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Pmi On PDF
Pmi On PDF
PMI
PMI System
(On-line)
Pressure Analyser
Version 2.0
Contents Return
About this Guide
This User's Guide applies to the MAN B&W Diesel's On-line PMI
System, Version 2.0. It provides an introduction to and an overview of the
entire PMI System for cylinder pressure measurements and analysis on
MAN B&W diesel engines on board ship and at stationary power plants.
The guide sets out to provide engine staff with the knowledge essential for
understanding the principle of operation and function of the PMI System,
so that they can more quickly begin using it for measurements.
Note: For first time use of the PMI System, it is essential that it is
correctly setup as explained in Chapter 4 of this User Guide.
Taking the PMI System in use will indicate your acceptance of these
conditions.
Trademarks
Windows is a trademark of the Microsoft Corporation, U.S.A.
3. Manual Measurements
3.1 Manual Measurements ...............................................................................3-2
3.2 Checking & Editing Measurements ...........................................................3-5
3.3 Deleting Measurements .............................................................................3-9
3.4 Backing Up & Restoring the PMI Database ..............................................3-9
Contents Return
Table of Contents
Appendix
A.1 Technical Specification............................................................................ A-2
On-line PMI System................................................................................. A-2
Computer Requirements .......................................................................... A-2
A.2 Care & Handling of PMI Equipment ....................................................... A-3
A.3 Technical Assistance................................................................................ A-5
Glossary
Index
Welcome to MAN B&W Diesel's PMI System for on-line cylinder pres-
sure measurements on diesel engines.
The PMI System is designed to provide engineers and service personnel
onboard ship and at power plants with a computerised tool for pressure
measurements and analysis on two-stroke diesel engines. The main advan-
tages of the system are:
• On-line measurement of cylinder pressure. Fully automated measure-
ment routine for measurements conducted from engine control room.
• Graphic display and print out of PT, PV and Balance Diagrams, together
with Mean Indicated Pressure and Max. Pressure deviation limits.
• Calculated values of Effective Power, Mean Indicated Pressure pi,
Compression Pressure pcomp, Max. Pressure pmax, and Scavenge Pres-
sure pscav, including proposed values for index adjustments, etc.
• Software interface for use with MAN B&W Diesel's engine perform-
ance and engine diagnostics software, e.g. CoCoS-EDS.
In this Chapter
• About this User’s Guide............... 1-2 Crankshaft Torsion Correction........ 1 - 9
General Overview........................... 1-2 Cylinder Identification.................. 1 - 10
PMI 'On-line Help' ......................... 1-3
Text Conventions ............................ 1-3 • Supplementary Features............. 1 - 10
• The Basic System.......................... 1-3 Standard PC Hardware.................. 1 - 10
Windows Display & Operation ..... 1 - 10
• Main Features ............................... 1-7
Pressure Measurement Views......... 1-7 On-line Help ................................. 1 - 11
Calculated Values ........................... 1-8 Data Backup.................................. 1 - 11
Determination of TDC ................... 1-9 Use with Other Software............... 1 - 11
Cyl: 1
Cyl: 2
Cyl: 3
Off-line
Calibration Cyl: 4
Scavenge Cyl: 5
Pressure PC with PMI
Cyl: 6 On-line Software
Cyl: 7 installed in
Cyl: etc. Engine Control Room
PMI PMI
Master Slave
Com. Unit Com. Unit
Fig. 1-1. Use of MAN B&W Diesel’s Communication Units to create an on-line sys-
tem for cylinder pressure measurements on two-stroke diesel engines
exposed directly to the harsh environment inside the cylinders they can be
left permanently mounted on the engine without risk of damage and are
capable of providing very reliable and stable measurements.
To obtain a pressure indication which accurately describes the change in
cylinder pressure throughout each work cycle of an engine, the pressure
detected by the transducer must be synchronised with the motion of the
engine. For this purpose, the PMI System is especially designed to be used
with different types of crankshaft pickup, for example:
Table 1-1. Crankshaft Pickups for use with the PMI System
PMI PMI
Master Slave
Scavenge Air Com. Unit Com. Unit 24V DC
Pressure Sensor Power Supply
Trigger Pulses
SC-1 from Crank Angle
Pickup, Angle
Calibration Box
CJB Encoder, etc.
with 8 m cable
SC-2
Abbreviations:
CA-7 CA: Charge Amplifier
SC: Signal Conditioner
Cyl. 7 Cyl: Engine Cylinder Sensor
CJB: Calibration Junction Box
Fig. 1-2. Example of MAN B&W Diesel's equipment setup for on-line cylinder pres-
sure measurements on diesel engines
The modules utilise a multi master mode of operation where they play an
equal role in handling communication. They provide a choice of inputs for
different signals, as well as a serial interface port which is configured for
operation with a PC.
