PIPER DIESEL DYNAMOMETER BROCHURE

CONTENTS PIPER Introduction and Customer Charter .........................................................................................1 Why you need a dynamometer for vehicle, plant or engine testing......................................................2 PIPER P1200 Dynamometer................................................................................................................3 PIPER P2400 Dynamometer...............................................................................................................4 PIPER P4000 Dynamometer................................................................................................................5 Fixed base mounting adapters ..............................................................................................................6 PIPER DC 720 Dynamometer ..............................................................................................................7 PIPER Rail engine Test System...........................................................................................................8 PIPER P1400 Heavy Duty Chassis Dynamometer .............................................................................9 Power curves .......................................................................................................................................10 Torque curves ......................................................................................................................................11 Drive assembly ....................................................................................................................................12 PIPER Dynamometer Instrumentation ...............................................................................................13 P15 EDA & P15 Instrumentation Configuration .................................................................................14 Installation Requirements ....................................................................................................................15 General.............................................................................................................................................15 1. Water tank................................................................................................................................15 2. Dynamometer supply pump.....................................................................................................16 3. PIPER instrument consoles ...................................................................................................16 4. PIPER dynamometers ............................................................................................................16 5. Pressure regulating valve ........................................................................................................16 6. Load valve controller................................................................................................................16 7. Engine cooling column or radiator...........................................................................................19 8. Throttle actuator controller.......................................................................................................19 9. Mobile engine test stand..........................................................................................................19 10. Dynamometer return flow control valve...................................................................................19 11. Dynamometer support trolley ..................................................................................................19 12. Inlet air .....................................................................................................................................19 13. Electronic throttle actuator.......................................................................................................19 14. Engine cooling column pump ..................................................................................................19 15. Cooling tower circulation pump ...............................................................................................19 16. Sump tank drain pump.............................................................................................................20 17. Load control valve....................................................................................................................20 18. Cooling Tower..........................................................................................................................20 21. Extraction fan ...........................................................................................................................20 22. Drain / sump tank.....................................................................................................................20 PIPER Accessories.............................................................................................................................21

PIPER TEST & MEASUREMENT LTD

PIPER Introduction and Customer Charter
Piper Test & Measurement manufactures engine test systems with its own product range such as the successful P1200, P2400 and P4000 engine dynamometers, CD1000 and CD2000 chassis dynamometers, and its associated instruments. Our instrumentation range is comprehensive and ranges from simple analogue to full computer based data acquisition systems. The majority of the basic equipment can be specified to incorporate RS232/485 output signals. The extensive knowledge gained during hands on experience with the workings of hydraulic, eddy current and DC absorption units, enables us to recommend an upgrade to PIPER instrumentation for existing installations. One-off specific test rigs are designed in close co-operation with the customer. Our knowledge of mechanical, electrical and hydraulic systems enables value for money units to be manufactured at short lead times, whilst our close co-operation with engine manufacturers enables the most suitable test schedules to be prepared. Our co-operation with proprietary peripheral instruments manufacturers of products such as smoke density recorders and fuel flow measuring devices, enables PIPER to offer its customers essential test room equipment. Technical back-up and assistance with peripheral services and, if required, liaison with subcontractors, ensures that customer experiences the minimum delay once the equipment is delivered on site. The PIPER design philosophy is based on incorporating known technologies. This ensures that the client has reliable, serviceable and, above all, user friendly equipment. Piper Test & Measurement is conveniently situated in the South East of England one and two hours respectively from Gatwick and Heathrow airport and half an hour from the ferry and tunnel links with Europe.

CUSTOMER CHARTER The value of customer service is embedded within the culture of our organization and is a personal belief of every staff member.

