Download BAYLAN AUTOMATED TEST BENCH 1. TEST BENCH PARTS

BAYLAN AUTOMATED TEST BENCH
At this test bench, the electromagnetic flow meters are used with the measurement method.
Calibrations of flowmeters are made with the help of the water collection tank and a calibrated scale.
Amount of the water, which passes inside of watermeters, is measured with help of electromagnetic
flowmeters. This data and data of optical sensors on the watermeters are used to calculate errors of
watermeters. System can be worked by software, which is installed to computer by BAYLAN, except
movement of the pistons. Its movement is controlled by buttons on the panel. Tests can be performed
for all watermeters between DN15-DN40 at any flowrate. The table, which is below, shows how many
watermeter can be connected to the test bench for different lengths, diameters, Qn and measuring flow
rates.
Length (mm)
Piece
Qn (m³/h)
DN
110
9
1,5
20
165
8
1,5
15
190
8
1,5
20
190
8
2,5
20
260
5
3,5
25
300
3
10
40
1. TEST BENCH PARTS
The main structure of test bench is stainless steel. Steel frame is coated with epoxy paint. On the
test bench, an air conditioner is used to regulate pressure. Connection pipes are made of POM, impact
and shatter resistant.
Picture – 1
Information about Picture 1
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Pneumatic water supply valve
Water inlet valves
Panel buttons
Computer monitor
Water collection tank
Electromagnetic flowmeters
Water flow control valves
Picture – 2
Information about Picture 2
1- Pressure piston for the static pressure test
2- Optical sensor connector
2. Scale
Maximum capacity of the scale is 300 kg. It has Five-digit LED displays and 2g sensitivity. It works at
220 VAC and 50 Hz (it is not affected by voltage dropping until 170 VAC).
Picture – 3
3. Manometer
Working pressure is between 0 and 25 bars. Moving part is made of brass. Pressure element is
made of CuSn8. Storages material is steel and front rings material is abs plastic. Manometer
connection is R 1/8"brass. Accuracy is 2,5%. Operating temperature range is from -25°C to
+60°C.
Picture – 4
4. Flowmeters
There are 3 electromagnetic flowmeters or different flowrates.
•
•
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First flowmeter is for 9000.00-450.00 l/s.
Second floweter is for 480.00-80.00 l/s.
Third flowmeter is for 80.00-3.00 l/s.
Picture – 5
Information about Picture-5
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Electromagnetic flowmeter (Qmax-Qn)
Electromagnetic flowmeter (Qt)
Electromagnetic flowmeter (Qmin)
Emergency stop button
Manometer
Valve for regulating flowrate (Qmax-Qn)
Valve for regulating flowrate (Qt)
Valve for regulating flowrate (Qmin)
Picture – 6
Information about Picture-6
1- Electromagnetic flowmeter measuring part.
5. Buttons
Picture – 7
Information about Picture-7
1- Compression buttons (piston): Press two yellow buttons at the same time to compress
watermeters to test bench.
2- Test bench is active: Lights is on while the test board is active.
3- Release button (piston): Make sure that the water pressure is zero before releasing piston in
the system.
4- Watermeters are compressed.
5- Emergency stop button.
6. Sensor
Sensors are 1. class accuracy and they shows excellent performance in measuring range. They
have the highest detection performance between 20 and 50mm. There are 8 pieces of graphic
display led at the sensor to program easily and monitor its working. There is 1. class detection visible
red light, wavelength 650 nm on the sensor. It works from 10 to 30 V DC voltages, and its maximum
current is 35 mA (electric charge). It is protected from reverse polarity, high voltage and fluctuations.
Display screen (8-segment) shows signal strength, reference point of laser.
Green LED: Power ON
Yellow LED: Output transmission
Connect watermeter to test bench for programming of the sensor. Provide low flowrate (like 90l/h).
Press (+) button on the sensor until 7. and 8. LEDs are on. If one LED is on, programming is accepted.
If 1, 3, 6 and 8 light is on, programming is not accepted. In this case, procedure is repeated. After
completed programming, all the light will be on by one by from left to right and right to left.
Programming process is done once, there is no need to program for each test. For correct placement
of sensor, flowrate must be suitable. If sensors are placed perfectly, light moves from right to left and
from left to right until last light. However, since light passes two light from middle line, reading is
sufficient.
Picture – 8
7. Test procedure
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•
•
•
•
•
•
•
•
•
•
Connect apparatus. its nominal diameter must be equal to watermeters nominal diameter.
Check o-rings which are at the connection regions.
Connect watermeters to test bench by paying attention to direction of flow and
watermeters. Space can be completed between additional pipes. Outlet and inlet of pipes'
lengths must be certain length.
Press two yellow buttons at the same time (Picture-7) and tighten the watermeters (the
green light will be on). Check all connections and make sure that there is no space
connection.
