BELL PROVER GAS METER TEST BENCH

I Test Bench Operation Manual

1.1 Brief Introduction………………………………………….1

1.2 Main Specification…………………………………………1

1.3 Main parts and working principle………………………….2

1.4 Structure chart and introduction……………………………3

1.5 Buttons and keyboard function…………………………….5

1.6 Key functions in keyboard……………………………... …6

1.7 Set parameter………………………………………………7

1.8 Automatic Qmin test…………………………………… …9

1.9 LED display for each meter ………………………………10

1.10 interface introduction…………………………………….11

1.11 preparation before test……………………………………11

1.12 installation and operation………………………………..12

II Software Operation Manual

2.1 System installation……………………………………… .13

2.2 System principle…………………………………………..13

2.3 Main function of system…………………………………..13

2.4 Keypad operation……………………………………….. ..23

2.5 Testing flow chart………………………………………….24

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I Test Bench Operation Manual

1.1 Brief Introduction

Bell Prover Gas Meter Test Bench is an equipment to test domestic gas

meter, the flow range 0.016m3/h～6m3/h..

Feature:

1. The device can test 4pcs gas meters simultaneously, the device is an

ideal testing equipment for gas meter factory and testing institute.

2. The standard meter is bell prover, accuracy 0.5%, it can test Qmax.

0.2Qmax. and Qmin separately as per different gas meters.

3. Test bench adopts single chip microcomputer, high accurate A/D

converter and accurate sensor technology, it can calculate the testing

result with the tested environment temperature, pressure, this ensures

stability and accuracy of test bench.

4. All the testing procedures is controlled by PC and run automatically, the

testing results can be saved, printed.

5. Test bench frame is made of industrial aluminum, with prefect outlook

and strong structure.

1.2 Main Technical Specification

1.2.1 Among the pipe system of test bench, the testing range of absolute

pressure sensor is 0~1bar, accuracy ≤0.2%; testing range of micro

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pressure sensor is -500Pa~500Pa, accuracy ≤0.5%; testing range of

temperature sensor is 0~50℃, accuracy ≤0.2%.

1.2.2. Bell prover specification:

Sealing liquid: clean water or transformer oil;

Standard tank: 100L;

Working pressure: ≥1Kpa；

Pressure variation: ≤50Pa；

1.2.3. Test bench accuracy:≤0.5%.

1.2.4. Tested meters: 4pcs

1.2.5. Suitable G1.6, G2.5, G4 gas meter.

1.2.6. Condition: environment temperature 20℃±5℃

Relative humidity 60%—70%

Atmosphere pressure 86kPa—106kPa

Power supply 220V（or 3*220V）±20V ~50Hz

1.3 Structure and working principle,

The device consists of bell prover and testing table. The effective

volume inside the bell prover is regarded as standard volume, when bell

prover falls, the air inside bell prover flows to tested meters, the fall

head can be converted to impulse signal by photoelectric encoder, then

the impulse signal can be converted to standard volume. Then testing

error is coming up by comparing display of tested meters and volume

flowed.
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1.4 Complete test bench

1.5 Button and Keyboard function

1.5.1 Power supply button

Power supply button has self-lock function and light indicator, it is a

power switch for test bench.

1.5.2 Up-down button

This button is to control a clamp for separate meter, which can be

clamped by pushing this button; the meter can be released by re-pushing

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the button.

1.5.4 Scanning-head-controlling button

This button is to control the scanning heads. All scanning heads can drop

down to test meter by pushing this button, and scanning heads can go

back by re-pushing this button.

Noted: this button can not ensure each scanning head can catch testing

mark properly, sometimes the position should be adjusted by operator.

1.6.5 Resetting button

This button is to stop the existing test and start new tests.

1.5.5 Button on keyboard

1.5.5.1 The top LED (6 digits) displays flow rate during test, and

displays testing items and input value during setup.

1.5.5.2 O at top of key indicates the relevant indicator.

1.5.5.3 When test bench is switched on or test bench is ready for work

after pushing ‘reset’ button, LED displays P – – – – – , the device

default right air input and testing 0.2Qmax, meantime 0.2Qmax

indicator is on.

1.5.5.4 LED displays L– – – – L when the system checks out leakage

in the pipes due to loose clip, and devise stop testing automatically.