We recognise that our customers are an important asset We are committed to providing an effective and efficient service We provide leading edge technology through proven engineering concepts We have the flexibility to cater for the specialised needs of our customers We pride ourselves on our reputation and integrity We are proud that our products contribute to a cleaner environment

WE CARE

PTM_brochure

Page 1

PIPER TEST & MEASUREMENT LTD

Why you need a dynamometer for vehicle, plant or engine testing
A dynamometer is a vital requirement for any efficient and reputable service or repair facility. A necessity to meet manufacturers standard and to enable "end of product" questionnaires to be completed. In today's environment it cannot be judged a luxury. It is a recommendation by diesel engine manufacturers who are conscious of both the environment and ensuring that they give their end users a product and service on which they can depend. With operating costs escalating in all aspects where the diesel is used, excessive downtime, especially come-backs cannot be tolerated, in addition to causing a financial drain with which customers and facilities cannot live. A dynamometer, especially a non-fixed base item, will pay for itself in a short period of time. It will allow the engine to be tested under load (even in the chassis) where the majority of the faults will occur. Problems that arise, which lead to come-backs, are usually diagnosed within the first hours of operation under load. Dynamometer testing can isolate these problems, verify repairs, while at the same time establishing power levels. The ability to pin point problems through objective testing rather than by opinions is the dynamometers biggest advantage. The portable PIPER engine dynamometer has several advantages over the convetionally mounted dynamometer. 1. Inexpensive to install 2. Can be mounted directly on the engine bellhousing or with adaptors directly after the transmission 3. Easier to pin-point performance losses - as drive train is not subjected to load 4. Ideal for investigative projects The reasons for a portable Dynamometer facility can be summarised as follows: Trouble shooting and problem isolation Reduces come back Power compliant verifications Fluid leak detection Cooling system check-out Smoke test Adjustment of injection equipment under load to optimize fuel economy Run in after overhaul Inexpensive for feasibility studies Easy to use and flexible in attachment No civil engineering costs to be incurred as associated with fixed bed dynamometer Can be used for "in chassis" testing Keeps quality control on your facility

PTM_brochure

Page 2

PIPER TEST & MEASUREMENT LTD

PIPER P1200 Dynamometer
500 BHP/1000 lb./ft. The P1200 absorption unit is designed for testing Diesel engines up to 520 HP and 1000 lb/ft of torque. The unit can be used in the conventional floor mounted method, or directly attached to the engine bell housing. The latter allows minimum civil engineering cost to be incurred. The unit can be supplied with a double mechanical seal arrangement if extended load testing is required.

SPECIFICATIONS Type of Absorption Water requirement Bearings Operating RPM range Torque transducer Speed sensing Drive attachment Water 35 gpm @ 45 psi Roller type grease filled and sealed 300-3000 Strain gauge 60 tooth wheel with sensor SAE 4- bell housing adapter (SAE 0-00 optional) 10 -18 nominal clutch diameter flywheel drive plates and torsional damper assembly

Material: Shaft EN 24T Housing & rotor Aluminium alloy Dyno attachments SAE - 0.5 - 4 Single or Double Trunnion Double Roller bearing The dynamometer is of compact design and can be used: 1 Direct on engine 2 Floor mounted (with drive shaft) 3. In chassis
PTM_brochure

P1200 AND P12 INSTRUMENT

Page 3

PIPER TEST & MEASUREMENT LTD

PIPER P2400 Dynamometer
900 BHP/2000 lb./ft. The P2400 unit is designed for testing diesel engines up to 900 BHP and 2000 lb/ft of torque. As with the P1200 it can be used in the conventional floor mounted manner, or directly attached to the engine bell housing. The latter allows minimum civil engineering cost to be incurred. The unit can be supplied with a double mechanical seal arrangement if extended no load testing is required and can be operated in single rotor mode for engines up to 520 BHP.

