HYBRID ENGINE TEST STAND
OPERATIONS MANUAL
MODEL:
STEAMER 1.0
TEAM STEAM
1
Contents
1
Getting Started................................................................................................................................................................................... 2
1.1
2
Requirements .......................................................................................................................................................................... 2
Safety ................................................................................................................................................................................................. 3
2.1
Safety Checks ........................................................................................................................................................................... 3
2.2
DOs and DON’Ts ...................................................................................................................................................................... 3
2.3
Recommended Safety Equipment: .......................................................................................................................................... 3
3
Motor Installation .............................................................................................................................................................................. 3
4
Setting Base Timing ............................................................................................................................................................................ 4
5
Test Stand Consumables .................................................................................................................................................................... 5
5.1
Fuel .......................................................................................................................................................................................... 5
5.2
Water ....................................................................................................................................................................................... 5
5.3
Power....................................................................................................................................................................................... 5
6
Load Cell............................................................................................................................................................................................. 6
6.1
Power ratings ........................................................................................................................................................................... 6
6.2
Water Cooling .......................................................................................................................................................................... 6
6.3
Connecting Load ...................................................................................................................................................................... 6
7
Graphical User Interface (GUI) ........................................................................................................................................................... 7
7.1
Introduction ............................................................................................................................................................................. 7
7.2
Front Panel .............................................................................................................................................................................. 7
7.3
Familiarization ......................................................................................................................................................................... 7
7.3.1
Data Acquisition Controls .............................................................................................................................................. 7
7.3.2
Engine Controls.............................................................................................................................................................. 7
7.3.3
Displays.......................................................................................................................................................................... 8
7.4
Starting GUI and Error Avoidance ............................................................................................................................................ 8
7.5
Defaults.................................................................................................................................................................................... 8
8
Preparation ........................................................................................................................................................................................ 9
9
Operation ........................................................................................................................................................................................... 9
10
9.1
Data Logging ............................................................................................................................................................................ 9
9.2
Starting the Engine ................................................................................................................................................................ 10
9.3
Setting IC Engine Speed ......................................................................................................................................................... 10
9.4
Enabling Load and Setting Power Output .............................................................................................................................. 10
9.5
Stroke Modes......................................................................................................................................................................... 10
Troubleshooting .......................................................................................................................................................................... 11
Appendix I – Minimum System Requirements ........................................................................................................................................... 12
Appendix II – Using Windows “Device manager” to determine or configure your USB COM ports. .......................................................... 13
Appendix III – System Architecture ............................................................................................................................................................ 14
2
1 Getting Started
Congratulations! You are now the owner of the Steamer 1.0, an engine test stand with the
capabilities of testing a hybrid gasoline/steam engine. Please review this entire document for
important safety and operation instructions prior to the use of the test stand. If the test stand was
not pre-fit with an engine pay special attention to Sections 3 and 4. After motor installation but
prior to test stand use, the base timing must be set.
GUI
Load
Cell
1.1 Requirements
For proper operation of the test stand, the following requirements must be met.






Modified Kohler CH5 style engine with
o Electronic valve control
o Cam attached 400PSI (minimum) pump for direct water injection
o Direct injection for water
Laptop or tablet computer with solid state drive (vibration safe). See Appendix I for
minimum system requirements.
o Windows XP, Vista, 7, and 8 are officially supported. Mac and Linux are not.
A standard (GHT) garden hose and source of running water for active load cooling.
Well-ventilated environment with floor drain for load cell drainage.
Standard grade fuel - 87 octane.
Standard 120VAC wall power source and 14 gauge (minimum) extension cord.
3
2 Safety
Safety precautions should always be taken when working with or around the Steamer 1.0. Note the
location of the emergency stop in the event of a malfunction.
2.1 Safety Checks




Prior to operation check for obvious leaks or blockages in the air, fuel, or water lines.
Prior to operation check for any obviously loose bolts.
Prior to operation ensure wires are secure and not close to rotating or hot components.
Prior to operation verify that the choke solenoid and all servos move freely.
2.2 DOs and DON’Ts






Use in a well-ventilated environment. Do not inhale fumes.
Do not stand in front of test stand during operation.
Do not touch anything inside the test stand during operation.
Do not store fuel on test stand.
