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, THAILAND
TEL. +66 (0) 24760034 FAX +66 (0) 24761500

E-mail: essom@essom.com
www.essom.com

020614

CONTENTS
Page
Receipt of goods
Safety guidelines

A
B-C

1. General description.
2. Instruction for use

1-1
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.

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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 damages
or 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 items
should 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 Liability
a) 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 the
equipment 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 the
instruction manual are observed.

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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 as
an 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 a
mechanical 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.

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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 maintenance
periods.
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 damaging
and 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 being
worked 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.

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INSTRUCTION MANUAL
HB 100 HYDRAULICS BENCH

Measuring tank

Bulls eye level

Flow control valve

Earth leakage circuit
breaker (ELCB) and
Power circuit breaker
(CB)

Volume scale

Storage tank

Pump

Front view

Bulls eye level

Water outlet to channel
or other accessories

Flow control valve

Overflow/drain
pipe
Channel
Measuring
tank

Volume
scale

Flowmeter (optional)
Storage tank
Pump

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 fiber
glass. 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.

1-1

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1.1 Technical Data

1.1.1 Pump
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7

Bench top dimensions

Open channel
Measuring tank
Main storage tank
Accessory
Power supply

: 0.37 kW centrifugal pump with a maximum flow rate

approximately 80 lpm.
: 126 cm long 77 cm wide.
: 70 cm long 25 cm wide 17 cm deep.
: Low flow 10 l, High flow 45 l.
: 165 l.
: Outlet hose with fittings for connection to accessory
: 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.

1-2

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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:

For hose to
apparatus

Bench outlet

Male quick
coupling

Adapter
Female quick coupling

Figure 2-1 Hydraulics Bench outlet.

Figure 2-2 Coupling.

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 the
measuring 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 bench
is 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.

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ADDENDUM 1
WATER PUMP MAINTENANCE

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 as
used 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.
Top plug

Drain plug
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 2 Open plug with screw driver

Figure 3 Turn pump shaft with screw driver.

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 close
the 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 the
suction hose.
Remove the discharge hose from the Hydraulics Bench and turn on the multi speed pump to ensure normal
flow.

Drain valve

Figure 4 Drain 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 to
turn the extended hex head bolt at the back of the motor to loosen the shaft as per below.

Water pump

Cooling fan cover

Hex head bolt

Figure 5 Hex-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).

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.

Pump shaft

Pump coupling
cover

Figure 6 Pump 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 as
required.
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.