SPECIFICATIONS Type of Absorption Water requirement Bearings Operating RPM range Torque transducer Speed sensing Drive attachment Water 70 gpm @ 45 psi Roller type grease filled and sealed 300-3000 Strain gauge 60 tooth wheel with inductive pick-up SAE 4- bell housing adapter P2400 with P12 instrument (SAE 0-00 optional) 10-18 nominal clutch diameter flywheel drive plate and torsional damper assembly EN 24T Aluminium alloy SAE - 0.5 - 4 (SAE 0-00 optional) Double Roller bearing

Material: Shaft Housing & rotor Dyno attachments Double Trunnion

The dynamometer is of compact design and can be used: 1 Direct on engine 2 Floor mounted (with drive shaft) 3. In chassis
PTM_brochure

Floor mounted version

Page 4

PIPER TEST & MEASUREMENT LTD

PIPER P4000 Dynamometer
1500 BHP/3750 lb./ft. The P4000 is a 1500 BHP - 3750 lb./ft uni-directional absorption unit specifically designed for low speed, high torque diesel engines presently being offered by all leading engine manufacturers. It can be used directly attached to the engine bell housing utilising the PIPER manufactured torsional damper assembly and SAE drive plates, thus incurring minimum civil engineering costs, or in the conventional floor mounted position. A double seal arrangement allows extended no-load testing. The P4000 can be supplied as a bi-directional low speed high torque absorber. The torque absorption capability of this unit is the same as that of the uni-directional unit and is especially suitable if anticlockwise marine engines are to be tested. Mechanical specifications with respect to dimensions, materials and drive arrangements are the same as for the standard P4000. The dynamometer is of compact design and can be used: Direct on engine Floor mounted (with drive shaft) In chassis Optional extras: SAE 0-00 bell housing adapter Additional flywheel drive adapters (one supplied with each system) Dynamometer support trolley SAE bell housing and flywheel bolts package Instrumentation - See PIPER specification sheet Torque absorption capability at 1400 rpm 1600 rpm 3400 lb./ft 3750 lb./ft

SPECIFICATIONS Type of absorption Water requirement Shaft Bearings Operating RPM range Torque Transducer Speed Sensing Drive attachment Water 120 gpm @ 70 psi Roller type grease filled and sealed 300-3000 Electronic strain gauge 60 tooth wheel with inductive pick-up SAE 4- bell housing adapter (SAE 0-00 optional) 11-18 nominal clutch diameter flywheel drive plates and torsional damper assembly EN24T Aluminium alloy Double arrangement with 2 roller bearings
P4000 with P12 instrument

Material: shaft housing & rotor Trunnions

PTM_brochure

Page 5

PIPER TEST & MEASUREMENT LTD

Fixed base mounting adapters

All our dynamometer are supplied complete with an 4,3,2,1 and 1/2 SAE bell-housing adapter and torsional damper assembly for direct attachment to an engine bell-housing and flywheel respectively. In some instances the customer may prefer a fixed base dynamometer which is bolted to a base in the test cell. A special range of mounting adapters have been designed for this purpose to suit our P1200 , P2400 and P4000 dynamometers. The engine is coupled to the dynamometer by means of a drive shaft, torsional damper assembly and SAE flywheel drive plate. One of each of these components is included with the relevant quoted part numbers. The torsional damper assembly bolts directly to any of our SAE flywheel drive plates which can purchased separately in addition to the one free issue drive plate. Part numbers PFBM - 1200 PFBM - 2400 PFBM - 4000

PTM_brochure

Page 6

PIPER TEST & MEASUREMENT LTD

PIPER DC 720 Dynamometer
720 BHP/2300 lb./ft. The DC720 is a 720 BHP - 2300 lb./ft bi-directional absorption unit specifically designed for low speed, high torque diesel engines presently being offered by all leading engine manufacturers. The DC720 is a fixed base dynamometer with trunnions and strain gauge. It is controlled with a 4 Quadrant thyristor controller and all power absorbed is regenerated into the site electrical supply. No water cooling system is required. This dynamometer can absorb and motor the test engine and is specifically suitable for transient test cycles such as the ETC European Transient Cycle ELR European Steady Cycle, ESC European Load Response Test and FTP Federal Transient Procedure. A range of alternative sized DC dynamometers is available. Contact for more information. 525 kW (720 BHP) Direct Current dynamometer. 3100 Nm torque and 3000 RPM capability. Trunnion mounted with load cell strain gauge. Double universal joint drive-shaft and torsional damper. 4 Quadrant Thyristor controller enabling motoring and absorption. Geared Throttle Servo actuator.