Do not leave excess fuel in graduated cylinder for extended periods of time.
Apply E-Stop and disconnect power when working within the test-stand.
2.3 Recommended Safety Equipment:



Safety glasses
Ear plugs
Nitrile gloves for fuel handling.
3 Motor Installation
Please refer to the assembly manual for detailed instructions on installing a modified Kohler CH5
style engine. The base-plate mounting holes, shaft coupling, and fuel connection match a Kohler
CH5 engine. Ensure any modifications to your Kohler CH5 Engine do not interfere with these
interfaces. Use provided hardware when installing the engine.
4
4 Setting Base Timing
To set the base water injection timing please adhere to the following method.
1) Refer to and take appropriate safety precautions (Section 2).
2) Find the point where the IC engine’s piston is at the top of the cylinder. This point is known as
top dead center or TDC.
a) Remove the spark plug. Refer to the engine manufacture’s specs for required socket.
b) Insert a 5/32” Allen key into the spark plug hole (circled in red) to make contact with the
top of the piston. (The Allen key will be needed later)
Warning: Do not drop anything into the cylinder!
c) Rotate the engine shaft counterclockwise by hand via the coupling (blue arrow) and use the
Allen key to find the point right before the piston starts to descend. This is TDC.
3) Loosen the encoder disk using the 5/32” Allen key
(green arrows).
4) While being careful to not rotate the engine shaft,
rotate the encoder disk (blue arrow) until the
transition point from clear (light beam unblocked)
to black (light beam blocked) is between the two
posts of the “Stroke Sensor” (red arrow).
5) Firmly hand tighten the encoder disk with the Allen
key (green arrows).
6) Re-insert and tighten spark plug to the engine’s
torque specifications.
5
5 Test Stand Consumables
5.1 Fuel
Fueling should take place at the time of operation. Limit fueling to the
amount required by the experiment and for operation. The graduated
cylinder is only to be used for standard octane gasoline.
Warning: Do not leave extra fuel in the graduated cylinder for
extended periods of time. Run engine until depleted.
5.2 Water
The water injection reservoir may be filled at any time. The water
reservoir is filled through the white PVC port on the top of the test stand
(circled in green). Replace the cap to prevent dirt or dust from entering.
5.3 Power
Standard 120VAC power must be provided to the test stand. A
minimum of a 14 gauge extension cord may be used. The 120VAC
connection is recessed on the right-hand underside of the test stand
(circled in blue).
6
6 Load Cell
6.1 Power ratings
The load for the test stand can support up to 5500 watts @ 120VAC. However, only 2000 watts
should be used with the test stand due to the limitations of the wire gauge and electric motor.
Three switches control the load amount. The 120VAC ratings are labeled. When enabling
multiple switches, the power contribution of each will sum.
Warning: Monitor the power output at all times to ensure 2000 Watts is not exceeded.
H2O Input
H2O Output
Switches
6.2 Water Cooling
The load should be supplied with a source of running water at all times during operation to
ensure proper cooling of the resistive elements. The load connects via a standard GHT garden
hose. The heated water drains locally. A floor drain or outdoor use is recommended.
Warning: Shut down engine if water starts to boil. Ensure valve is open and water is flowing.
6.3 Connecting Load
Simply plug load cell into test stand as shown below:
Please refer to Section 9, “Operation,” for methodology on safely maximizing power output.
7
7 Graphical User Interface (GUI)
7.1 Introduction
This portion of the Operations Manual will focus on the GUI. The GUI was developed in LabVIEW
and will therefore require the LabVIEW runtime environment be installed on the test stand’s
computer. When selecting a computer for the test stand, please refer to Appendix I for the
minimum system requirements.
7.2 Front Panel
The following screen capture is the GUI provided for the test stand.
7.3 Familiarization
7.3.1 Data Acquisition Controls
Data Acquisition Controls are in the lower left of the GUI. Here the sample rate, thermocouples,
and temperature limits may be configured. The thermocouples are configured within the table.
Thermocouples may also be added, removed, enabled, and disabled. Corresponding to each
thermocouple are temperature limits. If additional thermocouples are added, the user must
also define temperature limits. If the temperature exceeds these limits, the engine will be shut
down. If the minimum temperatures are not met, the water injection will be locked in the off
state. To begin data logging, simply click the “Log Data” button. For the experimenter’s
convenience, when pressing the “Test (Start/Stop)” button a prompt will appear for the user to
enter the starting fuel level. Pressing the button again, the user will be prompted for the ending
fuel level. Each test point will be logged so that the fuel consumption can be calculated.
