Instruction Manual: CT 159 Internal Combustion Engine Basic Module

Instruction Manual
CT 159
Internal Combustion
Engine Basic Module
11/2008
INTERNAL COMBUSTION ENGINE BASIC MODULE
All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000
CT 159
Instruction Manual
Please read and follow the safety regulations before the first installation!
Publication-no.: 916.000 00 D 159 03 (A)
DTP_4
ii
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CT 159
Table of Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Device description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Device design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Setting up the CT 159 basic module . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.1
Measuring fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.2
Measuring air consumption. . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Draining and filling the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.1
Screen displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Risk for personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Risks for unit and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Calculation formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
iii
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CT 159
1
Introduction
The CT 159 internal combustion engine basic
module is part of an equipment series designed
for investigations and experiments on engines and
machines such as internal combustion engines.
This module forms the basis for investigations and

experiments on various combustion engines with
outputs of up to approximately 1.5 kW.
The following accessories are available for
this purpose:
CT 150
four-stroke petrol engine module
CT 151
four-stroke diesel engine module
CT 152
four-stroke petrol engine /
variable compression
CT 153
two-stroke petrol engine module
The CT 159 is equipped with mechanisms for measuring fuel and air consumption. Electronic sensors register ambient and fuel temperatures; these
values are then displayed digitally.
Additional connections and displays for measurements of exhaust-gas temperature and the engine
ignition are included.
The CT 159 is also equipped with a program for recording and processing all the acquired measurement and consumption data. This program can be
installed on a PC (not included).
The system is designed exclusively for educational and experimental purposes.
1 Introduction
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2

Device description
A complete experimental setup includes:
CT 159
HM 365
Engine
A CT 159 combustion engine basic module
A HM 365 universal brake and drive unit
An experimental engine (for example, CT 150)
This type of setup permits a recording of engine

characteristics.
The employed combustion engine is loaded by the
HM 365 unit which acts as a brake in this case.
Fig. 2.1
Functional experiment
configuration
The CT 159 basic module is used in experiments

for measuring fuel consumption and combustion
air requirements. The control panel is furnished
with digital displays for:
Air consumption
Ambient temperature
Fuel temperature
Exhaust gas temperature
The voltage for the CT 159 basic module is supplied via a special connection on the HM 365 universal units rear panel.
Power from the test engine to the brake unit is
transmitted via a V-belt.
2 Device description
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2.1

Device design
11
10
9
1 Fuel tank with pump
12
2 Fuel hose
8
13
3 Air hose
4 Fuel Filter
5 Vibration dampers
6 Control elements
14
15
9 Reflux line connection
10 Air consumption display
11 Air temperature display
12 Fuel temperature display
16
13 Exhaust gas temperature display
17
14 Fuel line connection
7 Manual valve for fuel feed

8 Fuel measurement tube
15 PC measurement program interface

16 Air filter
17 Settling tank with measurement aperture
Fig. 2.2
CT 159 Device layout

The exhaust gas hose is not illustrated here
The basic module consists of a mobile laboratory

frame supporting a display and control panel
mounted on vibration dampers (5). The lower part
of the frame is equipped with a fixture for various
fuel tanks (1); a pipeline (not visible here) is used to
fill the measurement tube (8) for fuel consumption
measurements. A hose (2) with fuel filter (4) connects the fuel tank and pipeline. The measurement
tube is filled by means of a standard fuel pump.
Fuel consumption can be measured manually and
electronically. After the filling process, the fuel can
be fed to the engine via a connection with a
self-locking coupling (14); a second connection (9)
is provided for engines with a return line. The engine is mounted on a ready-to-install base plate
which is inserted into a seat and fastened in place.
The air drawn in by the engine first flows through a
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CT 159
filter (1) and then through a settling tank with a

measuring aperture (17). After that, it flows via an
air hose (3) to the engine. Electronic sensors measure the temperatures of the incoming air and fuel.
All measured values are output to digital displays
(10 - 13) and transferred to a PC for further processing. The connection for PC data acquisition
(15) is located on the side of the basic module.
Measurement data from the HM 365 universal unit
(torque and speed) are transferred via a separate
cable to the CT 159 basic module.
The following individual control elements (6) are
located on the panel:
(18) Engine on/off switch
22
18
19
23
21
(24) Button for starting filling by the fuel

pump
(20) Socket for connecting the ignition cable
24
20
(19) Fuel pump on/off switch
(21) Socket for connecting the exhaust-gas

thermocouple
(22) Valve for filling the measurement tube
(23) Valve for draining the measurement
tube
Fig. 2.3
Connections and
control elements
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2.2

