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Summary of Contents for HORN CPM
- Page 1 User Manual C P M mobile Cylinder Pressure Monitoring - D r . E . H o r n G m b H , G e r m a n y C P M , 05/15...
- Page 2 E-Mail service@dr-horn.org Tel.: +49 7031 6302-0 Address Dr. E. Horn GmbH Im Vogelsang 1 71101 Schoenaich Germany D r . E . H o r n G m b H , G e r m a n y C P M...
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Page 3: Table Of Contents
Contents Introduction................................... 5 Intended Use ................................. 5 Description of Components ............................7 Description and Technical Data .......................... 7 Initial Start-Up ................................9 Charger/ Battery ..............................10 4.1.1 Changing the Rechargeable Batteries ......................10 Charger ................................10 4.2.1 Changing the Plug ............................10 Connecting the Charger ............................. - Page 4 Software Description ............................29 7.4.1 Loading Data ..............................29 7.4.2 Analysing the Data ............................31 7.4.3 Zoom and Move ............................37 7.4.4 Store Data ..............................38 7.4.5 Exporting the Statistics Table ........................38 7.4.6 Exporting diagrams ............................38 7.4.7 Print Report ..............................38 7.4.8 Export engine configs ...........................
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Page 5: Introduction
Introduction Dear Customer, Thank you for purchasing the “CPM - mobile Cylinder Pressure Monitoring” set. Please read the instruction manual prior to use and adhere to the guidelines so that you can work with your meas- urement device safely. Intended Use This measurement device is suitable for measuring the internal cylinder pressure and conducting ultrasonic meas- urements of two-stroke and four-stroke engines within and during operation. - Page 6 Ultrasonic sen- sor port Cable for ultrasonic sensor Cylinder pressure Sensor Reset Button (not removable) Ultrasonic sensor Cylinder pres- sure sensor Case Key for Thomson adapter Charging cable port Plug adapter Charger Not included in delivery Data transfer cables 2.3b 2.3a USB / LAN (RJ45) USB-Port for...
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Page 7: Description Of Components
Description of Components The set consists of the listed parts below. Please check the completeness of the set upon receipt. 1 x Hard shell case 1 x Handset 1 x Cylinder pressure sensor (permanently connected to handset) 1 x Charger 1 x Battery (inside of handset) 4 x Adapter for on-shore connection/on-board supply system for charger 1 x Tool to release the cylinder pressure sensor... - Page 8 Three LEDs showing the state of the measurement unit: Measurement standby Running measurement Measurement finalization Low battery alert Deleting storage The dual-colored LEDs indicate these functions with the status ON, OFF or blinking (Table 10-1). Power is supplied by means of the 7.4 VDC rechargeable battery provided and inserted. Port for charger is located at the bottom (see Chapter 4.3 and page 6 graphic 2.4).
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Page 9: Initial Start-Up
Initial Start-Up The CPM comes with a built-in battery. Charge the battery completely and monitor the state of charge as described under 4.3 and following pages. Turn on the handset by pressing the START button (2 sec.). The LED POWER shining green. -
Page 10: Charger/ Battery
The assembly of the ultrasonic sensor has to be done. To do so, see also chapter 5.3 connecting the sensors. To install the software, see chapter 7. Charger/ Battery The CPM comes with rechargeable batteries for mobile use. The batteries are lithium-ion batteries, with no memory effect, low self-discharge and deep discharge protection. 4.1.1 Changing the Rechargeable Batteries To change the batteries, loosen both screws at the bottom and remove the lid. -
Page 11: Connecting The Charger
The adapter will be ejected. The right adapter needs to be placed in the fixture and pressed down, until it audibly clicks into place and tightly anchors to the charger. Pay attention to the mounting direction as the adapter will only fit in one position. -
Page 12: Getting Ready To Take A Measurement
The green LED displays “Stand by” status; the charger is connected to the power supply. The yellow LED displays “Charge” status. When it is ON, the battery is charging. When it is OFF, the battery is fully charged. Figure 4-3 Significance of LEDs of the charger Getting Ready to Take a Measurement Before beginning to measure, a few points need to be considered and addressed. -
Page 13: Setting-Up The Monitoring Device
Setting-up the monitoring device LED 1 = Power LED 2 = Cycle LED 3 = Status Turning the device on: Press the START button for 2 seconds. Once the LED 1 is green, the handset is ready. If LED 1 is red, this means that the battery is low. If the battery voltage drops even more, the device will switch off itself automatically. -
Page 14: Preparation Of The Measurement Points
Figure 5-1 Connection of ultrasonic sensor and handset Note! The ultrasonic sensor cable is a cable especially tuned for this particular sensor. In the event of damage, do not replace it with another one. Please contact for assistance. Attention! Sensors, cables and the handset are highly sensitive measure- ment instruments. - Page 15 Figure 5-2: Cutaway of cylinder head and ultrasonic sensor. Place sensor, as shown in the picture, on top of a level surface Cylinder head Ultrasonic sensor One by one, the measurement data are stored on a memory card. These data cannot be sorted. Therefore, it is essen- tial to number the cylinders.