Piper Windows based operating software in conjunction with InTouch SCADA package.
AK or GPIB protocol modules available for interfacing with: Mini tunnel Fuel meter Airflow meter (hot wire or equivalent) Smoke meter Gas analysers Weighing scale

SPECIFICATIONS
Type of absorption Water requirement Shaft Bearings Operating RPM range Torque Transducer Speed Sensing Drive attachment Direct Current electrical None Roller type grease filled and sealed 0 2800 Electronic strain gauge Tacho generator SAE double universal drive shaft and torsional damper Double arrangement with 1 roller and 1 ball bearing

Trunnions

PTM_brochure

Page 7

PIPER TEST & MEASUREMENT LTD

PIPER Rail engine Test System
The PIPER P2400 dynamometer based Railcar Engine Test System is suitable for the In Chassis testing of a range of diesel engines including those fitted to the Class 14X, Sprinter150, 153, 155, 156, 158,and 159 railcars. It enables operators to fault-find or undertake diagnostic work without removing the engine and or gearbox from the chassis while the engine is under load. To undertake such work, at present, the railcar has to be taken On-Route to simulate operating conditions and even then it is difficult for the testers to fully load the railcar. The adjustibility of the support frame allows the dynamometer to be fitted between the gearbox output flange and railcar differential pinion input flange. In most instances no auxiliary equipment needs to be removed from the railcar, only the gearbox/ differential cardan shaft. A laser speed sensor is fitted to the cardan shaft connecting the engine and gearbox which enables the monitoring of engine speed while the gearbox output speed is measured by a magnetic pick up and sender unit fitted to the dynamometer. The measuring of these two speeds enables operators to monitor gearbox ratios and gearbox efficiencies.

The basic system comprises the following major components: 1. PIPER P2400 dynamometer is mounted in double trunnions fixed to two vertical end support plates. The end support plates are connected to a horizontal connecting plate complete with two slider plates for bolting to the rail. 2. A hydraulic support trolley for lifting the above assembly. 3. PIPER P15 EDA computer based data logging system or any other instrument from the PIPER range of instrumentation. 4. Voith output adapter suitable for connection to the dynamometer cardan shaft. 5. Dynamometer water system including supply pump.

PTM_brochure

Page 8

PIPER TEST & MEASUREMENT LTD

PIPER P1400 Heavy Duty Chassis Dynamometer
Through the innovative application of proven heavy duty vehicle technology PIPER has produced a large roll 1,400mm chassis dynamometer built for sustained testing of trucks rated to 600 hp. The PIPER unit is designed to meet the exacting requirements of truck service facilities for a cost effective chassis dynamometer that can stand up under the rigors of hard use, while delivering long service life with a minimum of maintenance. The system design weight limit is 16,000 kg. The unit will operate to 130 kilometres per hour. Operating Principle/Features No tyre damage. The PIPER 1,400mm single roll design is the largest commercially available, and this big roll does not damage tyres. The large roll provides superior traction for greatly reduced tyre slippage, wear, heat and noise. Superior traction also means greater accuracy and repeatability of results. Single Large Roll Means Easier Operation No adjustments are required for single or tandem axles. Misalignment problems of dual roll system are eliminated. Power divider does not need to be locked on tandem axles. Utilizes a single power absorber and has one instrument readout only (hp and mph) The Most Cost Effective Chassis Dynamometer Available Compact unitized construction permits easy installation in just a few hours after site is prepared. Above or below surface installation. The entire P1400 Chassis Dynamometer System has been designed for maximum service with a minimum of ease to perform maintenance. Dual Dynamometer Capability The unit can be a double-duty dynamometer - two rugged units in one - since it utilizes a portable compact absorption unit. After quick and easy removal from the chassis dynamometer frame, the power absorber unit can be used as a direct engine dynamometer with all of the bolt-on compact PIPER features. With the addition of the PIPER P1400 to your service facility you can gain total dynamometer testing capability-chassis or engine. Instrumentation And Control Digital instrumentation, with built-in calibration check, for the P1400 reads out in mile-per-hour and road horsepower. The unit has easy to read L.E.D. digital display and can be pedestal, wall or pendant mounted. The hand-held remote control can be used from either in the cab or adjacent to the chassis dynamometer. Computer Interface may be specified.