There are two different water inlet valve (Picture-1) for different types of pressure for water
supplies. Do not open both valve at the same time. Otherwise, the water with high pressure
will flow to low pressure line. Open only one of them.
First of all click "AIR RELEASE" button by mouse or touch screen (Picture-10) to release water.
Check pipes, connections and watermeters for leak. If there is leakage, click "Close Valve"
(Picture-10) or emergency stop (Picture-5 and 7). If there is no leakage, place sensor.
To begin test, press "TEST" button on the screen (Picture-10).
After the pressing "TEST" button, the screen will display the watermeter types and flowrates
to select (Picture-11). First of all, select watermeter types then flowrate and at the end click
"LOAD" button for loading datas. To change datas, press "EDIT" button.
Press "START TEST" to start test (Picture-13).
At the end of the check manometer. Pressure must be zero to release piston.
Adjust flowrate for reading manually. Select type of watermeter and flowrate for reading
from sensor. Amount of water can be checked from flowmeter, computer or weighing
machine. Close valves after desired amount of water. The following table shows Amount of
water for Qmax, Qt, Qmin according to their classes.
Amount of Water
B Class
C Class
Qn
(l/h)
Qmax
(l/h)
Qmin=0,02Qn
(l/h)
Qt=0,08Qn
(l/h)
Qmin=0,01Qn
(l/h)
Qt=0,0,15Qn
(l/h)
1500 (60 kg)
3000 (80 kg)
30 (6 kg)
120 (15 kg)
15 (6 kg)
22,5 (15 kg)
2500 (70 kg) 5000 (100 kg)
50 (6 kg)
200 (15 kg)
25 (6 kg)
37,5 (15 kg)
3500 (100 kg) 7000 (100 kg)
70 (10 kg)
280 (25 kg)
35 (6 kg)
52,5 (15 kg)
•
Read last index of watermeter for manuel test and read actual amount of water from
electromagnetic flowmeter.
• Calibrate watermeters by adjustment screw according to error values of watermeters.
• After calibrations of the watermeters are done, error values of Qn, Qmax, Qmin, Qt must be
determined.
• After calibration and test of the watermeters are done, click "CLOSE VALVE". Drop pressure
to zero. Release piston to remove watermeters.
Note: For Accuracy final test results, test conditions must be compatible with the following
conditions.
Relative humidity: 45% - 75% from
Ambient atmospheric pressure: 86 kPa - 106 kPa (0.86 bar - 1.06 bar)
Ambient temperature: 15 °C - 25 °C
The test panel and the surrounding area should not be dusty and dirty.
During each test, the temperature and relative humidity shouldn't change more than 5°C or 10%.
Picture – 9
Information about Picture-9
1 - Meter connection pipes
2 - Optical Sensors
Picture – 10
Picture – 11
Picture – 12
Picture – 13
8. Static Pressure Test
There is a pressure piston for static pressure test. The pneumatic piston, is controlled by controller.
Before the test, water supply is opened and water flows in the system until no air remains. After the
evacuation of the air, valves are closed. Water supply valve is closed (Picture-1) and pneumatic
pressure of system is increased by controller. At the same time increasing at the manometer can be
observed. After reaching the desired pressure in the system, operator can check watermeters. When
time is completed, release pressure piston. Before releasing watermeter piston, check manometer.
Picture -14
Picture-15
9. Software of BAYLAN Test Bench
Baylan Test Benches’ Software are developed by R&D department of Baylan. Watermeters are
automatically tested by this software.
• Saves the test results
• Charts and draws the error curve
• Checks the test panel automatically
10. Menus
10.1.
Setup Menu
The serial port settings and user options can be set from "Settings" menu.
10.1.1. Serial Port
The serial port parameters should be as follows:
Baud Rate: 9600
Data Bits: 8
Stop Bits: 1
Parity: None
Flow Control: None
In this menu you can read records data of communication of the test bench.
10.1.2. Users
Each user can enter the program with its own password. User can process according to authority of
him. Only "admin" user has the authority to save new user. "Normal" user is only authorized to
change their own password.
10.2.
Report Menu
The test reports can be read after recorded test results. All records are listed if any box is not
checked.
Error curve graph can be drawn after selection of test and sensor number.
After selecting test and sensor, preview and the printing process can be done by "Print" button.
10.3.
Commands
3. Open Tank Command
The drain valve opens.
4. Close Tank Command
The drain valve closes.
5. Release Air Command
All valves are open.
6. Close Valve Command
The valve closes.
7.Refresh Command
To check latest status of the test bench. Incoming information is displayed on the screen.
11. Test Menu
At the entering test menu, "Tank Open?" prompt will be seen. For calibration test, tank must be
closed.
There are 3 submenus at the type menus
• Type of watermeter
• Test of watermeter
• Test point of watermeter
Type of watermeter:
Information about characteristic of watermeter
Type Code
Class
Water
Pulse/Liter
Qn
:
:
:
:
:
Shows name and code of watermeter.
