SITE UTILITIES

For Engine setups

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

General Computer
Foundation block Water supply
Engine exhaust Drain Water
Electric supply

Contents in the document subject to change without notice

APEX INNOVATIONS PVT. LTD.
E9/1, MIDC, Kupwad, Sangli - 416436 (MS) India Telefax: +91 233 2644098/2644398
Email: support@apexinnovations.co.in Web: www.apexinnovations.co.in
Site utilities…Engine setups
General
 Decide the location and working space considering permanent location of the setups. Temporary
location and foundation is not advisable as shifting of the setups, later on, is a tedious task.
 Following are the space/layout diagrams and photographs of Engine test setups. Note photos are
clicked from working front. Dynamometer is on working front side and engine is on the back side.
Single cylinder engine set up Multi cylinder engine set up

Space/Layout diagram Space/Layout diagram

Photograph Photograph

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Site utilities…Engine setups
 Layout for two setups: Following photograph shows recommended layout for two engine set ups. The
gap between the two foundation blocks should not be less than 1600 mm.

Following layout for two setups is not recommended

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

 Anti-vibration mounts instead of foundation block are not recommended.

 Foundation bolts of size M16 or 5/8” BSW, 250 mm long (8Nos ) 50 mm
threading length are required.
 Dig a pit as suitable to for size of the foundation block.

Engine setup Single cylinder Multi cylinder

Foundation Block size LxW mm 1700 X 700 1900 X 850
Depth (Black soil /rocky soil) mm 800-900 / 600-700 600-700 / 500-600
 Put a rectangular grid mesh box in the pit using 6 mm ms rods with 150 mm pitch or 8 mm ms rods
with 200 mm pitch.

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Site utilities…Engine setups

 Following are two methods for preparing foundation block

A) Foundation block with integrated foundation bolts

 Prepare a Template from ms flat or plywood for foundation holes.

 Prepare Support Box of height 150 mm for template using wood / plywood & battens.
 Fit the foundation bolts to the template ensuring threaded portion 50 mm above the template.
 Place the foundation bolt + template assembly on the Support box and place support box on the pit.
 Pour the concrete in the pit. Ensure that the foundation bolts distances are maintained.
 Next day remove the template and support box. Plaster the sidewalls and top of the foundation block.
Allow foundation block curing for 8 days.

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Site utilities…Engine setups
 Put round or rectangular supports on the foundation
block. Ensure that base frame bottom is above the top of
the foundation bolts. Slide the setup over the supports to
align the base frame holes with foundation bolts. Then
remove the supports.

B) Foundation block with pockets for foundation bolts

 Put vertical round/square/rectangular pieces at a pitch distance of foundations bolts. The size of the
pocket should be about 125-150 mm.
 Pour the concrete in to the pit. Ensure that the block height above the ground level is 150 mm.

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Site utilities…Engine setups
 Next day remove the side plates and pieces
inserted for pockets. Plaster the sidewalls and top of
the foundation block. Allow foundation block curing
for 8 days.
 Insert the foundation bolts in the pockets. Put the
engine set up on the foundation block. Fit the
foundation bolts to the engine set up frame from
bottom.
 Fill-up the pockets with concrete slurry and allow
for 3-4 days curing. Do not tighten the nuts of the
foundation bolts before curing period is over.

 Note that the foundation block height

should be 150 mm. As there is rigid water
piping between Engine panel and base
frame, extra height foundation block also
needs support block for engine panel.
Following picture shows Engine panel box
with support block due to extra
foundation block height

Extra height foundation (Not recommended)

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

Single cylinder engine set up Multi cylinder engine set up

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

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

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Water supply
 Following are pipe line sizes and water quantity requirements.
Engine setup Single cylinder Multi cylinder Single OR Multi cylinder
Dynamometer Eddy current Eddy current Hydraulic
Water line size 1” BSP 1.25” BSP 1.25” BSP
Water quantity @1000 LPH @4000 LPH @4000 LPH
 Water supply from overhead tank with positive head is preferred.
 Avoid water recirculation as the inlet water will continuously heat up and steady state shall not be
achieved
 Engine set up is supplied with water pump. If water supply is from existing pump, for avoiding flow
fluctuations, the pump supplied with the set up shall be bypassed.

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

Contents in the document subject to change without notice

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