7.3.2 Engine Controls
Engine controls are in the lower right. Here the engine can be started and stopped via the “IC
Engine” control, the load can be enabled and disabled via the “Load Control,” and the stroke
mode of the engine can be changed between 4 and 6 strokes via the “Stroke Mode” control. 6
stroke mode enables water injection. Additionally, by enabling the “Manual” button, the speed
and timing may be manually set by the user via the “Speed Control” and “Timing Control”
respectively.
8
7.3.3 Displays
Starting in the upper left, all temperatures are displayed graphically. The graph to the right
displays power as a function of the current and voltage across the load. RPM is displayed
towards the lower middle of the GUI. The RPM is calculated from a moving average of the time
it takes for the encoder to make one rotation.
7.4 Starting GUI and Error Avoidance
To avoid errors when opening the program make sure that all data acquisition hardware is
powered and properly interfaced with the computer prior to opening the GUI. Once the GUI is
opened, select the appropriate communication (COM) ports before attempting operation.
Please refer to Appendix II for a detailed guide on determining and configuring COM ports.
COM Ports must be configured in two locations:
1. Each thermocouple must be
assigned the associated port by
manually entering the COM
number in the thermocouple
configuration table. The format is
< COM# >.
2. The servo command port must also be selected by a drop down
menu under “Engine Controls.”
Please note the following default port configuration. The ports may also be set to match the
program’s defaults by modifying the COM port numbers in the Windows device manager.
7.5 Defaults





Thermocouples default to COM ports 3 through 5.
The servo controller defaults to COM port 6.
The Data Acquisition unit (NI’s USB-6008 DAQ) is automatically configured.
Upon opening the program all test-stand controls will be initialized to their defaults.
o Engine controls include the “Speed Control” – 0%, “Timing Control” – 10%, “IC Engine” OFF, “Load Control” – OFF, and “Stroke Mode” – OFF.
o Data logging is not automatic and must be enabled by the user by pressing the “Log
Data” button under “Data Acquisitioning”.
The engine cannot run unless data logging is enabled.
9
8 Preparation









The user should have a pre-determined experimental procedure detailing the following:
o Amount of fuel. Note: For precision measurements, make sure no air is left in the lines
before experimenting. Warm up the engine and check for no air bubbles.
o Warm-up duration
o Timed sequences for load amount, 4 / 6 stroke modes, speed, and timing.
Ensure all safety measures / checks have been taken.
Prepare load cell. (See Section 6 for more info and pictures)
o Connect the load cell to the test stand. The connection point is labeled.
o Fill bucket with water and maintain a steady flow during operation.
Fill the water injection reservoir with at least a quart of water. The reservoir does not need
to be topped off. If water leaks out the top of the container it is full.
Set computer atop test stand and connect the computer via the provided USB cable if not
done so already. An extra power plug is available within the stand if external power is
desired.
Power on the test stand: Attach a 120VAC source to test stand and depress the E-stop. The
E-stop should be illuminated.
Boot computer and open the GUI. Upon opening, the GUI will initialize defaults and enable
the test stand controls by powering the 5 and 12 VDC switching power supply.
Add fuel amount according to user’s experimental procedure.
The stand should now be ready for operation. All operation is performed within the
provided Graphical User Interface. See Section 7 for GUI specific information.
9 Operation
If at any time problems are encountered, turn the system off and refer to the troubleshooting
tips in Section 10. To turn the engine off, simply set the “IC Engine” control to “OFF” or exit the
program. Only press the E-stop with the IC engine running in an emergency. Any control use and
setting modification should be done according to the user’s experimental procedure.
9.1 Data Logging
To operate the test stand, start by clicking the “Log Data” button. Upon doing so, the user will be
prompted to select the save location of the log. The log is stored in the comma separated value
(.csv) format. The CSV file may be opened in MS Excel. Temperature(s), power, and RPM will be
logged and displayed according to the specified sample rate.
Sample rates much faster than 500ms may be error prone.