Shows class of watermeter.
Shows type of wateremter (Cold-Warm).
Shows puls number of watermeter.(tour of pointer per liter).
Shows flowrate at the Qn.
Watermeter Testing:
Test Code
Water
Test Type
: Specifies the test name or code.
: Shows type of watermeter (hot or cold type).
: Specifies the type of test. There is only one type of test "Start Stop" test.
Water Meter Test Points:
Shows the parameters of the selected test point.
Point Type
: Type of flow indicates that the test be done.
Point Flow
: Shows flowrate of the test.
Test Duration
: Test duration in seconds.
Volume
: The volume of water will pass from watermeter during test. It is calculated
automatically multiplying the test time and flowrate.
Flowmeter
: Shows the flowrate to be selected according to the test point.
Constant Flowmeters :Flow meter pulse would indicate how many of each per liter.
Max Flow
: the maximum allowable flowrate indicates at the test point.
Flow Min
: the minimum allowable flow rate indicates at the test point.
Max Error Rate
: The maximum allowable error rate indicates at the test point.
Minimum Error Rate : the minimum allowable error rate indicates at the test point.
New Button
Type Code, Test Code and Test Point menus, whichever is selected, the selected section is shown in
blue. Select one of them and click "NEW" to enter data which menu you choose. After adding
parameters, click “OK”.
Edit Button
To modify data, click data whichever you want to change then click “EDIT”.
Delete Button
To delete data, click data whichever you want to delete then click “DELETE”.
Load Button
To start test, click “LOAD” button to load data of your test.
12. Test Menu
Click "Test Start" to start test. Datas about weight and temperature will be seen on the screen. To
finish test, click "Test Finish" button and test result so far will be seen on the screen. To cancel the
test click "Test Cancel" After test finishes, pals and errors will be seen on the screen.
12.1.
Ok Button
After test finishes, to save error values, click Ok button.
12.2.
New Test Button
Click "AIR RELEASE" button to adjust flowrate. Click "New Test" button then the selected meter type
and test type test points appears. Select the test which you want then click "LOAD" button to start
test again.
12.3.
Save Button
To save data, click "SAVE" button. By that way, test number is increased. If operator don't click
"SAVE" button, test number will be same.
12.4.
Serial No Button
To add serial number to test results, click “SERIAL NO” button.
12.5.
Calibration Test
Test menu and calibration test are same. At the calibration test, values of flowmeters and
weigthingmachine are compared. Flowmeter calibration can be done according to calibration value.
13. Parameters
These parameters are very important for the testing process.
Pulse liter
Test Duration
Qn
The first weight
First heat
First Pals
Last weight
: The number of pulses produced when 1 liter of water passes
: Test duration in seconds.
: Flowrate
: The weight of tank at the begining of the test
: The water temperature at the begining of the test
:0
: The weight of tank at the end of the test
Last temperature
: The water temperature at the end of the test
Last pulse
: The number of pulses produced by the watermeter during the test process
Net Weight
: The weight difference between the first and the last weight.
Avg. Temperature
: The average temperature of the first and last temperature.
Density
: The density of water according to the average temperature.
Constant Flowmeter : The number of flowmeters pulses.
Error
: The error between the value of the amount of volume as measured by the
watermeter and value of the real volume.
OK
: The error is not within the accepted limits, it is zero otherwise one.
Weight and density information is only used in the calibration process. Volume information is
obtained by flowmeters.
Test Procedure
Step 1: Adjust (COM) port settings from the "Settings Menu" . Please skip this step after making the
settings once.
2. Step Two: Click "Test Menu" button and select the parameters. Skip this step if you are already
entered these parameters.
Step 3: Enter "Test Menu". Select the type of watermeter test type and test points.
Step 4: Click "Upload" button
Step 5: Click "Test Start" button.
Step 6: After finishing the test click "OK" button. If you want to do another test, click “Air discharge”
then adjust flowrate and click "New Test" button. Return to step 4.
Step 7: After all the tests, click "Save" button to save the test results.
Calibration of flowmeter by weightingmachine
Calibration test result is used for calibrate GKL number of flowmeter.
For calibrating GKL number:
Press “Button 1” for 2.5 sec. then release button.
Select “Quick Setup” by “Button 1”
Move to “Process input” by “Button 3” or “Button 4”
Select “Process input” by “Button 1”
Move to “GKL Number” by “Button 3” or “Button 4”
Select “GKL” by “Button 1”
Change “GKL” by “Button 1”, “Button 3” and “Button 4”
Ex: Calibration value is -2.00 from calibration test and GKL number is 1000.
GKL number + [(GKL number x calibration number)/100]=New GKL number
1000 + [(1000 x -2) / 100] = 980
“Due to continuous development of our products, we reserve the right to modify our product design or construction without prior notice.”