Professional Documents
Culture Documents
Operating Instructions
General
This operating manual provides instructions on how to use this product
properly, effectively and safely to the intended purpose. Please, do
read all instructions, notes on danger and warning attentively. Please
follow all safety hints and precaution notes in order to avoid damages
to people or property during the work process. LEUTERT cannot be
responsible for damages or injuries resulting from unsafe product use,
incorrect product operation or lack of maintenance.
The operating manual is directed mainly to technically trained personnel.
In case of uncertainty regarding the safety hints or the operation,
please do not hesitate to contact LEUTERT for help. Should you notice a
faulty description or depiction or if you would like to point out hints for
improvement, we are looking forward to hearing from you.
Please keep the operating instructions near the product to have it
available if needed. Make sure that the instructions are protected from
dirt and moisture.
Explanation of the different symbols:
DANGER
Immediate danger is possible causing severe injuries or even death if
you do not follow the instructions given.
WARNING
If you do not follow the warning, dangerous situations may occur
leading to severe injuries or even death.
CAUTION
Follow the instructions carefully, otherwise dangerous situations may
occur leading to injuries or damages to property.
NOTICE
Please follow the recommendations and instructions for a correct and
flawless operation of the device or measuring system.
Contents
1
Product description....................................................................... 4
1.1 Application and function ..................................................... 4
1.2 Technical data...................................................................... 4
1.3 Scope of delivery.................................................................. 6
5 Start of operation....................................................................... 12
5.1 Principal procedure for operating the DPI system................ 12
5.2 Charge battery................................................................... 13
5.3 Configure system............................................................... 14
5.3.1 Set time and date.................................................... 14
5.3.2 Select language...................................................... 16
5.3.3 Enter engine parameters......................................... 17
5.4 Delete data memory ......................................................... 20
5.5 Define measuring settings.................................................. 24
5.6 Install and adjust TDC sensor.............................................. 26
5.7 Install Crank Angle Encoder CAE........................................ 28
5.8 Installing the incremental encoder...................................... 30
6 Indication procedure................................................................... 32
6.1 Enter engine and cylinder number...................................... 33
6.2 Record measured data........................................................ 34
6.3 Check measuring settings and loading pressure.................. 36
6.4 Automatic recognition of alpha value................................. 38
6.5 Complete measuring series and remove pressure sensor...... 39
6.6 Display measuring results.................................................... 40
6.6.1 View data sets at the DPI........................................ 40
6.6.2 Transfer data sets to PC........................................... 40
6.7 Error messages................................................................... 41
6.8 Warnings........................................................................... 42
7
Maintenance.............................................................................. 43
7.1 Maintenance of pressure sensor.......................................... 43
7.2 Cleaning of the sensors...................................................... 43
7.3 Changing the battery pack................................................. 45
Product description
1.1
: 32 data sets
Sampling frequency
: 7.0 kHz for 2-stroke engines
16.6 kHz for 4-stroke engines
Pressure resolution
Angle resolution
Error class*)
: 0.5 shaft
Degree of protection
Battery charger
Input
Output
220 mm x 130 mm x 45 mm
110 mm x 65 mm x 26 mm
= 60 mm , L = 210 mm
= 12 mm , L = 85 mm
= 62 mm , L = 190 mm
= 58 mm , L = 29.4 mm
470 mm x 365 mm x 146 mm
Weight
Hand-held unit
Battery charger
Pressure sensor
Carrying case
790 g
180 g
830 g
6500 g incl. contents
:
:
:
:
0 55 C
10 40 C (during charge)
0 55 C
0350 C
0 85 C
0 80 C
0125 C
0 70 C
CE labels
Basic EMC Emission Standard DIN EN 50081-1, Class B
Basic EMC Immunity Standard DIN EN 61000-4-1, susceptibility level 3
Safety regulations for electrical measuring, control and laboratory
instruments DIN EN 61010-1
Classification of degrees of protection provided by enclosures DIN
EN 60529
Pressure Equipment Directive 97/23/EC
*)
Design
Operating keys
The DPI system includes the pressure sensor depicted in Fig.2, which
serves to determine the cylinder pressure in diesel engines. It is
characterized by a high level of precision, rugged design and longevity.
Please refer to chapter 1.2 of this manual for the technical features.
4.1
You operate and configure the DPI using the four push buttons. Menu
texts and measuring data are displayed in the illuminated four-line LC
display.