Setting up the CT 159 basic module
To produce a functional experimental setup, the
basic module needs to be connected to the HM
365 universal unit as shown in Figure 2.4. For this
purpose, the two devices are aligned mutually
such that they can be linked via the snap closures.
Small lugs welded to the frames facilitate this union. After the connection has been established, the
frames need to be secured against inadvertent
motion by means of their lockable guide rollers.
SV
Fig. 2.4
Basic module assembly
The fuel tanks are then filled. One tank each is provided for high-octane petrol, diesel and two-stroke
mixtures. The fuel pump is immersed into the tank
containing the fuel specified for the engine being
used.
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2.3

Measurements
The basic module is designed to measure fuel and
air consumption.
2.3.1
Measuring fuel consumption

The measurement tube is used for measuring fuel
consumption. It is equipped with an electronic pressure sensor for PC data acquisition. This sensor measures the hydrostatic pressure of the liquid column.
S
PS
If the data acquisition module is connected, the

pressure-time characteristic can be used to calculate the fuel consumption values which are then displayed on the PC.
For manual ascertainment of fuel consumption without PC data acquisition, the measurement tube is
furnished with a linear scale with intervals of 5 mm.
The fuel consumption is determined with the help of
a stopwatch. The difference between two filling-level readings needs to be divided by the corresponding difference between the reading times.
The consumption can then be calculated precisely
taking into account the fuel density.
CF
(L 1 -L
Dt
AR rF
Fuel consumption in g/sec.
Filling levels indicated in mm
Dt
Time difference between

filling level L1 & L2 in sec.
rF
Fuel density in g/ml
CF
L1, L2
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AR
Measurement device
cross-section in cm2
AR
= 4,8 cm 2
On a change of engine and fuel, it is advisable to

rinse the measurement tube with the newly filled
fuel type.
NOTE: The measurement tube has an internal diameter = 24mm, i.e. a cross-section of 4.52 cm2.
The measurement tube is also connected to a parallel bypass tube located inside the switching
housing. The corresponding volume needs to be
accounted for during measurements of the fuel
consumption. The bypass tube has a diameter
= 6mm, i.e. a cross-section of 0.28 cm2.
AR = 4.52 + 0.28 = 4.8 cm2
2.3.2
(see above)
Measuring air consumption

1
3
2
Experiments with this module involve engines

which draw in air through their piston stroke. The
air is first routed through an air filter (1) and then
through a measuring aperture (2) into a settling
tank (3). The measuring aperture is connected via
hoses to an electronic differential pressure sensor.
This sensor outputs a voltage signal which is proportional to the differential pressure, converted
into volumetric flow and then indicated directly in
litres/
min. All electronically measured values are
also available for transmission to a PC.
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2.4

Draining and filling the fuel system
Filling the measurement tube:
22
18
19
23
Turn on the fuel pump by means of its

switch (19).
Fully open the filling valve (22).
Fully close the drainage valve (23).
Hold down the filling button (24) until

the required filling level has been attained.
24
20
21
Draining the measurement tube:
Fully close the filling valve (22).
Fully open the drainage valve (23); the

fuel then flows into the fuel tank.
On a change of engine and fuel, it is advisable to

rinse the measurement tube with the newly filled
fuel type.
2.5
Maintenance
The robust and simple design of the CT 159 basic
module makes it virtually maintenance-free. Due
to the vibrations generated during engine operation, however, it is advisable to regularly check the
tightness of all screws on the basic module.
The air filter insert needs to be cleaned at regular
intervals (for example, using compressed-air
blown out from inside). Spare air filters can be procured from G.U.N.T.
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2.6

Software
Conducting experiments supported by PC data
acquisition provides the user with several
advantages:
2.6.1
Clearly arranged screen displays facilitate

learning
Flow diagrams elucidate relationships
Measured values become directly available

for further processing
Results from currently measured data can be

directly calculated and displayed
Tabular and chart values can be saved and

printed out
Screen displays
Once the data acquisition card and software have
been installed, the program can be started via the
following menu item:
Start / Programs / G.U.N.T. / CT 159"
The first time the program is invoked, a language
selection dialogue appears.
The menu "Start"provides the options listed below:
Charts,
display of recorded measurement curves
Measurement Diagram,
recording characteristic curve
Systemdiagram,
display of all measured values
About GUNT,
language setting and general information
EXIT,
to quit the program
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System diagram window
Fig. 2.5
System diagram
This program module displays a function and flow

diagram representing the systems configuration.
Currently measured values are indicated at the
corresponding points.
The fuel consumption is also indicated here. The
program uses an internal time base to calculate
the fuel consumption. For this purpose, the user
must first select a time interval in a corresponding
dialog. This interval can be 20, 60 seconds or 2, 3,
4, 5, 10 minutes. Correct consumption values are
only indicated after the measurement time has
elapsed.
10
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CT 159