All of the equipment is powered by an external 24 V DC source and with
exception of the PC, is mostly located in the vicinity of the diesel engines
on which measurements are made. For subsequent calculation, display and
storage of the data using the PC, the software supplied with the PMI Sys-
tem must be installed on the PC.
Similarly, by dragging the mouse over any portion of the pressure curves
you can zoom in and obtain a magnified view of the area selected.
Also, several toolbars are included. One of these is situated just below the
main menu and is for quick access to the most frequently used commands
that are available with the PMI System, while the other is located along
side the measurement views that are presented and is used to select pres-
sure curves for each of the individual cylinders of a diesel engine.
For example, measurements can be transferred from the PMI System to the
CoCoS-EDS Engine Diagnostics System which is available from MAN
B&W Diesel.
This Chapter explains about operation and use of the PMI System after the
system has been setup and calibrated as described in Chapter 4. It provides
basic details on the main window elements and commands which are avail-
able with the PMI System and shows you how to view on-line measure-
ments as well as capture and store cylinder pressure curves for detailed
examination at a later date.
In this Chapter
• The PMI Windows Environment. 2-2 • Capturing and Storing
Starting the 'PMI On-line On-line Values ............................... 2 - 8
Analyser' Program .......................... 2-2 • Viewing Stored Measurements .. 2 - 10
Main Window ................................. 2-2
Opening Stored Measurements ..... 2 - 10
PMI Communication Monitor........ 2-4
PT Diagrams ................................. 2 - 11
Mouse/keyboard Operation ............ 2-5
PV Diagrams................................. 2 - 15
• Opening Engines........................... 2 - 6
Balance Plots................................. 2 - 16
• Monitoring & Viewing
On-line Values............................... 2 - 7 Calculated Values.......................... 2 - 17
Title bar:
This bar indicates the name of the particular software application which is
being run, plus the particular diesel engine that is chosen for making new
Title bar
Menu bar
Toolbar
Status line
Fig. 2-1. The primary elements of the PMI System's main window
Menu bar:
This shows the names of the PMI’s main menus. Clicking on the names
with the left mouse button, lists the functions and commands that are avail-
able with each of these menus. Clicking on a command listed in the menu,
activates the command.
Note: Only those commands which are fully visible can be activated.
They depend on the particular window and the command which you last
activated.
Toolbar:
This contains a row of buttons each marked with a function symbol. By
using the mouse to slowly move the display cursor across the Toolbar, hints
are flagged about the purpose of each button. Clicking on the buttons with
the mouse provides quick access to the most frequently used commands
which are also available using the Menu bar located just above the Toolbar.
As with the commands listed in the Menu bar, only those tool buttons
which are fully visible can be activated. They depend on the particular
window and the command or tool button which you last activated.
Status line:
The status line provides information about the operating status of the sys-
tem for measurements, processing and saving results.
For additional information about communication with the engines that are
connected, a separate Communication Monitor window is opened along-
side the On-line Analyser window. This lists the particular engines con-
nected, as well as indicates their current communication status.
in Fig. 2-2. This lists the particular engines in your engine plant which are
connected on-line with the PMI System, as well as indicates whether they
are communicating correctly with the PMI System.
On selecting an engine, its name is shown in the title bar at the top of the
PMI On-line Analyser window. Provided that correct communication is
established, then a “No Error” status message will be shown beside the
name of the engine listed in the PMI Communication Monitor window
(see Fig. 2-2). If, on the other hand, a “Timeout on serial connection” mes-
sage is indicated instead, then check that the power and communication
lines are properly connected to the PMI equipment installed on the engine.
Fig. 2-4. A PMI System 'On-line Values' scheme. The scheme is continu-
ously updated with the latest cylinder pressure values
Fig. 2-5. The 'Save Measurement As' dialogue as viewed with the 'List'
function
Fig. 2-6. The 'Save Measurement As' dialogue as viewed with the 'Details'
function
Fig. 2-8. The 'Open Measurement' dialogue as viewed with the 'Details'
function
Measurements are opened by selecting them either with the mouse or with
the arrow and enter keys on the keyboard. Opening a measurement, dis-
plays its pressure versus time curve, i.e. 'PT diagram' view, which is
explained in the following section.
2.5.2 PT Diagrams
A PT Diagram is displayed immediately on opening a measurement with
the 'Open Measurement' command (see previous section). Alternatively,
you can select a PT Diagram either by selecting it in the 'View' menu or by
clicking on the corresponding button in the Toolbar.
A 'PT Diagram' is shown in Fig. 2-10 and can contain pressure curves for
up to 24 cylinders, depending on the number measured. Each curve is
shown over a full work cycle of the engine, i.e. pressure [bar] versus crank-
shaft angle [degrees], but is plotted relative to a common TDC so as to
allow easy comparison with the other curves that are shown. Also, each
curve is plotted with a separate colour, in order to help distinguish between
them.
