HB100(E) Hidraulic Bench

7/25/2019 HB100(E) Hidraulic Bench

1/12

020614

INSTRUCTION MANUAL

HB 100 HYDRAULICS BENCH

(The equipment sent to a customer may have some differences from the above picture, mainly depending on options and our

continuing improvement of products.)

ESSOM COMPANY LIMITED

508 SOI 22/1 SOMDET PHRACHAO TAKSIN RD.BUKKALO THONBURI BANGKOK 10600, THAILANDTEL. +66 (0) 24760034 FAX +66 (0) 24761500

E-mail: [email protected]

www.essom.com
mailto:[email protected]:[email protected]


2/12

1 290409

CONTENTS

Page

Receipt of goods A

Safety guidelines B-C

1. General description. 1-1

2.

Instruction for use 2-1

Addendum

Addendum 1 Water pump maintenance

All rights reserved. No part of this publication may be reproduced in any material form (including photocopying

or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this

publication) without the written permission from ESSOM COMPANY LIMITED.

250709


3/12

A 010212

RECEIPT OF GOODS

1. On Receipt of Goods

a) On receipt of the goods at the consignees premises, the shipment should be immediately inspected for any damagesor missing package. This should be checked against the packing list or shipping documents. Any damage should be

reported immediately to the insurance agent.

b) The package should then be open to check items or parts against the delivery list. Any damaged or missing itemsshould be immediately claimed to the insurance agent with copy to the supplier.

c) If insurance has been arranged by the buyer then you must notify your insurer in writing of any damage or loss of

parts which was observed regarding this shipment within a specified period of time as stated in the Terms and

Conditions. This should include detailed photographs of the damaged equipment.

d) If insurance has been arranged by the seller you should notify the insurances representative along with any

correspondence including the insurance certificate supplied by the seller. These should include detailed photographs for

evaluation of damages or replacement parts pertaining to the shipment.

e) The supplier will only replace damaged items or missing on notification by the insurance company that the claim has

been accepted. The insurance company may refuse responsibility if parts are damaged or missing while under custodys

for a long time without prior claim. Immediate claim is therefore vital.

2. Manufacturers Liabilitya) Before proceeding to install, commission, or operate the equipment listed in the instruction manual, we would like to

alert the user to the health and safety aspects of people who will work on or operate our equipment with regard to the

liability of the manufacturers or suppliers.

b) Manufacturers or suppliers are absolved of any responsibilities with regard to misuse of their equipment causing harm

or financial charges being incurred against them from clients or third parties for consequences of failure or damage of theequipment in any way if the equipment is not installed, maintained and operated as outlined in the instruction manual

published by the manufacturers or suppliers.

c) In order to safeguard the students and operators of the equipment it is vital that all safety aspects as outlined in theinstruction manual are observed.


4/12

B 241108

3. Safety Guidelines

3.1General Safety Concerns

Before proceeding to install, commission, or operate the equipment described in the instruction manual we would like to

alert you to the dangerous potential hazards that would be present if safety practices were not performed in accordance

with the local standards and governing bodies regulations.

-Injury would occur to the operational staff of the equipment through misuse, electric shock, rotating equipment hazards

and lack of cleanliness.To be able to achieve the aim, of accidents can be avoided it must be ensured that the equipment is installed correctly,

regularly maintained and operators of the equipment are made aware of the potential hazards associated with the

particular equipment.

We would like to inform our valuable customers of the safety guide lines when using their equipment.

3.2 Awareness of Safety Hazards

(a) Before attempting to work on the equipment the personnel who are going to install, commission, or operate the

equipment must be qualified and fully aware of all the manufacturers and suppliers recommendations and instructions.

(b) Ensure that the all the recommendations specified in the instruction manuals are maintained as stated in the contents.

4. Electrical Safety

(a) Ensure that the person who works on the equipment is a qualified electrical engineer/technician who is competent in

the safety aspects and operational mode of the equipment.

(b) If the electrical supply to the equipment is supplied by means of a portable trailing cable, protective devices such asan Earth Leakage Circuit Breaker (ELCB) must be installed.

This protective device must have a very high sensitivity (20-30mA).This device is also referred to as a residual current

device(R C D) within the electrical supply circuitry for personnel protection.