NOTE! To obtain reliable measurement results,
ensure that the manual drainage valve is fully
closed.
The air ratio is displayed with "lambda".
Calorific value correction:
The program performs calculations on the basis of

the following calorific values:
Standard fuel
43500 kJ/kg
Diesel fuel
43000 kJ/kg
2-stroke mixture 1:50 -
43500 kJ/kg
These values are stored in a file and loaded each

time the program is started.
[GUNT Einstellung]
SPRACHE=-1
[CT159]
Normal fuel=43500.0
Diesel fuel=43000.0
Gasoline 1:50=43500.0
Fig. 2.6
Engine-settings
If fuels of considerably different qualities are used, it

might become necessary to change these values.
The engine-settings file located in the CT 159
programs root directory contains a list of calorific
values.
To modify a value, open the engine-settings file
with any ASCII editor (for example, NOTEPAD,
WORDPAD, Ultra-Edit etc.) and make the required entry.
NOTE: Before performing any changes to the engine-settings files, save a copy of the original version.
11
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CT 159
Charts window
Fig. 2.7
Charts
This program module displays a time chart of the

type commonly used in technical applications.
All available measurement values are displayed in
the lower part. The corresponding time characteristics are also displayed.
The scaling of an axis can be changed by double-clicking on its final value and overwriting it with
a new number.
The print window function can be used to output
screenshots to a printer.
The "print" function can be used to output the diagram only to a printer.
12
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CT 159
"Measurement Diagram" window
Fig. 2.8
Measurement Diagram
This program module is used to record and save

engine characteristics.
The module functions similar to a recorder whose x
and y axes can be freely assigned. This makes it
possible to select different representations in addition to typical engine characteristics.
13
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CT 159
"Choose Axis" window
Fig. 2.9
Choose Axis
Selections are made with menu "View" and the

Choose axis button for assigning axes to parameters to be displayed.
A maximum of 4 recorded curves can be displayed
at a time.
14
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CT 159
Curves are recorded as follows:
Select the new series item in the File

menu. The program then opens a new,
empty file and prompts for the entry of a file
name.
The "open file" item in the "File" menu,

opens an existing file.
The save series item in the File menu is

used to save the current data record.
The take record button in the "Edit" menu

is used to write the current data record to the
open file. Measurement data records are sequentially numbered.
The arrow keys (1) are used to scroll between individual measuring points. Erroneous data measurement records can be deleted with the delete records button.
Viewing, editing and saving curves:
To view a previously recorded curve, activate

the open file item from the File menu and
then select the required file.
Individual curves can now be viewed and

modified (for example, with delete record).
The save series option is used to save the
currently selected curve, overwriting the old
data record in the process.
The save all series option is used to save all

curves in the list to a single file.
The "delete all series" option is used to delete all curves in the single file.
delete series is used to delete a data record.
15
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CT 159
print curve is used to output data records

to a printer.
"print table" is used to output a table to a

printer
"print window" is used to output a

screenshot to a printer.
Data records generated with new series can be

viewed and edited with any standard editor (for example, NOTEPAD, WORDPAD, Ultra-Edit etc.).
These data records can also be imported and edited
in MS-EXCEL.
16
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CT 159
Safety instructions
3.1
Risk for personal safety

DANGER
Spinning belts
Heavy bruise resp. avulsion of fingers and

hand by touching the spinning belts
Protection cover to be installed
Do not touch beneath the cover
CAUTION
Inflammable fluids
Risk of Damages and burnings due to fire or
explosion
Open flame is not permitted
Smoking is not permitted
Escaped fuel to be wiped up and to be

bind with proper agents
Premises to be ventilated properly
CAUTION
Hot plant components
Risk of damages and burnings due to hot
components
3 Safety instructions
Do not touch plant components during

operation
Plant components to be cooled down after

operation
17
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CT 159
3.2

Risks for unit and function
The measuring tube can overflow during the
filling process.
Turn off fuel pump promptly.
Operating the engines (especially the Diesel

