of various efficiencies,
Energy
in fuel
(A)
IP
(B)
BP
(C)
v (%)
AirFlow ( Kg / Hr)
100
/ 4 D L(m ) N ( RPM ) / n NoofCyl AirDen( Kg / m 3 ) 60
2
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Power in kW = (Pm LAN/n 100)/60 in bar
where Pm = mean effective pressure
L = length of the stroke in m
A = area of the piston in m2
N = Rotational speed of engine RPM
n= number of revolutions required to complete one engine cycle
n= 1 (for two stroke engine)
n= 2 (for four stroke engine)
Thus we can see that for a given engine the power output can be measured in
terms of mean effective pressure. If the mean effective pressure is based on
brake power it is called brake mean effective pressure (BMEP) and if based on
indicated power it is called indicated mean effective pressure (IMEP).
BMEP (bar )
BrakePower ( KW ) 60
L A ( N / n) NoOfCyl 100
IMEP (bar )
IndicatedP ower ( KW ) 60
L A ( N / n) NoOfCyl 100
Basic measurements
The basic measurements, which usually should be undertaken to evaluate the
performance of an engine on almost all tests, are the following:
1 Measurement of speed
Following different speed measuring devices are used for speed measurement.
1 Photoelectric/Inductive proximity pickup with speed indicator
2 Rotary encoder
2 Measurement of fuel consumption
I) Volumetric method: The fuel consumed by an engine is measured by
determining the volume flow of the fuel in a given time interval and multiplying it by
the specific gravity of fuel. Generally a glass burette having graduations in ml is used
for volume flow measurement. Time taken by the engine to consume this volume is
measured by stopwatch.
II) Gravimetric method: In this method the time to consume a given weight of the
fuel is measured. Differential pressure transmitters working on hydrostatic head
principles can used for fuel consumption measurement.
3 Measurement of air consumption
Air box method: In IC engines, as the air flow is pulsating, for satisfactory
measurement of air consumption an air box of suitable volume is fitted with orifice.
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The air box is used for damping out the pulsations. The differential pressure across
the orifice is measured by manometer and pressure transmitter.
4 Measurement of brake power
Measurement of BP involves determination of the torque and angular speed of the
engine output shaft. This torque-measuring device is called a dynamometer.
The dynamometers used are of following types:
I) Rope brake dynamometer: It consists of a number of turns of rope wound
around the rotating drum attached to the output shaft. One side of the rope is
connected to a spring balance and the other to a loading device. The power is
absorbed in friction between the rope and the drum. The drum therefore requires
cooling.
Brake power = DN (W-S)/60,000 in kW
where D is the brake drum diameter, W is the weight and S is the spring scale
reading.
II) Hydraulic dynamometer: Hydraulic dynamometer works on the principal of
dissipating the power in fluid friction. It consists of an inner rotating member or
impeller coupled to output shaft of the engine. This impeller rotates in a casing, due
to the centrifugal force developed, tends to revolve with impeller, but is resisted by
torque arm supporting the balance weight. The frictional forces between the impeller
and the fluid are measured by the spring-balance fitted on the casing. Heat
developed due to dissipation of power is carried away by a continuous supply of the
working fluid usually water. The output (power absorbed) can be controlled by
varying the quantity of water circulating in the vortex of the rotor and stator
elements. This is achieved by a moving sluice gate in the dynamometer casing.
III) Eddy current dynamometer: It consists of a stator on which are fitted a
number of electromagnets and a rotor disc and coupled to the output shaft of the
engine. When rotor rotates eddy currents are produced in the stator due to magnetic
flux set up by the passage of field current in the electromagnets. These eddy
currents oppose the rotor motion, thus loading the engine. These eddy currents are
dissipated in producing heat so that this type of dynamometer needs cooling
arrangement. A moment arm measures the torque. Regulating the current in
electromagnets controls the load.
Note: While using with variable speed engines sometimes in certain speed zone the
dynamometer operating line are nearly parallel with engine operating lines which
result in poor stability.