(c) The supply cable must be sized accordingly for all fault and physical conditions pertaining to its use. The supply

network must also incorporate a protection device that will disconnect and isolate the supply voltage in the case of an

overload in a specified period of time without causing any damage to the equipment. (An overload relay)

5. Installation

(a) On receipt of the equipment extreme care should be used to avoid damage to the equipment on handling and

unpacking. If slings are used ensure they are held on a rigid part of the equipment, the structure. In the case of amechanical lift such as a fork lift ensure the lifting forks are beneath the structure framework so that no damage will

occur during the lifting operation.(b) In some cases it is imperative that the equipment be installed on a level and solid foundation

5.1 Electrical Supply Cables

(a) The normal color code of the power cables supplied on this equipment is as follows:

- Black----------------------------Line.- Gray or white -----------------Neutral.

- Green-Yellow-----------------Ground.

(b)The three phase power cable has five wires.

- Red, blue and black ---------Line.- Light gray or white ----------Neutral.

- Green-Yellow ----------------Ground.

5.2 General Precautions for Equipment with Water Including Evaporative Cooling Towers

(a) Any water contained in the system should be drained regularly. If it is left in the system for a long period of time

without circulation it will stagnate.

(b) The equipment should be flushed regularly with clean water.

(c) Impurities in the water will cause scale or algae and must be cleaned on a regular basis. An anti rust additive such as

used in the automobile industry is recommended to inhibit this process.

(d) The water should be at temperature under 45 degrees C to maintain effectiveness.

(e) Many of the problems encountered with water contamination can be reduced and prevented by means of a water

treatment program being introduced using the expertise available locally or on site.


5/12

C 241108

5.3 Rotating Equipment

(a)If the equipment is supplied with any rotating parts such as a motor, generator, fan etc these items are provided with

a protection shield or a guard to protect the operator from any dangers which may occur when the rotating parts fail.

These guards must be in place whenever the rotating parts are in operation (rotating) and only removed for maintenanceperiods.

After maintenance is carried out ensure that the machine guards are replaced back in service. Do not operate any

rotating parts unless machine guards are in place.

5.4 Steam Equipment

(a)When using steam equipment, there are a number of vital precautions which must be remembered by the operators

and maintenance crew and placed into operation when both operating and performing maintenance schedules. During

operation of this equipment the steam and water are at a high temperature and pressure which can have a very damaging

and hazardous effects on students if safety precautions are not observed.(b)Ensure that critical values of temperature and pressures listed in the instruction manual are maintained and not

exceeded on the equipment.

(c) Safety valves should be calibrated on a regular basis with mandatory service records maintained. This should also

include pressure reducing valves.

(d) Calibration of any instrumentation such as pressure gauges, thermometers and sensors should be checked regularly.

(e) Visual inspection of the equipment should be regularly observed for leaks of steam etc and any frameworks or joints

should have the hardware checked for tightness.

(f) Always use protective clothes including gloves when carrying out maintenance on the equipment.

5.5 High Temperature Equipment

(a) When using high temperature equipment there are a number of vital precautions which must be remembered by the

operators and maintenance crew and observed when both operating and performing maintenance schedules. During

operation of this equipment the air, gas or water is at a high temperature and pressure which can have a very damagingand hazardous effect on students if safety precautions are not observed.

(b) Ensure that critical values of temperature and pressures listed in the instruction manual are maintained and not

exceeded on the equipment.

(c) Calibration of any instrumentation such as, thermometers and sensors must be checked regularly for safe operation.

6. Maintenance Safety Practices

(a) Always isolate the equipment from the electrical supply when carrying out maintenance on the equipment

(b) Ensure that safety notices are placed on the equipment supply advising personnel that the equipment is beingworked on, inspected and should not be operated.

(c) Check the operation of any protective devices, such as an ELCB so that it operates in accordance with its

specifications thus ensuring the safety of all operational personnel working on the equipment. Any malfunction of the

device must be corrected by a qualified electrician before returning the equipment back to a service condition.

(d) Ensure on completions of the work that the equipment is returned to its original state and that no covers, panels are

left open along with loose screw drivers, spanners are left in the equipment.

(e) If water is used with the equipment then there are certain preventative mandatory regulations that have to be taken to

prevent infection from harmful micro organisms.

7. General Safety Conditions when Operating or Maintaining the Equipment

(a) When operating or carrying out maintenance on the equipment the Health and Safety of the students can be

safeguarded in many ways by wearing protective clothing.

(b) Loose fitting clothes should never be worn in a laboratory. These clothes can cause a serious accident if caught in

rotating equipment, i.e. tie etc.(c) Protective gloves must be used if handling toxic materials or where there is a high temperature present.