- Page 16 Exhaust Side Control Side Wärtsilä Exhaust Side Control Side V-Engines MAK / Caterpillar Side A Side B Figure 5-3 Counting methods for MAN, Wärtsilä and MAK engines Special Features of V Engines For measurements using a V-engine, begin on bank A at the cylinder station 1 and then measure the entire bank. Only then should you start to carry out measurements on bank B in the same order.
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Page 17: Carrying Out Measurements
Carrying Out Measurements Cylinder Pressure Measurement Cylinder pressure measurement is an essential diagnostic tool to monitor the status of the engine and its individual cylinders. To do so, the march of pressure of all strokes is measured and represented. The measured data is transferred into a diagram with cylinder pressure over the degree of the crank angle [°CA]. It represents a curve, from which the following points regarding supervision and state-based maintenance can be an- alyzed: Start of compression... - Page 18 The device is ready for the next measurement, if LED 1 only is green. Close indicator cock. Unscrew cylinder pressure sensor. You may have to use the tool provided. Do not hit it with a hammer or a similar object. Repeat step 6 to 16 for all remaining cylinder stations.
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Page 19: Explanations Regarding Cylinder Pressure Measurements
Explanations Regarding Cylinder Pressure Measurements Figure 6-1 Cylinder Pressure Curve Description of Figure: = 0.1 MPa), is located on the vertical axis, on the left-hand side. The Cylinder pressure, in bar (1 bar = 100,000 piston path is displayed in degree of crank angle [°CA] and is located on the horizontal axis, lower limit. The curve shows an open p/α... - Page 20 With 2-stroke engines, the pressure range of –180 °CA to +180 °CA is displayed. This corresponds to 360 °CA = one engine revolution = charge exchange + compression stroke + power stroke. Rotational EO = exhaust valve opens direction EC = exhaust valve closes IO = inlet opens IC = inlet closes TDC = top dead centre...
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Page 21: Diagnosis Of The Cylinder Pressure Course
With 4-stroke engines, the pressure range from –180 °CA to 540 °CA is displayed. This corresponds to 720 °CA = two engine revolutions = compression stroke + power stroke + exhaust stroke + induction stroke. Rotational TDC 2 360° EO = exhaust valve opens direction EC = exhaust valve closes IO = inlet opens... -
Page 22: Ultrasonic Measurement
State of the engine (depends on the state of the piston rings, valves, the piston, and the liner) The slope of the curve in area 3 should be steep and should reach the necessary compression pressure as specified by the manufacturer. You can find information on compression pressure in the engine operating data sheet diagram which was supplied by the manufacturer. -
Page 23: Carrying Out An Ultrasonic Measurement
environment. The ultrasonic sensor measures these high-frequency waves and generates an analogue signal from them. The signal is amplified and all irrelevant frequencies (low-frequency) are filtered out so that in the end only the streaming of gas, injection with combustion, and the opening and closing of the valves, are contained in the measurement value. -
Page 24: Explanation Of The Ultrasonic Measurement Values
Explanation of the Ultrasonic Measurement Values Figure 6-2 Ultrasonic progression for two-stroke engines You can see the progression of the ultrasonic measurement (coloured red) in this picture. You can also see the cylinder pressure progression (coloured blue). The handset has triggered the time of measurement such that both measurements are displayed at the same time with regard to the crank angle. -
Page 25: Software
In area 3, the pressure drops are most clearly discernable. The more even the gradient of the curve up to the slope and the steeper the first deflection climbs, the smaller the losses through the inlet/ exhaust valve. In the figure above the valves are in good condition, ensuring low-loss sealing of the combustion chamber. -
Page 26: Software Installation
The software must be installed on a PC for the measured values to be evaluated and stored. If received the installa- tion file on CD, place the disk in the CD drive and open the folder. Select ”CPM Setup.exe” with a double click and follow the steps that are indicated. - Page 27 Enter the inlet and outlet value opening times as crank angle (degrees) for the first cylinder. CPM SETTINGS. This is where the settings for taking measurements can be changed. Attention! TDC is the reference point and corresponds to a crank angle of 0°. Engine timings before TDC must be expressed with a minus sign.
- Page 28 7 calcul. range 1 (before TDC) 8 calcul. range 2 (after TDC) Figure 7-4 CPM settings CPM settings Measurements with/without ultrasonic sound: tick the box next to ACOUSTIC EMISSION if you take measure- ments using ultrasonic sound. Angle compression pressure: if the engine’s injection time lies before TDC, select the crank angle as value; if the engine’s injection time lies after TDC, select zero.
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Page 29: Addition / Deletion Of Engines To / From The Configuration
From the handset. The measured values stored in the handset have to be transferred to the PC. To do this, start the “CPM” program on the PC. The following screen will appear: 1 File| 2 Display| 3 Config| 4 Help... - Page 30 Push to separate Data cable plug connect separate Figure 7-6 Connection of Data Cable with Handset Insert the other end of the cable into the RJ 45 socket of the PC. Turn on the handset. The software recognizes the handset automatically and the data can be transferred via the Internet Protocol (IP). Using the USB-cable Insert the smaller plug into socket 2.3b (USB Port page 8) and the other one into a free socket of the PC.