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I) Indicator diagram:
cylinder head to sense combustion pressure. A rotary encoder is fitted on the engine
shaft for crank angle signal. Both signals are simultaneously scanned by an engine
indicator (electronic unit) and communicated to computer. The software in the
computer draws pressure crank-angle and pressure volume plots and computes
indicated power of the engine.
Conversion of pressure crank-angle plot to pressure volume plot:
The figure shows crank-slider mechanism. The piston pin position is given by
x r cos l cos
From figure r sin l sin and recalling cos 1 sin
2
x r cos l r 1 r l sin 2
The binomial theorem can be used to expand the square root term:
.1
sin 2 1 / 2 1 / 2 cos 2
.2
r / l 4 terms,
shows that these terms will be at least an order of magnitude smaller than
r / l 2
terms.
The approximate position of piston pin end is thus:
x r cos l / r 1 1 (r / l ) 2 1 / 2 1 / 2 cos 2
2
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desired speed and output is noted. Then combustion in one of the cylinders is
stopped by short circuiting spark plug or by cutting off the fuel supply. Under this
condition other cylinders motor this cylinder. The output is measured after
adjusting load on the engine to keep speed constant at original value. The difference
in output is measure of the indicated power of cut-out cylinder. Thus for each
cylinder indicated power is obtained to find out total indicated power.
VCR Engines
The standard available engines (with fixed compression ratio) can be modified by
providing additional variable combustion space. There are different arrangements by
which this can be achieved. Tilting cylinder block method is one of the arrangements
where the compression ratio can be changed without change is combustion
geometry. With this method the compression ratio can be changed within designed
range without stopping the engine.
Calculations
BP
2NT
60 x1000
2N (WxR )
60000
BHP
TxN
75x60
BMEP
BPx 60
/ 4 xD xLx( N / n) xNoOfCylx100
2
n = 2 for 4 stroke
n = 1 for 2 stroke
X scale (volume)
1cm =
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..bar
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Area of PV diagram
..cm2
IP
IPx 60
/ 4 xD xLx( N / n) xNoOfCylx100
IMEP
FP IP BP
FHP IHP BHP
BHP IHP FHP
BSFC
BThEff
BP 3600 100
FuelFlowIn Kg / hr CalVal
BThEff
IThEff MechEff
BHP
OR
100
FuelHP
IThEff
IP 3600 100
FuelFlowIn Kg / hr CalVal
IThEff
BThEff 100
MechEff
MechEff
FuelflowIn kg / hr
BP
BP 100
IP
VolEff
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AirFlow 100
Theoretica lAirFlow
AirFlow 100
/ 4 D Stroke ( N / n) 60 NoOfCyl Aden
2
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A/ F
AirFlow
FuelFlow
HeatEquivalentToUsefulWorkIn%
C)
HeatEquivalentToUsefulWork 100
HeatSuppli edByFuel
C P ex
F 4 C PW (T 4 T 3)
..KJ / Kg 0 k
( F1 F 2) (T 5 T 6)
Where,
Cpex
kJ/kg0K
Cpw
kJ/kg0K
F1
Fuel consumption
kg/hr
F2
Air consumption
kg/hr
F4
kg/hr
T3
T4
T5
T6
K
K
K
K
HeatInExha ust %
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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)
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
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 water pump. Adjust the flow rate of "Rotameter (Engine)" to 250-350
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.
Start the engine by hand cranking and allow it to run at idling condition for 45 minutes.
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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.,
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 (and compression ratio for VCR engine). 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 (and compression ratio for VCR engine). 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
view next readings click "Next Data".
The results are displayed on all the three screens. For printing the results click
"Print" and select appropriate option.
Click "File Close" after printing & checking. Click "Exit" and then Shut Down
the computer.