(d) Ear protectors should be worn when operating noisy equipment.

(e) Eye protection should always be used when there is a risk to the eyes.


6/12

1-1 290409

INSTRUCTION MANUAL

HB 100 HYDRAULICS BENCH

Front view

Water outlet to channel

or other accessories

Storage tank

Channel

Measuring

tankVolume

scaleFlow control valve

Flowmeter (optional)

Pump

Bulls eye level Overflow/drain

pipe

Diagram

Figure 1-1 HB100 Hydraulics Bench (with 165 l storage tank)

1. GENERAL DESCRITION

This is a basic unit which provides water supply and volumetric measurement services for use in conjunction

with accessories for specific experiments (separately supplied).The bench top is molded into a measuring tank and a channel. Water is admitted at one end of the channel via

a female quick coupling for connection to an accessory which is mounted across the channel. The accessory

discharges water into the open channel which in turn discharges water into the measuring tank. The tank discharges

water to the main storage tank which is drained at the bottom. Both bench top and storage tanks are made of fiberglass. The measuring tank is stepped to enable accurate measurement of both high and low flow rates. A level gauge

at the side of the bench measures volume in the measuring tank. A bulls eye level is provided to indicate the bench

is level. The unit is on steel frame on wheels.

240913

Measuring tank

Volume scale

Storage tankPump

Earth leakage circuit

breaker (ELCB) and

Power circuit breaker

(CB)

Bulls eye level

Flow control valve


7/12

1-2 290409

1.1 Technical Data

1.1.1 Pump : 0.37 kW centrifugal pump with a maximum flow rate

approximately 80 lpm.

1.1.2 Bench top dimensions : 126 cm long 77 cm wide.

1.1.3 Open channel : 70 cm long 25 cm wide 17 cm deep.

1.1.4 Measuring tank : Low flow 10 l, High flow 45 l.

1.1.5 Main storage tank : 165 l.

1.1.6 Accessory : Outlet hose with fittings for connection to accessory1.1.7 Power supply : 220 V, 1 Ph, 50 Hz.Other power supply is available on request.

1.2 Optional Equipment

1.2.1 HB 001 Bench leveling screws.1.2.2 HB 002 Two side level gauges are provided instead of one. The second level gauge measures level in

the channel.Thus flow over a notch experiment can be run without using hook and point gauge.

1.2.3 HB 003 Variable speed pump with a control panel instead of fixed speed pump.1.2.4 HB 005 Measuring tank stilling baffle.1.2.5 HB 006 Full length storage tank with capacity 250 l instead of short storage tank.1.2.6 HB 007 0.37 kW submersible pump with flow rate over 150 lpm instead of centrifugal pump.1.2.7 HF 011 Variable area flow meter, up to 75 lpm to facilitate the experiments.

1.2.8 HF 011-120 Variable area flow meter 20-150 lpm.1.2.9 HP 002 Pressure gauges at pump inlet and discharge for pump pressure vs flow rate curve.1.2.10 Stainless steel pump can be supplied on request.

240913


8/12

2-1 241108

2. INSTRUCTIONS FOR USE

2.1 Fill the reservoir to nearly full. Be sure that the tank and the water are clean.

2.2 Close the pump flow control valve.

2.3 Outlet coupling details:

Figure 2-1Hydraulics Bench outlet. Figure 2-2Coupling.

2.3.1 The bench outlet is a 1 in. internal thread outlet.

2.3.2 A 1 in. male adapter with 3/4 in.female quick coupling is attached to the bench outlet.2.3.3 Most Hydraulics Bench test apparatus use 3/4 in. male quick coupling for connection to the bench for

water supply. Simply press the female coupling down to release the male coupling.

2.4 Place the apparatus on the bench and connect the bench outlet to the test apparatus.

2.5 Start the pump (both ELCB and CB) and slowly open the flow control valve to the required flow rate by

observing the Rotameter (optional) reading.

Note:If an inverter is used, adjust inverter to regulate pump speed, thus flow rate.

2.6 Use of measuring tank is as follows:

2.6.1 When the flow from the test equipment to the measuring tank is steady close the tank drain valve.

The water level will now slowly increase.

2.6.2 Start the stop watch when the water level reaches 0 and stop the watch when the required level is

reached. The upper tank is measured the same way.