The easy-to-read menu structure enables you to operate the measuring
system intuitively. Thanks to the menu-driven control, you will be able
to use the DPI effectively after only a short time.
Leutert DPI
Version 2.04
Leutert DPI
measurement
measured data
settings
10
start measuring
cyl 1 alpha 180
engine 1
main menu
save
r
pmax
pdel
again
108.8 rpm
137.9 bar
17.2 bar
averaging [1]
filter
[1]
TDC sensor
FI sensor
0
1
1
0
save
pinj
mip
Pow
again
691.5 bar
16.1 bar
1884 kW
FI sensor
CAE sensor
show mip
back
0
0
1
engine 1
cylinder 12
alpha
180.0
back
engine 3
boost
2.3bar
back
time/date
German/English
configuration
main menu
time
[08:56:28]
date
[26-02-08]
read config.
back
TDC signal
CAE signal
TDC signal
engine data
measurement
back
engine 1
number cyl 16
2/4 stroke 4
back
off
off
key
engine
boost
cylinder
back
view
send
delete
main menu
averaging [1]
filter
[1]
TDC sensor
FI sensor
0
1
1
0
FI sensor
CAE sensor
show mip
back
0
0
1
no 4 14:50
21-09
engine 1
cyl 16
pmax 77
pdel 34
r 746
mip 16.1
delete all
engine 1
send
back
yes
no
delete all
delete eng.
delete indiv.
back
delete data
engine 1
11
Start of operation
5.1
1) Charge battery
You should charge the battery built into the DPI as a matter of course
when the charge message appears respect. after 6 months of disuse.
2) Configure system
You should prepare the measuring system for the specific operating
conditions, so that it will provide the correct results. This includes
entry of the engine parameters and setting date and time. Enter
these settings on the DPI hand-held unit where they will be put
into memory and will still be available when the unit is switched off
and back on again.
3) Delete data memory
We recommend that you delete the data sets put into memory in
the DPI completely before starting a new measuring series. The
configuration settings are not affected by this!
4) Preset measuring settings
Use the filter or average generation function to prevent unwanted
interference of the measuring results.
5) Optional: Installing and, if applicable, adjusting the TDC
sensor, crank angle encoder (CAE), or incremental encoder
Mount the sensors on the engine in accordance with the
instructions.
6) Install pressure sensor
Install the pressure sensor at the indication bore of the diesel
engine. At the beginning of the measurement, when the sensor still
is cool, do not tighten the sensor hard to the cylinder in order to
prevent it from getting stuck.
7) Install fuel injection sensor
Install the fuel injection sensor on the appropriate mounting hole
of the respective injection pump.
8) Connect sensors at the DPI hand-held unit and record
measuring data
Connect the sensors with the DPI hand-held unit and carry out the
measuring series. The DPI stores the measuring data of a maximum
of 32 cylinders. You have the option of following the measuring
procedure on the display of the DPI and, as necessary, of reacting
to error messages with corresponding measures.
9) Display measuring data
You may view stored data sets independently of the measuring
location on the display or transfer them to a PC, in order to carry
out a machine diagnosis with the assistance of the DPI software.
12
13
Leutert DPI
measurement
measured data
settings
4) Pressing the P button again will take you to the setting window for
time and date. The flashing cursor is the time line.
time
[08:56:28]
date
[26-02-08]
read config.
back
14
time
[08:56:28]
date
[26-02-08]
read config.
back
6) Carry out step 7 to change the number marked. If the figure marked
is correct, press P. The cursor thus jumps to the next adjustable
figure.
time
[08:56:28]
date
[26-02-08]
read config.
back
time
[08:59:28]
date
[26-02-08]
read config.
back
9) When you have worked through all figures of the time using P, the
cursor switches to the back line. If you notice wrong settings or
you would like to change the date you can move the cursor using
or to the time or date line and repeat from step 5.
10) Initiate the back command using the P button to return to the
superior menu settings.
time/date
German/English
configuration
main menu
15
Uhrzeit/Datum
Englisch/Deutsch
Konfiguration
Hauptebene
3) Use the P button to switch between the two languages. The menu
texts always appear in the language currently activated. The cursor
marks the language currently not selected.
time/date
German/English
configuration
main menu
4) If you have the menu texts in the preferred language, move the
cursor using the or buttons for setting further items or switch
back to the main level.
time/date
German/English
configuration
main menu
16
in 0.5 CA steps
in 0.1 bar steps
(Cylinder no.)