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4 Fuel measuring interval (sec):60
5 Fuel display bias: As reqd.
6 Orifice diameter (mm): 20
7 Dynamometer arm length (mm):185
8 Speed scanning interval (ms): 2000
9 Plot reference for cylinder pressure: as reqd
10 Plot reference for Diesel pressure: as reqd
Theoretical constants
1 Use default values: Yes
2 Fuel density (kg/m^3): 830
3 Calorific value of fuel (KJ/Kg): 42000
4 Orifice coef of discharge: 0.60
5 Sp heat of exhaust gas (Kj/Kj.K): 1.00
6 Max. sp. heat. Of Exhaust Gas (KJ/Kg.k): 1.25
7 Min sp. heat of exhaust gas (KJ/Kg.k): 1.00
8 Sp heat of water (KJ/Kg.K): 4.186
9 Air density Kg/m^3): As displayed
10 Ambient temperature (Deg C): Ambient temperature.
Graph X axis
Load (Kg) 0 to 20 kg
Plot details
Diesel plot : Yes or No
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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.
Wait for steady state (for @ 3 minutes) and collect the reading as per
Observations provided in Cal234 worksheet in Engine.xls.
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Procedure
Run the engine set up at any load and store the observation in a data file or
use previously stored data file in EnginesoftLV for indicated power
calculation.
Export the data file in ms excel worksheet. The pressure crank angle and
volume data is available in excel.
Copy
the
pressure
readings
from
exported
data
file
in
to
the
IP
Observe the Pressure crank angle diagram, pressure volume diagram and
indicated power value. (The calculations are explained in theory part).
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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.
Change the compression ratio for next observation and repeat above steps.
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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.
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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1 TDC 5
Compression
Expansion
Induction
Exhaust
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
range 12 to 18
Dynamometer
Dynamometer
Loading
unit
Propeller shaft
Manometer
Piezo sensor
White
coaxial
teflon
cable
Shaft
Size:
Voltage
Size
5-30V
6mmxLength
DC,
Output
12.5mm,
Push
Pull
Temperature sensor
Make
Radix
Type
K,
Ungrounded,
Sheath
Connection
1/4"BSP(M)
adjustable
compression fitting
Temperature transmitter
Make
Wika,
model
T19.10.3K0-4NK-Z,
Input
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24VDC, Calibration: 0-1200deg.C.
Temperature transmitter
Load sensor
Load indicator
Power supply
Digital voltmeter
Make
Yokogawa,
Model
EJA110-EMS-5A-92NN,
Rotameter
BSP
vertical,
screwed,
Packing
neoprene
Rotameter
BSP
vertical,
screwed,
Packing
neoprene
Pump
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Components manuals
Rotameter (PG series)
Rotameter works on the principle of variable area. Float is
free to move up & down in a tapered measuring glass tube.
Upward flow causes the float to take up a position in which
the buoyancy forces and the weight are balanced. The
vertical position of the float as indicated by scale is a
measurement of the instantaneous flow rate.
Technical specifications
Model
PG-1 to 21
Make
Eureka
Packing/Gaskets
Neoprene
Measuring tube
Borosilicate glass
Float
316SS
Cover
Glass
Accuracy
Range ability
10:1
Scale length
175-200mm.
Max. Temp.
2000C
Connection
Principle of operation
The rotameter valves must be opened slowly and carefully to adjust the desired flow
rate. A sudden jumping of the float, which may cause damage to the measuring tube,
must be avoided.
Fig.1
Edge
The upper edge of the float as shown in fig. 1 indicates the rate of flow. For
alignment a line marked R.P. is provided on the scale which should coincide with the
red line provided on measuring tube at the bottom.
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Maintenance
When the measuring tube and float become dirty it is necessary to remove the tube
and clean it with a soft brush, trichloroethylene or compressed air.
Check
Leakage on glands
Consult manufacturers
expected
Showing correct reading initially but
Replace float
few days
Showing correct reading initially but
soft brush
some months.
Fluctuation of float
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Maintain
operating
pressure
below
Manufacturers address
Eureka Industrial Equipments Pvt. Ltd.
17/20, Royal Chambers,
Paud Road, Pune 411 038.
Email: eureka.equip@gems.vsnl.net.in
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Technical specifications
Model
MINI-18SM
Make
Kirloskar
Supply
6-18 meter
Discharge
1650-720 Lph
Connection
20 x 20mm
Water seal
Mechanical
Pump Unit
CI.