1.5.5.5 Keyboard is as following

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X X X X X X

○ ○ ○ ○ ○

Setting R/L Qmax 0.2Qmax Qmin

○ ○ ○ ○ ○

F1 F2 F3 F4 F5

○ ○
１ ２ ３
Start Stop

○
４ ５ ６ ７
Enter

Reset ８ ９ ０ OK

1.6 Function of Keyboard

1.6.1 ‘Set’ key is for setting parameter.

1.6.2 ‘left/right’ key is for choosing meter type. Press this key, the

indicator is on to test meter with left air input, on the contrary, to test

meter with right air input.

1.6.3 Qmax、0.2Qmax、Qmin are for choosing test flow points.

1.6.4 Key F1, no function

1.6.5 Key F2, no function

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1.6.6 Key F3 is to record bell prover pulse coefficient. Press the key,

bell prover falling head is converted to pulse by encoder.

1.6.7 Key F4 is to shift automatic to semi-automatic test during testing

Qmin.

1.6.8 Key F5 is to shift manual or automatic tests.

1.6.9 Key ‘Start’ is for starting tests.

1.6.10 Key ‘Stop’, press this key to force stop of all tests during testing;

press this key to save setup of parameter and logout during setup.

1.6.11 Key ‘air input’, press this key to raise bell prover.

1.6.12 Key ‘reset’, it is for reset hardware, equal to initialization.

Usually it is forbidden to press this key, especially on testing process.

1.6.13 Key ‘0-9’ is for setting parameter during setup.

1.6.14 Key ‘confirmation’ is for confirm data and save during setup.

1.6.15 Press F1, the indicator is on, LED displays 000000, the test

bench is ready for tests, please open the outlet valve in the bell prover

and start calculate, the formula is as following:

Basic pulse×100L

Bell prover coefficient（pulse/100L）=

Basic volume（L）

After test, press F1, the indicator is off and LED displays – – – – –, test
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stops.

1.7 Set testing parameter and test bench parameter

1.7.1 Set testing parameter

1.7.1.1 Press ‘set’ once, the indicator is on, LED displays 1– – – –L,

it means to set the testing pulse, press ‘confirmation’ to display

XXXX(range 0000-9999), meantime please set testing pulse for Qmax,

0.2Qmax and Qmin, then press ‘confirmation’ to save the data.

Press F2, the indicator is on and displays XXXXXX (range

000000~65535L), it is to set testing volume for Qmin test by

semi-automatic test, please use figure keys to set value and press

‘confirmation’ to save.

1.7.1.2 Press ‘set’ twice, no function.

1.7.1.3 Press ‘set’ 3 times, the indicator is on and LED displays 3– –

– –P, it is to set bell prover meter coefficient (pulse /100L), press

‘confirmation’ and display XXXXXX (range 000000~999999 /100L),

please use figure keys to set value and press ‘confirmation’ to save.

Bell prover meter coefficient:

Meter coefficient (pulse /100L)=100L×basic pulse ÷ basic volume (L)

1.7.1.4 Press ‘set’ 4 times, the indicator is on and LED displays 4– –

– –L, it is to set gas meter coefficient (mL), press ‘confirmation’ and

display XXXXXX (range 0000~9999mL), please use figure keys to set

value and press ‘confirmation’ to save.

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1.7.1.5 Press ‘set’ 5 times, the indicator is on, LED displays 5– – – –-

L, it means to set start-delay time for testing Qmax, 0.2Qmax and Qmin

(run without load, unit: second), press ‘confirmation’ to display

XX(range 00-99s), meantime please set the time for Qmax, 0.2Qmax

and Qmin, then press ‘confirmation’ to save the data.

1.7.1.6 Press ‘set’ 6 times, the indicator is on, LED displays 6– – – –-

L, no function.

1.7.1.7 Press ‘set’ 7 times, the indicator is on, LED displays 7– – – –-

L, it means to set balance-pressure time (unit: second) for leakage test,

press ‘confirmation’ to display XXX(range 000-999s), meantime please

set the time with figure keys then press ‘confirmation’ to save the data.

1.7.1.8 Press ‘set’ 8 times, the indicator is on, LED displays 8– – – –-

L, it means to set leakage testing time (unit: second), press

‘confirmation’ to display XXX(range 000-999s), meantime please set the

time with figure keys then press ‘confirmation’ to save the data.