1
9
2
0
40
80
(TDC offset)
7
120
4
160
5
200
6
240
3
280
8
320
17
time/date
German/English
configuration
main menu
4) Move the cursor into the engine data line using or.
NOTE: In the event that the Engine data menu is locked, you are
not authorized to carry out the following steps.
TDC signal
engine data
measurement
back
6) Press P when the cursor is in the line in which you would like to
configure the values. Begin with the engine. Instead of the engine
number, the engines name may be displayed once the engines
data has been transferred from a PC.
engine 1
number cyl
2/4 stroke
back
1
4
engine 1
number cyl
2/4 stroke
back
1
4
engine 3
number cyl
2/4 stroke
back
18
1
4
engine 3
number cyl
2/4 stroke
back
1
4
10) Press the P button in order to enter the number of cylinders of this
engine. The cursor jumps onto the corresponding figure.
engine 3
Anzahl Zyl
2/4 stroke
back
1
4
engine 3
number cyl
2/4 stroke
back
12) Acknowledge your entry with P. The cursor now appears in the
next line for selection of the type of engine. Change between 2- or
4-stroke engine using the P key.
12
4
13) If the correct parameter is being displayed, move the cursor to the
back line using button or .
engine 3
number cyl
2/4 stroke
back
12
4
14) With P you switch back to the superior menu in which the line
boost (pressure) is marked.
engine
boost
cylinder
back
For entering the characteristic values appearing there, you should use
the handling procedures from step 6 as a guide. Then switch to the
parameter cylinder. Make sure the entries in the above areas are
precise.
19
Leutert DPI
measurement
measured data
settings
The DPI hand-held unit is switched on. You see the start menu in the
display window. Now follow the procedure described.
view
send
delete
main menu
delete all
delete eng.
delete indiv.
back
20
6a) In order to delete all stored data sets, press P, when the cursor is in
the line delete all.
delete
all
yes
no
view
send
delete
main menu
You can abort the deletion procedure by moving the cursor onto no
with the button and press P.
21
6b) If you want to delete only data sets of one engine, move the cursor
to delete eng. and press P.
delete data
engine 1
delete data
engine 5
no
delete all
delete eng.
delete indiv.
back
At this stage you can abort the process by moving the cursor with
the key to no and confirm with P.
Otherwise just confirm the deletion of the engine by pressing P.
Once you have started the process of deleting the data it cannot be
stopped or interrupted.
7b) With the command back you get back to the pertinent superior
menu level. Navigate to the required setting level using the
buttons.
22
6c) To delete certain data sets, press button P when the cursor is in the
line delete individually.
delete no 1
engine 1
cyl 1
time
[08:56:28]
date
[26-02-08]
Press P when the data set appears that you want to remove from
the memory. To delete further data sets individually, repeat step 6c.
delete all
delete eng.
delete indiv.
back
7c) With the command back you get back to the pertinent superior
menu level. Navigate to the required setting level using the
buttons.
23
Leutert DPI
measurement
measured data
settings
time/date
German/English
configuration
main menu
TDC signal
engine data
measurement
back
averaging [1]
filter
[1]
TDC sensor
FI sensor
24
0
1
0
0
Filtering (Filter 0, 1 or 2)
Use the filter function of the DPI to suppress the occurrence of unwanted
vibration, e.g. whistling vibrations. These are interfering vibrations
covering the measuring signal which can be caused by the indicating
channel.
Filter 1
Filter 2
2-stroke engine
400 Hz
160 Hz
4-stroke engine
1.6 kHz
660 Hz
Smoothing
slight
strong
Choose between filter 1 or filter 2, to achieve a targeted bandlimit, i.e. smoothing of the measuring signal. Due to the strong
smoothing factor of Filter 2 it should only be used in exceptional cases.
Starting from version 3.24, the DPI software contains a filter
function. We recommend that you disable the filter function
in the DPI hand-held unit by setting it to Filter 0. This will
enable detailed, unfiltered data to be stored. You can decide
subsequently in the DPI software, based on the curve shape,
whether you wish the data to be displayed with or without filter
on the monitor.