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Page 31: Analysing The Data
Click on the Remove File button [2] to cause the selected record (with blue background) to be removed and all the following records to move up. Click on the Load Files button [3] to start the program. If the scavenge air pressure is less than 0.3 bar, first a new window will appear to ask for confirmation of the scavenge air pressure. - Page 32 1 Menu bar 2 Name of engine 3 Engine speed [rpm] 4 Date and time of measurement 5 Cylinder Figure 7-8 SHOW OVERVIEW View [1] The menu bar shows the menu items File, Display, Config and Help and the buttons for these functions are arranged directly underneath it.
- Page 33 9 p/α Diagram 1 Leakage Window 3 Valve Timings 6 Reference Curve 10 Hide Leakage 2 TDC/BDC 5 TheoreticalCurve Theoretic compres- sion curve Leakage Window 7 arrow key| 8 Table Figure 7-9 SHOW DETAILS with ultrasonic sound Speed is engine speed at the time of measurement p scav is air pressure at time of loading (scavenge pressure) p comp is compression pressure...
- Page 34 Angle to TDC shows the position on the cylinder pressure curve. Pressure is cylinder pressure at this position on the curve. To see the cylinder pressure curve with pressure vs. piston displacement, click on Figure 7-11 Table with the data of current cylinder menu item Display and then on p/v Diagram or else click on the button [1] (Fig.1-11).
- Page 35 Take Note! With 2 stroke engines there are no exhaust and intake pressure values! Clicking on menu item Display and then on Display bar charts opens the next window. All bar chart diagrams have a table in which the graphic values are also stated numerically along with the average value over all the cylinders. Clicking on buttons 2 and 3 (Fig.7…14) fades in lines that mark the alarm thresholds, once for the compression pressure and once for maximum pressure.
- Page 36 Scavenge air pressure gives a diagram that shows the scavenge air pressure (load pressure) at the time “inlet valve just closed”. Horse Power gives the indicated power in units of “Brake horse power” (bhp). Probability of Leakage displays the computed probability of pressure loss due to defective valves. In the table below [5] (see Figure 7-145) this probability is expressed numerically.
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Page 37: Zoom And Move
When is Valve Maintenance Required? Probability [%] Meaning and Recommendation Bar is green: the valve is in good condition: no leakage present, no action 0 – 40 required. Bar is yellow: small pressure losses. 40 – 80 Check at short regular intervals and with results near 80% or worse, take a second measurement and compare the results. -
Page 38: Store Data
The statistics table can be stored by clicking on the File menu item and then on Export Statistics. The standard target location is C:\Program Files (x86)\Horn\CPM\Statistics The name of the engine that is currently open is automatically included in the file name. The table contains the measured values, which can also be found by clicking Display→... - Page 39 1 Preview| 2 Save| 3 Print| 4 XML |5 Email| 6 Template| 7 Name| 8 Initials Figure 7-16 Create Report View The to XML [4] button enables you to save the report as an XML-sheet. The Mail button [5] supports transmission of the report through the Internet. For this you also need e-mail programs and access to the Internet.
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Page 40: Export Engine Configs
7.4.8 Export engine configs This function allows rapid transfer of engine configurations from one PC to another. This saves time and prevents data entry errors when defining engines on another PC. In addition, you can use this function to transfer configura- tions from the registry to a folder of your choice which you can access at all times, particularly when you are installing software updates. -
Page 41: After Use
7. The manufacturer accepts no liability above and beyond the warranty claims described above. 8. This manual is subject to change or update without prior notice. Furthermore, all general terms and conditions of Dr.E.Horn GmbH apply. The general terms and conditions were provided with your delivery note and are available on www.dr-horn.org. -
Page 42: Faq (Frequently Asked Questions)
FAQ (frequently asked questions) Here, you can find possible problems, causes, and proposed solutions. If your question is not included in this table or the procedure does not help, please contact Dr.E. Horn GmbH by email: service@dr-horn.org Question / situation / error... -
Page 43: 10.1 Summary Of The Significance Of The Leds
10.1 Summary of the significance of the LEDs Item Holding time LED colour Significance START key number when LED 1 illuminates the handset is on release the key for more 1= ON green actions Briefly pressing the key starts a measurement Measurement is performed automatically LED 2 turns off when the measurement is finished 1= ON... -
Page 44: Description Of The Features In Version 3.2.1
By clicking Help → Send raw data a window opens where you can choose raw data files for sending to Dr. E. Horn GmbH. The raw data are subdivided in engine type and date of measurement. Before sending the raw data are packed in the zip-format. -
Page 45: Notes On Safety And Surrounding Area
By clicking Display → Display history or clicking “H” in the toolbar the history window opens. All measurement files found in the measurement folder (…\Horn\Measurements) can be selected to be shown in the history tool. Any other folders including subfolders are ignored. -
Page 46: Ownership Information
Dr.E. Horn GmbH. Copyright © 2015 Dr. E. Horn GmbH. All rights reserved. This manual and the information contained within, including extracts, must not be reproduced, copied, transmitted, transferred, saved to a data processing system, or translated into another lan- guage without written permission from the manufacturer.
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