If press F2, the indicater is on LED displays XXX(range 000-999s), it is

to set recording the starting/stopping time for Qmin test by

semi-automatic test, meantime please set with figure keys then press

‘confirmation’ to save the data

1.7.1.9 Press ‘set’ 9 times, the indicator is on, LED displays 9– – – –-

set, please press ‘confirmation’ to display XXXXXX, please input 0 or 1,

the first place from right, 1 means that bell prover raises automatically
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after tests, 0 means that bell prover raises manually after tests, please set

the rest place as 0.

1.7.2 Set test bench parameter

1.7.2.1 Press ‘set’ 10 times, the indicator is on, LED displays a– – – -

–, it means to set the falling head of bell prover, press ‘confirmation’ to

display XXXXX (range 00000-65535pusle), meantime please set with

figure keys then press ‘confirmation’ to save the data.

1.7.2.2 Press ‘set’ 11 times, the indicator is on, LED displays b– – – -

–, it means to set test bench series No, press ‘confirmation’ to display

XXX(range 00-99), meantime please set with figure keys then press

‘confirmation’ to save the data.

1.7.2.3 （G4——36；G2.5——24；G1.6——10）

Press ‘set’ 12 times, the indicator is on, LED displays c– – – –, it

means to set system amendment value for test pressure loss at Qmax,

press ‘confirmation’ to display 1 XX(range 00-99), please set the

pressure loss for gas meter G1.6 at Qmax with figure keys, and press

‘confirmation’ to save the data, the same to set for gas meter G2.5 and

G4. We suggest to set as G4—36；G2.5—24；G1.6—10.

1.8 Semi-automatic Qmin test

1.8.1 The test bench has a function shift key F2, when F2 is pressed, the

indicator is on and test bench enter semi-automatic testing stage:

Open 0.2Qmax to pre-run, close all flow points to test leakage,

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meantime record the initial counter, when leakage tests over, test bench

open Qmin flow points automatically, test bench will stop automatically

when test is over.

This test can be operated manually in test bench or by computer.

1.9 LED display for each meter

1.9.1 When test bench is switched on, the test bench is at initial state and

LED displays

– –b–

A: to test gas meter with left air input, B: to test gas meter with right air

input.

1.9.2 During tests, LED displays as following, the relevant indicator is

on for different testing points.

Qmax

0.2Qmax

Qmin
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1.9.3 LED display as following:

X X X X X

X X X X X

X X X X X

4-1

1.10 Interface introduction

1.10.1 RS232 port

RS232 port is for connecting PC. Before performance, the test bench

should be connected with PC. The function of pins: pin ②— TXD, pin

③— RXD、pin ⑤— GND.

1.10.2 Scanning head port

This port is for connecting scanning head. The function of pins: pin ①

— +5V,pin ②— GND, pin ③—impulse signal.

For testing impulse meter, this port is for connecting the impulse cable.
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1.11 Preparation before test

1.11.1 Put tested meters at testing position and clip tightly, adjust the

scanning heads to proper positions.

1.11.2 Adjust flow-controlling valve as different tested meters and raise

bell prover, then start to test after the bell prover is stable for 1 minute.

1.11.3 Choose the correct meter type (right/left air input), then choose

the testing points and start tests.

1.11.4 After tests, the LED displays testing error automatically.

1.12 Installation and Adjustment

1.12.1 Test bench is assembled, adjusted and tested in factory, it is

packed as several parts for transportation. So it should be re-assembled,

installed and adjusted at destination

1.12.2 Notes:

The test bench should work indoor with stable temperature 20°C±2°

C，humidity: 30~80％RH。

During tests, the temperature different should be less 0.5°C~1.0°C

between air inside bell prover, water or oil and room temperature.

Every time test bench stop work, please raise the bell prover and switch

power supply.

If water is adopted as isolation liquid, please clear the bell prover

regularly, 1 time/year.
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II Introduction of Administrative Software

2.1 System Installation

Inset CD to CD driver and system will be installed automatically or

install manually by clicking the file name“setup.exe”.