PTM_brochure

Page 9

PIPER TEST & MEASUREMENT LTD

Power curves

kW / 0.745 = HP HP x 0.745 = kW

PTM_brochure

Page 10

PIPER TEST & MEASUREMENT LTD

Torque curves

1 lb.ft. X 1.36 =NM NM 1.36 = lb.ft.

PTM_brochure

Page 11

PIPER TEST & MEASUREMENT LTD

Drive assembly

PTM_brochure

Page 12

PIPER TEST & MEASUREMENT LTD

PIPER Dynamometer Instrumentation
PIPER P9 Torque & Speed. Compact digital instrument console for the display of torque and speed. This table mounted unit comes complete with all the necessary leads and quick connect plugs and sockets. Ideal for customers who wish to upgrade to a basic digital display unit. PIPER P12 Torque, Speed & Horsepower. Similar in size and specification to the P9 but with an additional digital horsepower display.

PIPER P10 Torque & Speed. Pedestal mounted instrument console utilising the latest electronic technology to display torque and speed. Fitted as standard with emergency stop button and starting/ignition key. PIPER P11 Torque, Speed & 6 Temperatures. Similar to P10 but fitted with additional 6 temperature channels which are displayed by selection on a single digital unit. Probes and interface box are supplied as standard equipment.

PIPER P15 Desk type instrument console digitally displaying torque, speed, horsepower, boost, oil, crankcase and fuel pressures and 6 temperatures. In-cell transducer box which transmits signals to console, is fitted with additional oil pressure and speed display for operator observation when in-cell. Stop/start/emergency buttons and various warning light are included. RS 232/485 interface ports can be specified for transmitting signals to a personal computer which utilises PIPER P15 EDA software for display, disc storage or print out.

PIPER P15 EDA The Engine Data Acquisition system is an interface system utilising the transducers, software and data transmission developed for the P15. Transducer signals are transmitted to the serial port of a personal computer via a 232/485 converter. The PIPER software allows the same P15 -13 channels to be displayed on the screen. The operator can add engine build specifications and other notes of importance manually. Data can be selected and stored on disk or output as hard copy via a dot matrix printer.

PTM_brochure

Page 13

PIPER TEST & MEASUREMENT LTD

P15 EDA & P15 Instrumentation Configuration

PTM_brochure

Page 14

PIPER TEST & MEASUREMENT LTD

Installation Requirements
General
For the successful operation of the equipment an adequate water supply is necessary. The power absorbed by the dynamometer is converted into heat and carried away by the water flowing through it. It is an efficient and inexpensive method and the heat generated is directly proportional to the power absorbed. Water is therefore an essential element and, as large quantities of hot water are produced, it must be cooled and recycled or disposed. To dispose of large quantities of water may not only be illegal but also wasteful. In many cases a simple, large, inexpensive plastic or steel storage tank without any heat dispersion fac ility, such as a cooling tower or heat exchanger, may be used. The dynamometer is supplied, via a pressure pump, from this tank. The hot water is then returned to the tank. However, the power and subsequent heat generated by the dynamometer and engine will gradually increase the tank water temperature, but if short periods of testing are the norm, this facility will suffice. See temperature calculations for factual values. The size of the tank will depend on the anticipated duration of the test and the power level at which the test will be performed. From these parameters the volume of the tank can be calculated. It is essential to ensure that the temperature levels do not exceed 180F (80C) at any point in the system. As a rule of thumb, 100 BHP generates 4242 BTU/min (74447 watts) and if no heat exchanger is available a 1000 gallon (4540 lt.) tank will enable a 100 BHP engine to run for 4 hours assuming a starting tank water temperature of 120F (50C). A 500 BHP engine can run for 50 minutes before unacceptable tank water temperatures are reached. If extended periods of testing are required, a surface evaporating cooling tower will need to be fitted within the system. This would not waste any water but will require an initial financial outlay. To maintain a constant tank temperature, the cooling tower must be capable of coping with 320000 BTU/hrs for every 100 BHP absorbed by the dynamometer and engine cooling system.. The following will offer some explanation as to the requirement and speci fication of the various components which make up a successful facility. Please do not hesitate to contact PIPER if in doubt.