2.7 There is a level indicator on the side of the bench to indicate water levels in the channel as well as in themeasuring tank. The level gauge for the bench channel is a special feature provided by HB 100. Thus, a

flow over a notch experiment can be carried out without using the hook and point gauge.

2.8 The reservoir should be drained when the bench is not in use and the pump should also be drained if the benchis not going to be used for a long time. Leaving water in the pump will induce rust and the pump shaft may

seize. (See also Addendum 1 Water Pump Maintenance)

2.9 After the experiment, turn off both ELCB and CB.

Note:It is recommended to add anti rust liquid to the water to minimize rust in the system.

Bench outlet

For hose to

apparatus

Male quick

couplingFemale quick coupling

Adapter

250709


9/12

ADDENDUM 1

WATER PUMP MAINTENANCE


10/12

WATER PUMP MAINTENANCE

When using a pump, the following should be observed and corrected:

1. WATER SUPPLY.

Water used in fluid mechanics experiments should always be clear and clean water. Rust inhibitor fluid such asused in automobile radiator may be added to minimize rusting.

2. WATER BECOMES RUSTY

2.1 If the pump is made of cast iron, the pump casing will get rusted on the initial use with water. This is normal.

2.2 After a few weeks of use, the rust is fully developed and protects the casing from further rusting.

2.3 The circulating water should then be drained and replaced with new clean water.

3. PUMP USE.

3.1 Do not run a pump when there is no water since this can damage the pump seal.

3.2 If the pump is not in use for a long period of time, drain all water inside the pump by opening the drain plug at

the bottom of the pump casing.

Figure 1 Top plug and drain plug

3.3 Before running the pump, check that the check valve is not stuck and fill the pump up fully with water.3.4 The motor and the pump are aligned at the factory. If they are separated, care must be taken when

reconnecting. Otherwise, the shaft vibration will cause serious damage to the bearings and the seals.

4. PUMP SEIZED.

Leaving water in the pump without use for along period of time may cause pump shaft seizing.

Turn on the main power supply switch and turn on the pump.

If there is no flow make sure the flow control valve at the rotameter is open.

4.1 Multi Speed Pump

If the pump does not turn, the shaft may be seized. Turn off the pump and open the plug at the top of the pump

and turn the shaft with a screw driver. Once turn, close the plug (see figures below).

Figure 2Open plug with screw driver Figure 3Turn pump shaft with screw driver.

Drain plug

Top plug


11/12

If the pump turns but no water flow (make sure the flow control valve before the flow meter is open), there is a

chance that air bubble is trapped in the pump.

In the case of Heat Exchanger unit:

Connect the drain valve next to the pump discharge to outside water supply, open the drain valve and closethe flow control valve before the rotameter. The water supply will purge out air bubbles.

Close the drain valve and remove the outside water connection.

Turn on the pump again to ensure water is circulating.In the case of HB030M Series and Parallel Pump, multi speed:

Connect the pump discharge hose to the Hydraulics Bench discharge.

Remove the check valve on the pump suction hose.

Open all valves and turn on the Hydraulics Bench pump to purge out air bubbles from the multi speed pump.

After 1-2 minute, turn off the Hydraulics Bench pump and immediately put back the check valve on thesuction hose.

Remove the discharge hose from the Hydraulics Bench and turn on the multi speed pump to ensure normalflow.

Figure 4Drain Valve

4.2 Pump without Coupling

If the pump does not turn when it is turned on, the shaft may be seized. Turn off the pump and use a wrench toturn the extended hex head bolt at the back of the motor to loosen the shaft as per below.

Figure 5Hex-head bolt

In the case that the hex head bolt as the above is not provided, the pump shaft may be turned by removing the a

drain plug at the bottom of the pump or a plug at the top of the pump, and use a screw driver to turn the

impeller (hence the shaft).

Drain valve

Hex head bolt

Water pump

Cooling fan cover


12/12

Pump coupling

cover

Pump shaft

4.3. Pump with Coupling

If the pump does not turn, the shaft may be seized. Turn off the pump and remove the pump coupling cover.

Pump shaft will be then exposed. Use a pipe wrench to turn the pump shaft loose.

Figure 6Pump coupling cover and pump shaft

5. WATER PUMP MOTOR

5.1 In case of motor is equipped with a gearbox, check oil level regularly and refill with specified lubricating oil asrequired.

5.2 In case of an AC motor, adjustment of speed must be sticky in accordance with the instruction of the inverter in

the Addendum.

Documents

HB100(E) Hidraulic Bench