Power Rating
0.18Kw/0.25hp
Type of Motor
Insulation
B class
Rating
Continuous
Impeller
H.T. Brass
Delivery casing
Cast Iron
Motor Body
Cast Iron
Shaft
Carbon steel
Priming
The pump is of self priming model. It is only essential to fill about 300ml. of water
into the casing once during installation and shut the filler cap tightly. After switching
the pump on, during the first operation it will have to remove the air in the suction
pipe and will take min. 2 minutes before the water begins to flow. During consecutive
operations you will get water immediately on switching the pump.
Troubleshooting
Problem
Check
Capacity
the
decreases
pump
satisfactorily.
is
after
running
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Check the pipe for leakage and correct it.
Change to the recommended size.
Pump over loaded. (Takes
Manufacturers address
Kirloskar Brothers Ltd.,
Ujjain Road, Opp. Railway Station,
Dewas 455 001.
E-mail: mkt@dws.kbl.co.in
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Engine
Technical specifications
Model
TV1
Make
Type
cooled, Diesel
No. of cylinder
One
Bore
87.5 mm
Stroke
110 mm
Combustion principle
Compression ignition
Cubic capacity
0.661 liters
17.5:1
Peak pressure
77.5 kg/cm2
Direction of rotation
Clockwise (Looking
2000 rpm
750 rpm
1200 rpm
230 BTDC
Valve timing
Inlet opens BTDC
4.50
35.50
0.18 mm
0.20 mm
Bumping clearance
0.046 0.052
Lubricating system
Power rating
1. Continuous
7/1500 hp/rpm
2. Intermittent
7.7/1500 hp/rpm
6.35 kg/cm2
Gear type
6.50 lit/min.
Sump capacity
2.70 liter
234 mm
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Overall dimensions
Weight
160 kgs
Manufacturers address
Kirloskar Oil Engines Ltd.
Dealer:
Ashwini Enterprise
Kolhapur.
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Kubler
Model
8.3700.1321.0360
Supply voltage
5-30VDC
Output
PPR
360
axial
Encoder Diameter
Dia. 37,
Shaft size
Dia.6mm x length12mm
Weight
120 gm
Manufacturers address
Kuebler Germany
Indian supplier:
Rajdeep Automation Pvt. Ltd.
Survey No. 143, 3rd floor,
Sinhgad Road, Vadgaon Dhayari,
Pune 411 041.
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Piezo sensor
Introduction
These
miniature
sensor
series
are
intended
for
general
purpose
pressure
versatile
compression,
transducer
combustion,
series
is
explosion,
designed
pulsation,
for
dynamic
cavitations,
measurement
blast,
of
pneumatic,
Technical specifications
Sensor name
Make
Model
M111A22
5000 psi
10000 psi
Maximum pressure
15000 psi
Resolution
0.1 psi
Sensitivity
1 mV/psi
Resonant frequency
400 kHz
Rise time
2 s
500 s
0.001 Hz
2%
Output polarity
Positive
Output impedance
100 ohms
Output bias
8-14 volt
Acceleration sensitivity
0.002 psi/g
Temperature coefficient
0.03 %/0F
Temperature range
-100 to +275 0F
Flash temperature
3000 0F
Vibration / Shock
Ground isolation
No (2)
2 to 20 mA
+18 to 28 VDC
Sensing geometry
Compression
Sensing element
Quartz
Housing material
17.4 SS
Diaphragm
Invar
Sealing
Welded hermetic
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Electric connector
Mounting thread
M7 x 0.75 pitches
6 gm
Cable model
Principle of operation
Dynamic pressure transducer: It is necessary only to supply the sensor with a 2
to 20 mA constant current at +20 to +30 VDC through a current regulating
diode or equivalent circuit. Most of the signal conditioners manufactured by PCB
have adjustable current features allowing a choice of input currents from 2 to 20
mA. In general, for lowest noise (best resolution), choose the lower current
ranges. When driving long cables (to several thousand feet), use the higher
current, up to 20 mA maximum.
Troubleshooting
Problem
Check
No signal
operate
Calibration
1. Piezoelectric sensors are dynamic devices, but static calibration techniques
can be employed if discharge time constants are sufficiently long. Generally,
static calibration methods are not employed when testing sensors with a
discharge time constant that is less than several hundred seconds.