1.

Water tank
The water tank can be manufactured from plate steel (protected against corrosion), plastic, concrete (suitably sealed) or any other material able to withstand temperatures up to 195F (90C) and not affected by an antifreeze solution. The tank is not subjected to any pressure other than the weight of water in it and therefore does not require any certification. A baffle in the middle of the tank will create a hot and cold well. This baffle acts as a buffer but not a sealant between the two wells. It separates the cold water required to supply the dynamometer and the engine cooling system from the returned hot water. If a cooling tower is fitted, the hot water is circulated through the cooling tower while the cooled water is returned to the cold well. The location of the tank is important. It is essential that the water level in the tank is below the outlet port of the dynamometer so that the water can run freely away from it without any back pressure. Any resistance in the return lines will create overheating of the dynamometer and can cause serious damage. The location of the tank will influence the actual overall dimensions of it. If a pit can be excavated, the overall surface area required can be kept to a minimum as the depth of the pit will give increased height and, therefore, volume. While an above ground tank is restricted in depth since this is dictated by the outlet port height of the dynamometer. This usually dictates a larger surface area for an equal volume. Ideally the total tank volume required is between 1200 and 1500 gallons, this equates to between 4.8 and 6 cubic metres respectively. For example, an above ground tank is limited to 0.6 metre in height (to stay below the outlet port of the dynamometer). We therefore require a surface area of:

PTM_brochure

Page 15

PIPER TEST & MEASUREMENT LTD

volume = depth 4 = 0.6 S.A. = 6.6 sq.metre This equates to a tank of 2.58 x 2.58 surface area or any other combination which equals to 6.6 sq. metre. surface area S.A. Provision in the tank must be made for the following connections and services: (i) For the Dynamometer pump supply :Ideally this should be situated at the bottom of the tank for flooded pump suction or, if the pump is above the water level, a non-return valve will need to be incorporated. Connection in cold well. (ii) For the engine cooling pump supply:same as (i) (iii) For the cooling tower heat exchanger supply:Same as (i) but connection to be in the hot well. (iv) Tank "top-up" supply from mains:To be connected in the top of the tank and should enter via ball valve. (v) Overflow - at least 2 times the diameter of the mains supply. (vi) Cooling tower return - water for the cooling tower usually free-falls through the tower back into the cold well of the tank and generally does not require any fixed connections into the tank.

2.

Dynamometer supply pump

The pump should be mounted with its inlet or suction port below the level of the water in the tank so that a non-return valve is not required and the pump can therefore operate with a constant head of water. The pump is required to supply the P1200, P2400 and P4000 dynamometer with 45 GPM(205lt/min), 90gpm(410lt/min) at 45psi (3.2kg/cm) dynamic( (flowing pressure) and 140 GPM/640lt/min) at 70psi (4.8kg/cm) dynamic respectively. Pump suppliers will require the following information:i) The distance from the water tank to the dynamometer including the pipe diameters and length. ii) The height from the pump to the dynamometer inlet port. Suction must be from the cold section of the tank.

3. 4.

PIPER instrument consoles

See P9, P10, P11, P12, P15 and P15 EDA instrumentation specification sheets.

PIPER dynamometers
P1200, P2400 and P4000 absorption unit are bolted directly onto and close coupled to the engine. Floor mounted adapters and drive shafts are available for all models. See dynamometer specification sheets.

5.