For switching between filters 0, 1 or 2 press button P when the cursor
is in the line filter. When the required value is displayed, switch to
the line TDC sensor using button or .
averaging [1]
filter
[1]
TDC sensor
FI sensor
0
1
1
0
averaging [1]
filter
[1]
TDC sensor
FI sensor
0
1
1
0
FI sensor
CAE sensor
show mip
back
1
1
1
FI sensor
CAE sensor
show mip
back
1
1
1
25
4) Move the sensor until its distance to the magnet is 22.5mm, see
Fig 4. Use the distance gauge for this.
5) Plug the TDC sensor cable into the pertinent connecting socket of
the DPI.
time/date
German/English
configuration
main menu
TDC signal
engine data
measurement
back
7) Confirm the menu item TDC signal here. The message TDC
signal on must appear on the display of the DPI as shown in the
lower depiction.
TDC signal on
CAE signal off
key
26
9) Now move the magnet carefully back as far as necessary until TDC
signal on appears again on the display. Mark this position.
10) In the case of a surface mounting like in Fig. 4, fix the magnet with
adhesive exactly on the marked position. Please also read the advice
for using the adhesive supplied.
11) To implement a flush mounting as in Fig. 5, do the drilling in such a
way that the magnet projects at least2.5mm after being inserted.
Then readjust the distance of the magnet to the sensor.
TDC sensor
magnet
27
When installing the Crank Angle Encoder (CAE) take care that the
flywheel teeth are not deformed by the turning gear. The best position
to install the Crank Angle Encoder is the outer edge of the flywheel,
because the gear mostly affects the middle of the teeth. Due to the
deformation, the distance between the CAE and the flywheel teeth
may decrease, and the CAE may be destroyed.
The Crank Angle Encoder has to be mounted such that the flat faces
of the CAE housing are parallel to the turning direction of the flywheel
(Fig. 6).
Alternatively, the CAE may be mounted pointing to one side of the
flywheel to prevent this problem. In both cases, the holder for the
CAE must be installed and the minimum distance must be determined
between holder and teeth that is required for one complete turn of
the engine. The CAE may be mounted at a minimum distance of one
millimeter to this minimal distance. This way, a possible later increase
in the play of the bearing would be taken into consideration. The
maximum distance should not exceed 2.5 millimeters.
28
The CAE and TDC sensor are linked to and inter-connected inside a
junction box. The linked data stream is transferred to another junction
box, which is equipped with a bushing for connecting to the DPI handheld unit (Fig. 7).
1 CAE
2 GND
3 +U
4 TDC
shield
DPI
Handheld
Unit
CAE sensor
white : signal
green : minus power
brown : plus power
black : shield
CAE 1
GND 2
+U
TDC 4
shield
TDC sensor
yellow : signal
green : minus power
brown : plus power
29
30
Leutert DPI
measurement
measured data
settings
time/date
German/English
configuration
main menu
TDC signal
engine data
measurement
back
TDC signal on
CAE signal off
key
13) Reinstall the cover of the RT-flex sensor using the M12x60 screws
(see fig. 10).
14) Install the upper junction box on the top platform of the engine.
31
Indication procedure
cyl1
The menu on the left shows the waiting period until the optimum
operating temperature of the sensor is reached.
Do not switch off the DPI hand-held unit before completion of
the measurements, otherwise you would have to wait for the
preheating time of the pressure sensor again.
32
6.1
Leutert DPI
measurement
measured data
settings
start measuring
cyl 1 alpha 180
engine 1
main menu
start measuring
cyl 1 alpha 180
engine 3
main menu
start measuring
cyl 2 alpha 180
engine 3
main menu
33
start measuring
cyl 1 alpha 180
engine 3
main menu
save
r
pmax
pdel
again
108.8 rpm
137.9 bar
17.2 bar
save
r
pmax
pdel
again
108.8 rpm
137.9 bar
17.2 bar
start measuring
cyl 2 alpha 180
engine 3
main menu
34
save
r
pmax
pdel
again
108.8 rpm
137.9 bar
17.2 bar
save
pinj
mip
Pow
again
691.5 bar
16.1 bar
1884 kW
memory full
replace
abort
replace no. 8
engine 1
cyl 2
time
[09:53:26]
date
[26-02-08]
start measuring
cyl 2 Alpha 180
engine 1
main menu
35
Leutert DPI
measurement
measured data
settings
averaging [1]
filter
[1]
TDC sensor
FI sensor
0
1
0
0
2) Use the button to activate the menu for the measuring settings
when the cursor is in the first line under start measuring.