10
9.2 Starting the Engine
To start the engine simply click on the virtual “IC Engine” toggle switch. The test stand will start
the engine in the following automated manner. When starting, the choke is enabled, the speed
control is automatically set to 75%, and the electric motor begins cranking. When the RPM
reading indicates that the engine has started, the electric motors stops cranking, the choke is
disabled, and the throttle is set to 25%.
If the engine does not start after 5 seconds the starter will enter a cool down period for 10
seconds and then try again. If the engine will not start after 2 or 3 tries, set the “IC Engine”
switch to “OFF” and investigate the problem.
9.3 Setting IC Engine Speed
In order to set the IC engine’s speed, click and drag the “Speed Control” virtual slider. Engine
speed will vary with the load amount. Be careful when going from a load to no load condition
due to an increase in engine speed. Do not exceed 2500 RPM.
9.4 Enabling Load and Setting Power Output
Before enabling the load, set all physical load cell toggle switches off. To enable the load, click the
virtual “Load Control” toggle switch. Now turn on load cell switches as necessary starting with the
lowest powered. Increasing the engine RPM will also increase the power output. Do not exceed
2000 Watts. Once familiar, the load cell switches may be on prior to enabling the load via the
GUI.
Warning: Do not exceed 2000 watts or 2500 RPM for extended periods of time during operation.
Prolonging these conditions will result in overheating and excessive wear to the electric
motor.
Warning: NEVER disconnect the load with the engine running due to dangerous voltage spikes.
9.5 Stroke Modes
Prior to changing to 6 stroke mode, make sure the timing is set to 10° or less. To change the
stroke mode, click the virtual “Stroke Mode” toggle switch. 4 stroke mode will cause the
modified IC engine to run as an unmodified engine. 6 stroke mode enables the water injection
and modified valve control.
Warning: Drastically advancing the water injection timing may harm the engine and should
therefore be increased conservatively.
11
10 Troubleshooting
Symptom
General error message.
Action(s)
Check all connections and ensure all components are
getting power. The thermocouple connectors should have
a red light, the USB hub a blue light, the DAQ a flashing
green light, and the servo controller an intermittent
orange and green light. Refer to the System Architecture
in Appendix III for more information.
Restart the GUI. (Close and open the program)
Restart the computer.
No error displayed and
nothing is responsive.
Restart the GUI.
Restart the computer and wait for program to respond.
Data logging is enabled but Check for broken or disconnected thermocouples.
there is no incoming data.
Restart data logging.
Sporadic RPM
measurements.
Check encoder components.
 Ensure encoder disk is secure and balanced.
 Ensure photo interrupter sensors are aligned with
the encoder disk. Refer to assembly manual for
proper alignment.
Troubleshoot wiring and ECU (electronic control unit).
Data logging is enabled but Restart data logging
no data is being returned.
Restart Computer and GUI
Check for broken thermocouples.
12
Appendix I – Minimum System Requirements
Windows
Run-Time Engine
Processor
Pentium III/Celeron 866 MHz or equivalent
RAM
256 MB
Screen
Resolution
1024 x 768 pixels
Operating
System
Windows 7/Vista (32- and 64-bit)
Windows XP SP3 (32-bit)
Windows Server 2003 R2 (32-bit)
Windows Server 2008 R2 (64-bit)
Disk Space
353 MB
Mac OS X
Run-Time Engine
Processor
Intel-based processor
RAM
256 MB
Screen
Resolution
1024 x 768 pixels
Operating
System
Mac OS X 10.5, 10.6 or 10.7
Disk Space
563 MB
Linux
Run-Time Engine
Processor
Pentium III/Celeron 866 MHz or equivalent
RAM
256 MB
Screen
Resolution
1024 x 768 pixels
Operating
System
Linux kernel 2.2.x, 2.4.x, 2.6.x, or 3.x for the Intel x86
architecture, GNU C library (glibc) Version 2.4.4 or later
Disk Space
115 MB
13
Appendix II – Using Windows “Device manager” to determine or
configure your USB COM ports.
Please visit the following website for an extensive guide on determining and configuring COM ports in
Windows XP up to Windows 8. The process outlined applies to all serial USB hardware. MAC and Linux
are not officially supported and thus are not covered in the guide.
Link:
http://www.g4zlp.co.uk/Instructions/Device_Manager/Device%20Manager.pdf
QR Code for convenience:
14
Appendix III – System Architecture