Pressure regulating valve

It is advisable to fit all the pumps with a by-pass system so that when the load control valve to the dynamometer and thermo-static valve to the engine cooling column are closed, water can return to the tank without continually pressurising the pumps. These by-pass control pipes and valves are teed off the outlet port of the pumps and allow water to return to the cold well of the tank. An automatic pressure regulating valve supplied by PIPER (contact factory) or stopcock valve will suffice for bypass water flow control.

6.

Load valve controller

See point 17

PTM_brochure

Page 16

PIPER TEST & MEASUREMENT LTD

PTM_brochure

Page 17

PIPER TEST & MEASUREMENT LTD

PTM_brochure

Page 18

PIPER TEST & MEASUREMENT LTD

7. Engine cooling column or radiator
Either an PIPER engine cooling column, radiator or overhead tank is required to control the engine water jacket temperature. To control this temperature a cooling column has been designed to control engine water temperatures for engines up to 1500 BHP. The water system operating pressure can be controlled between 5 and 40 p.s.i. by means of an adjustable pressure relief valve activated by a handle at the bottom of the column. Cool water is introduced from the main tank via a thermostatically operated valve or valves. Hot water returns back to the main tank via this adjustable pressure relief valve. A sight glass at the top will indicate if exhaust gases are escaping from a leaking combustion chamber into the engine cooling system. A fill and drain system is incorporated allowing limited loss of water. Water flow and pressures supply to the column are depended on the size of engines to be tested. PIPER offer a range of suitable supply pumps which are shown on our Supply and circulation pump product sheet. Alternatively an engine radiator or overhead wall mounted tank may be used. The radiator, of the industrial/stationary installation type, in combination with either an engine or electrically driven fan, is required to maintaining a constant temperature at full power. Alternatively, an overhead plastic or steel tank with sufficient volume - min 45 gallons must be placed adjacent to and above the front of the engine. Provision must be made in the tank for connection to and from the engine. An overflow and supply connection will also be needed. The supply can be controlled by a thermo-static valve.

8. 9.

Throttle actuator controller

See point 13.

Mobile engine test stand.

PIPER manufacture a engine support stand suitable for a wide range of engines. The engine can be tested in a relative light frame as all the torque reactions are retained within the engine / dynamometer package. Contact factory for specific details.

10.

Dynamometer return flow control valve.

It is recommended to fit a manual control valve in the dynamometer water return pipe. (or pipes if the P2400 is fitted) This valve size depends on the model of the dynamometer used. Contact factory for further details.

11.

Dynamometer support trolley

This trolley supports the dynamometer when not attached to an engine. It prevents accidental damage and is adjustable for height and easy dynamometer alignment to the engine bell - housing. The trolley is fitted with two steering and two fixed wheel castors.

12.

Inlet air
Inlet air should enter the test cell just above ground level via trunking attached to, or incorporated in the test cell wall. Louvered vents, adjustable from the cell, will allow the trunking to be shut off from the atmosphere when not in use. Typical cross area dimensions for the trunking, if two are fitted, would 2 sq.ft. each.

13.

Electronic throttle actuator

For remote operation of an engine throttle or fuel pump control rack, PIPER offer a push - pull manual throttle cable and handle or alternatively an electronic actuator which can be fitted in the test cell connected to engine throttle lever, by means of a short push - pull cable and operated remotely by a switch or potentiometer mounted on the operator control panel or PIPER instrument. Actuator is supplied for connection to a 24 Vdc supply.

14.

Engine cooling column pump

This pump, as with the dynamometer pump, should be mounted so as to operate with a constant head of water. Generally, it may be assumed that it will require to pump a third of the flow and pressure of the dynamometer supply pump. Suction is from the cold section of the tank.

15.

Cooling tower circulation pump

This pump, if possible, should be mounted so as to operate with a constant head of water. The inlet port of the pump must be connected to the warm section of the tank and sized according to the flow capability of the cooling tower.