2.2 System principle diagram

2.3 Main function of system

2.3.1 Set up
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a．System data list

Operator can input data through data list easily, moreover data can be

added and deleted

b. Set parameter

For the performance, the system data should be set as test bench status,

later these data should be fixed.

Communication port should be set as PC port, COM1 or COM2.

Set testing parameter

Pre-running time: the running period without load after shifting to

another testing points.

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Balance time: when airtightness test, the period for pressure balance in

testing pipes of test bench.

Testing time: when airtightness test, the testing period after the pressure

is balance in testing pipes

Testing pressure: when airtightness test, the pressure which the test

should be run under.

Leakage rate: this is a basic value to judge the airtightness test is past or

not.

Pressure loss: this is a basic value to judge the pressure loss test is past

or not for Qmax, 0.2Qmax and Qmin.

Testing time: the period for pressure-loss test.

c. Set testing points

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There are different testing scheme for different meter, meantime testing

scheme can be set as user’s demands. Testing points-setting menu is for

setting testing points, testing times, testing volume, error limit, testing

time, etc as different meters

2.3.2 Test Gas Meter

a. Choose testing scheme

Before testing, the testing data should be chosen as tested meters such as

air direction, meter accuracy, testing points, airtightness, pressure loss,

etc, the menu is as following:

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Once choosing tested meters, sending-data button is activated, click this

button to enter testing state as setup.

Noted: when the tested meter is changed, the testing scheme should be

changed as well.

b. Testing operation

At testing stage, first step is to drop clamp, if for all clamps, please

choose meter No. 0, the click ‘drop clamp’ button.; if for separate meter,

please choose the meter No, then click ‘drop clamp’ button;

c. Test Airtightness

After choosing ‘Airtightness’, the menu is as following:

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If click ‘single’, after finishing airtightness test, the system enter waiting

state.

If click ‘continuous’, after finishing airtightness test, then system enter

the next tests automatically.

Note: the testing parameter can not be modified at testing state.

d. Test Pressure Loss

Click ‘pressure loss’ to have pressure loss test, the menu is as following:

The testing result will be compared with the set max. and mini. limit and

judge whether meter is eligible or not,

If click ‘single’, after finishing pressure loss test, the system enter

waiting state.
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If click ‘continuous’, after finishing pressure loss test, then system enter

the next tests automatically.

Note: the testing parameter can not be modified at testing state.

e．You can click ‘single’ or ‘continuous’ to have error tests, the main

function of menu:

If click ‘single’, after finishing a testing points test, the system enter

waiting state. This is suitable for test single flow points.

If click ‘continuous’, after finishing a testing point test, then system

enter the next tests automatically till all the testing points are finished,

and the system stop automatically.

Note: if the testing results is within max. and mini. limit, the figure is

black, on the contrary, the figure is red.

2.3.3 Check Data

The testing results can be checked and saved after tests.

Note: vacant meter number can not be saved.

2.3.4 Data arrangement

Data arrangement is main method to record data, which can record

current system operation. The following is the introduction of the main

buttons.
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Edit: this button is to edit meter model, tester, etc.

Checking method: please input checking term, then click ‘confirm’.

Print recorder: it is main method to output data, the are 2 printing

formats, the following is the printing column.

Click ‘error’button to check the testing error for existing meters,

moreover system can draw error curve as per errors of all the testing
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points. The curve can be enlarged and reduced or removed left and right.

2.3.5 Operation Statistic

Statistic can be as per daily, monthly, yearly and range. The menu is as

following:

The statistic displays the quantity and testing data of tested meters and

the information can be printed.

2.3.6 Delete Record

The unnecessary recorder can be deleted as per testing date or appointed

meter number.

2.3.7 Backup Data

In order manage the testing data efficiently, avoid losing data

unexpectedly, ensure system security and quicken system running speed,

it is necessary to backup important data. Here introduce to backup 2 files:

CSFZK.DBF and CSFZK.dbt

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Backup adopts copy of file, first choose content as flowing:

Then click ‘confirm’. After backup is successful, operator can

decide whether to erase the existing data base as system mentions.

2.3.8 Tool Box

Configure interface automatically

First please confirm the test bench is at working condition, and connected

with PC, once the system can remember the interface, once searching (3-10s),

the procedure is as following:

2.4 Keyboard Operation

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This is for fast operation for adjusting test bench.

2.5 Testing Flow Chart