36
Leutert DPI
measurement
measured data
settings
start measuring
cyl 1 alpha 180
engine 3
main menu
3) Activate the menu for checking the loading pressure with the
button.
engine 3
boost
2.3bar
back
4) Check the correctness of the set loading pressure. Correct the value
as necessary and then enter back to return to the previous menu
to start measurement.
Changes to the loading pressure made within the menu
measuring are lost when the DPI is switched off.
37
Please, decide whether you want to change the TDC offset or continue
measuring with the previous value:
change continue
start measuring
cyl 12 alpha 120
engine 1
main menu
38
39
Leutert DPI
measurement
measured data
settings
view
send
delete
main menu
no 4 14:50
21-09
engine 1
cyl 16
pmax 77
pdel 34
r 746
mip 16.1
view
send
delete
main menu
You may exit this menu at any data set number using the P button.
Please, switch off the DPI hand-held unit.
40
no TDC signal
key
CAE Sensor
no signal
key
recharge battery
no connection
key
storage error
key
Cause:
The pressure sensor is not correctly connected or the indication
valve is not open.
Recommended measure:
Check the firm seat of the pressure sensor connector, its contacts
and the sensor cable. Control the indication valve.
Cause:
The TDC sensor is not properly connected or a non-connected TDC
sensor is activated. The engine speed is too low (<50rpm).
Recommended measure:
Check firm seat of the TDC connector, its contacts and the TDC
cable. Choose the correct option for the TDC sensor according
to chapter 5.5. Control correct mounting and setting of the TDC
sensor according to chapter 5.6.
Cause:
The Crank Angle Encoder (CAE) is not connected properly or non
connected CAE is activated.
Recommended measure:
Check firm seat of the TDC connector, its contacts, the cable and
the connections in the junction box. Deactivate the CAE if none
is available according to chapter 5.5. Check the mounting and
adjustment of the Crank Angle Encoder. Refer to chapter 5.7.
Cause:
The battery capacity is exhausted.
Recommended measure:
Quit all measurement activity immediately and recharge the battery
according to chapter 5.2.
Cause:
The connection between the DPI and the PC via the serial interface
is disrupted.
Recommended measure:
Check the connectors, cables and PC port settings as well as the
correct order according to chapter 6.6.2.
Cause:
If this message is displayed when the DPI is switched on, the stored
calibration data of the pressure sensor are incorrect.
Recommended measure:
Contact LEUTERT for debugging.
41
6.8 Warnings
Warnings indicate that undesirable or faulty results may occur during
further use of the device. Press any key to remove the message, and
carry out the recommended measures.
wrong alphavalue
180 CA
check:
cylinder number
change continue
Meaning:
The automatically measured TDC offset does not match the stored
value.
Cause:
The cylinder number selected at the DPI hand-held unit does not
match the measured cylinder.
Recommended measure:
Correct the cylinder number manually at the DPI hand-held unit
and repeat the measurement.
Cause:
The indication valve is not opened correctly and/or defective.
Recommended measure:
Please ensure that the indicating valve is completely opened
and then continue the measurement. Check the valve after the
measurement and replace it if necessary.
memory full
replace
abort
no data
key
menue locked
back
42
Cause:
The data memory is completely filled.
Recommended measure:
Delete the data memory according to chapter 5.4 before starting the
measurement or overwrite existing data sets during the measuring
series according to chapter 6.2.
Cause:
There are no data stored under the chosen engine number.
Recommended measure:
Choose the correct engine number.
Cause:
The menu for changing the engine parameters or measurement
settings, respectively, is locked. You are not authorized to change
the values previously transmitted to the DPI hand-held unit via the
DPI software (starting from version 3.24).
Recommended measure:
The menu can only be enabled by means of a password via the DPI
software by the person responsible for measurements
Maintenance
7.1
The DPI hand-held unit is maintenance-free. Make sure that the device
and the pertaining pressure sensor are returned to the company Leutert
for control of the calibration data after approx. 100 operating hours or
after 3 years, respectively.
While the calibration settings are controlled at LEUTERT, the
pressure sensor will be cleaned simultaneously.
7.2
Before cleaning, allow the sensor to cool down to less than 50C.
Use only the supplied cleaning agent.
Do not introduce any tools into the sensor bore.
Do not disassemble the sensor unit.
Wear safety glasses when blowing out the sensor bore.
43
44
7.3
2) Press the latch lock and pull the connection plug from the battery
pack.
To install the battery pack please follow the steps in reverse order.
45
46