PTM_brochure

Page 19

PIPER TEST & MEASUREMENT LTD

16. Sump tank drain pump.
In installations where it is not possible to install a tank with a water level below the outlet port height of the dynamometer (preventing water to drain away from the dynamometer without back pressure) an intermediate sump tank is required which allows the water from the dynamometer to flow away without back pressure or resistance. A drain or transfer pump then pumps the water back to the main tank which can now have a water level above the dynamometer outlet port height. We have selected a range of suitable pumps and we recommend that you contact our factory for details.

17.

Load control valve

The absorption capability of the dynamometer is directly proportional to the water passed through the unit which is controlled by a mechanical load valve in the system. This valve may be situated in the operator control area and is mounted in the water pipe between the dynamometer supply pump and the dynamometer. In some instances its positioning may be difficult to achieve due to the extra pipe length or building restrains. As an alternative to this manual valve we can offer a remote electronic valve which may be placed in a more convenient position and which allows the opportunity to eliminates the water pipes from entering the operator control area. Control of this valve is by switch or position potentiometer and requires a 24 Vdc supply.

18.

Cooling Tower
PIPER can supply a range of cooling towers developed for use with our dynamometers. The sizing of these towers depends very much on local climatic conditions and may vary from our recommended units. We will require local humidity and average temperatures to advise on the most suitable unit. Please contact the factory for further details These units combined with its circulation pump, is an optional extra. It will need to be considered if extended test periods are required. Water is pumped from the warm well in the tank to the top of the tower where it falls over a broken surface and, with the aid of a fan, heat is evaporated and the cooled water is returned to the main tank. A local cooling tower manufacturer or supplier will require the following information before recommending the most suitable unit for a particular duty and environment. (i) Flow through tower. As a separate circulation pump is used for the tower the manufacturer should be able to advise on the tower flow capability. This information will be required by the pump supplier to size the cooling tower circulation pump. (ii) Temperature coolant range: For the system to maintain a constant temperature the cooling tower must be able to dissipate 4242 BTU/min for every 100 BHP absorbed in addition to the 1060 BTU/min generated by the engine cooling system or 320000BTU/hr. (iii) The design ambient and operating altitude will be required for the correct sizing.

19.

Cooling column bypass control valve.

A manually operated by pass control valve is recommended so that when the cooling column thermostatically operated control valve is closed, water can return to the tank without continually pressurising the pumps.

20.

Cooling tower control valve

The cooling tower pump is sized to optimise the flow through the cooling tower. However it is advisable to fit a manual control valve which will allow the operator to reduce the flow if necessary .

21.

Extraction fan
The extraction fan and ducting should be mounted high in the test room. The fan motor can drive the fan by means of "V" belts and therefore out of the hot air flow. The installation should be capable of 15000 C.M.F. at 1" static pressure. It is advisable to incorporate a back or aft damper and bird screen.

22.

Drain / sump tank

In installations where it is not possible to install the main tank with a water level below the dynamometer outlet port height, preventing water draining away from the dynamometer without back pressure or resistance, an intermediate sump tank is required which allows the water from the dynamometer to flow away without resistance. This tank may be situated in the test cell as shown on the diagram and will require a float switch operated transfer pump to pump the water to the main tank

PTM_brochure

Page 20

PIPER TEST & MEASUREMENT LTD

PIPER Accessories

PFBM Fixed base adapters

PEHC Torque calibration system

PDS-DD-CT-CC Supply & circulation pumps

PSAE SAE 0-00 Bell housing adapter

PTCA Torque calibration arm PCTW Cooling tower

PFDP SAE Flywheel/drive plate

PETA Throttle actuator

PBLT SAE Bolts package PCOL Engine cooling column

PLCV Load control valve

PTRL Dynamometer support trolley

PDSM Diesel Smoke Meter PPRV Pressure regulating valve PDSB Dynamometer support bracket
PTM_brochure Page 21

PIPER TEST & MEASUREMENT LTD

PTM_brochure

Page 22

PIPER TEST & MEASUREMENT LTD

PTM_brochure

Page 23

PIPER TEST & MEASUREMENT LTD

PTM_brochure

Page 24