engine) can produce strong vibrations.
Avoid placing objects on the Basic Module or
the HM 365 Universal Unit.
3 Safety instructions
18
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CT 159
Appendix
4.1
Technical data
Voltage supply
Connected via a HM 365 universal unit
Nominal: 230 V, ~50 Hz,
Optional alternatives, see rating plate
Dimensions
LxWxH:
900 x 800 x 1900 mm
Weight:
approx. 100 kg
Fuel pump
130 ltr/h
Qmax
Fuel measurement tube
Material : Polycarbonate
Diameter:
24 mm
Effective cross-section for

determining fuel consumption:
4.80 cm2
Pressure sensor for fuel consumption

Measuring range:
0...100 mbar
Differential pressure sensor for

air consumption
Measuring range:
0...5 mbar
Measuring ranges
Ambient temperature:
0...100 C
Fuel temperature:
0...100 C
Exhaust-gas temp.:
Air consumption:
4 Appendix
0...1000 C
0...333 ltr/min
19
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CT 159
4.2

Calculation formula
Mechanical power:
2 p n M
Pmech =
60 1000
[kW]
Average mechanical power:

2 p n M
P mech =
60 1000
[kW]
Speed [1/min]
Torque [Nm]
Fuel Consumption:
Dpfuel 100 p 0,00612 3600
FuelCons =
9,81
4
Dt
[kg/h]
Dpfuel Differential pressure [mbar]

Dt Time difference between filling level L1 & L2
in [s]
Specific Fuel Consumption:

1000 FuelCons
[g/kWh]
spec _ fuel _ cons =
Pmech
Efficiency:
Efficiency =
4 Appendix
P mech
FuelCons Heizwert
360000 [%]
20
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CT 159

Volumetric Efficiency:
Vair
h=
Vtheo
Vtheo = HubVol n Type
for Type = 0,5
Vtheo =
HubVol n
2
Vair
Volumetric air flow (reading)
HubVol
swept volume
(to key in)
Speed (reading)
Type
Motor type coefficient:
Type = 1,0 for 2-stroke engine
Type = 0,5 for 4-stroke engine
Air mass flow rate:

p
T0
60

m
amb Vair _ mean
air = r 0
T0 -T2 p 0
1000
4 Appendix
[kg/h]
r0
Air density under normal conditions

= 1.292 kg/m (constant)
T0
0C in Kelvin = 273,15K (constant)
T2
Ambient temperature (reading) in K
pamb
Ambient pressure (to key in) in mbar
p0
Pressure under normal conditions

= 1013 mbar (constant)
V air_mean
Average Volumetric air flow (reading) in ltr/min
21
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CT 159

Air Ratio:
l=

m
air
FuelCons Lmin
L
Lmin
Air requirement:

m
air
L=
FuelCons
4 Appendix

m
air
Air mass flow rate
FuelCons
Fuel Consumption
Lmin
Theoretical air requirement

[kg air per kg Fuel]
(to key in)
Air fuel Ratio (Air requirement)

[kg air per kg Fuel]
22

Instruction Manual: CT 159 Internal Combustion Engine Basic Module

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Instruction Manual

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

Publication-no.: 916.000 00 D 159 03 (A)

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

Measuring fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . 6

Measuring air consumption. . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 Draining and filling the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 8

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

This module forms the basis for investigations and

INTERNAL COMBUSTION ENGINE BASIC MODULE

A CT 159 combustion engine basic module

A HM 365 universal brake and drive unit

An experimental engine (for example, CT 150)

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

This type of setup permits a recording of engine

The CT 159 basic module is used in experiments

Exhaust gas temperature

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

9 Reflux line connection

10 Air consumption display

11 Air temperature display

12 Fuel temperature display

13 Exhaust gas temperature display

14 Fuel line connection

7 Manual valve for fuel feed

15 PC measurement program interface

CT 159 Device layout

The basic module consists of a mobile laboratory

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

filter (1) and then through a settling tank with a

(24) Button for starting filling by the fuel

(19) Fuel pump on/off switch

(21) Socket for connecting the exhaust-gas

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

Basic module assembly

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

Measuring fuel consumption

If the data acquisition module is connected, the

Fuel consumption in g/sec.

Filling levels indicated in mm

Time difference between

Fuel density in g/ml

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

On a change of engine and fuel, it is advisable to

Measuring air consumption

Experiments with this module involve engines

INTERNAL COMBUSTION ENGINE BASIC MODULE

All Rights Reserved G.U.N.T. Gertebau GmbH, Barsbttel, Germany 09/2000

Turn on the fuel pump by means of its

Fully open the filling valve (22).

Fully close the drainage valve (23).

Hold down the filling button (24) until

Draining the measurement tube:

Fully close the filling valve (22).

Fully open the drainage valve (23); the