2.
Direct couple the sensor to the DVM readout using a T-connector from the
Xducer jack or use the model 484B in the calibrate mode.
3. Apply pressure with a dead weight tester and take reading quickly. Release
pressure after each calibration point.
4. For shorter TC series, rapid step functions of pressure are generated by a
pneumatic pressure pulse calibrator or dead weight tester and readout is by
recorder or storage oscilloscope.
Manufacturers address
PCB Piezotronics, Inc.
Indian supplier:
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gauge
load
cell
and
speed
AG10
Make
Water inlet
1.6bar
Minimum kPa
160
Pressure lbf/in2
23
Air gap mm
0.77/0.63
Torque Nm
11.5
60
5.0
9.8
Speed max.
10000rpm
Load
3.5kg
Bolt size
M12 x 1.75
Weight
130kg
Principle of operation
1. The dynamometer unit comprises basically a rotor mounted on a shaft running in
bearings which rotates within a casing supported in ball bearing trunnions which form
part of the bed plate of the machine.
2. Secured in the casing are two field coils connected in series. When these coils are
supplied with a direct current (DC) a magnetic field is created in the casing across
the air gap at either side of the rotor. When the rotor turns in this magnetic field,
eddy currents are induced creating a breaking effect between the rotor and casing.
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The rotational torque exerted on the casing is measured by a strain gauge load cell
incorporated in the restraining linkage between the casing and dynamometer bed
plate.
3.
Troubleshooting
Problem
Check
in accuracy limit
Calibrate
the
weights
from
authorized source.
Clean
&
lubricate
properly
with
grease
Vibrations to dynamometer
Dynamometer
foundation
bolts
tighten properly
Abnormal noise
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Replace bearings
Operation
1. New dynamometers are run in before delivery to ensure that all components
run smoothly and grease is evently distributed within the shaft bearings.
2. The dynamometer has been calibrated the power developed by the engine on
test may be calculated using the following formula:
Power (kW) =
Power (hp) =
WN
k
Manufacturers address
Saj Test Plant Pvt. Ltd.
72-76, Mundhwa, Pune Cantonment,
Pune 411 036.
Email:sajdyno@vsnl.com
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Load indicator
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Manufacturers address
Selectron process controls Pvt. Ltd.
E-121/120/113,
Ansa
Industrial
Delear:
Estate,
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Load cell
Introduction
Load cell are suitable use for static & dynamic
weighing, bin/hopper weighing, force measurement,
scales
and
electro-mechanical
conversion
kit.
Technical specifications
Make
Sensortronics
Model
60001
Type
S Beam,Universal
Capacity
0 50Kg
Mounting thread
M10 x 1.25mm
3.00
+/-0.25%
+/-0.1mV/V
Non-linearity (FSO)
<+/-0.025%
Hysteresis (FSO)
<+/-0.020%
Non-repeatability
<+/-0.010%
<+/-0.020%
-200C to +700C
Rated excitation
10V AC/DC
Maximum excitation
15V AC/DC
Bridge resistance
Insulation resistance
+/-0.001%
+/-0.002%
<+/-0.025%
150%
300%
Protection class
IP 67
Overall dimensions
51 L x 20 W x 76 H mm
Weight
380 gm
Manufacturers address
Sensortronics Sanmar Ltd.
38/2A, Old Mahabalipuram Road,
Perungudi, Chennai 600 096.
E-mail: KBS@SANMARGROUP.com
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Manufacturers address
WIKA Instruments Ltd.
Garmany.
Web: www.wika.de
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Technical specifications
Model
EJA110A-DMS5A-92NN
Make
Yokogawa
Output signal
Measurement span
Calibration range
Process connections
SCM 435
Installation
Electrical connection
1/2NPT female
Cover O rings
Buna-N
Supply
10 to 24VDC
-40 to 120 0C
Housing
Weather proof
Weight
3.9Kg
Manufacturers address
Yokogawa Electrical Corporation
Indian supplier:
2-9-32, Nakacho,
Musashino-shi,
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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.
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