As a reminder, a “No 0-Diagram Data” message is displayed whenever
measurements are opened which do not include a '0-Diagram' reference
measurement. See Chapter 4 for details about editing measurements and
linking them with 'O-Diagram' measurements.
PT Tool Panel:
The PT Diagram is equipped with a Tool Panel (see Fig. 2-11). This is
located on the right-hand side of the display screen and can be used to acti-
Grid
On / Off
Cursor
On / Off
Zoom Out
to 100%
Cylinders
vate or de-activate various elements of the diagram. For example, you can
toggle 'On' and 'Off' the display grid, display cursor and the individual
curves shown for each of the cylinders, simply by clicking on the corre-
sponding buttons.
Also, by using the mouse to move the display cursor across these buttons,
you can obtain hints about the purpose of each button.
Display Grid:
To switch on the 'Display Grid', click the button shown. The grid is active
when the button is depressed.
Display Cursor:
When the 'Cursor' button is activated (i.e. button depressed), you can move
the cursor up or down, or to the left or right by pressing the appropriate
arrow key on the keyboard. Also you can step from one curve to the next
simply by aligning the cursor on a raised portion of the curve and pressing
the up or down arrow key. The selected cylinder and cursor position are
indicated at the bottom of the display.
Zoom Function:
If you want to examine diagrams in more detail you can zoom in and mag-
nify any portion of the diagrams as shown in Fig. 2-12.
To zoom in on part of a diagram, position the mouse cursor at the start of
the region of interest on the display and then press the left mouse button
and while keeping the button pressed, drag the cursor diagonally over the
area of interest and release the button. This will magnify the area.
When you want to return to the original view, press the 'Zoom' button in
the tool panel to deactivate it.
2.5.3 PV Diagrams
A 'PV Diagram' is shown in Fig. 2-13 and can be displayed either by
selecting it in the 'View' menu or by clicking on the corresponding button
in the Toolbar.
The 'PV Diagram' shows the cylinder pressure [bar] as a function of the
relative volume [%] of the cylinder. The area contained by the curve is pro-
portional to the work done during the work cycle.
As with the PT Diagram, the PV Diagram is equipped with a Tool Panel.
This also has buttons for toggling the display grid, display cursor, zoom,
etc., which function in precisely the same manner as described earlier for
the PT Diagram. See section 2.5.2.
On the left of the display is given the mean pressure (i.e. arithmetic aver-
age of the individual cylinder pressures combined), while on the right of
the display the difference between the actual pressure measured and the
mean pressure (i.e. deviation from mean) is indicated for each cylinder.
Fig. 2-15. A 'Calculated Values' scheme for a two stroke diesel engine
The scheme gives values for the Compression Pressure pcomp, the Maxi-
mum Pressure pmax and the Engine Speed. In addition, it gives values for
the Mean Indicated Pressure pi, the Scavenge Air Pressure pscav and the
Effective Power of two stroke engines.
Also, indicated are calculated values for the fuel pump index adjustments
of two stroke engines. These can be seen by moving the scheme with the
scroll bar located at the bottom of the scheme.
The values for index show how much the index of each of the cylinders
must be adjusted to get the engine properly balanced. The results are
expressed as an “Index Adjustment” (i.e. change of index), as well as in
terms of a “Rotation of link” (i.e. the number of turns required to obtain a
certain displacement of the rod) or “Shim Adjustment” (i.e. the number of
shims to be inserted or removed) depending on the type of adjustment pro-
vided with the engine.
Manual Measurements
This chapter explains how to make manual measurements using the PMI
System together with its Calibration Transducer. In addition, it explains
how to save, edit and/or delete measurements, as well as how to backup the
measurement data base.
In this Chapter
• Manual Measurements................. 3 - 2 • Deleting Measurements ................ 3 - 9
• Checking & Editing • Backing Up & Restoring
Measurements............................... 3 - 5 the PMI Database.......................... 3 - 9
The view in Fig. 3-1 will now appear which shows a series of panels,
one for each cylinder of the engine.
Initially, the panels are coloured grey, but change to green after meas-
urements on the corresponding cylinders have been completed.
4. Connect the Calibration Transducer to the Control Box and the
multipole plug of the Control Box to the Calibration Junction Box
located in the engine room. See Fig. 1-2 and 3-2.
Connector for
Pressure Transducer
'Error' 'Start'
indicator button
Red Green
Fig. 3-2. The Calibration Control Box of the On-line PMI System
5. Wait until the engine is running with an even load and is stable.
The PMI System is ready for measurements when the green 'Start' but-
ton on the Control Box is lit.
6. Mount the Transducer on the indicator cock of Cylinder No. 1 and
open the indicator cock.
7. Press the green 'Start' button on the PMI Control Box to start the meas-
urement.
When the green light next lights, the measurement will have been com-
pleted.
8. Close the indicator cock and remove the Pressure Transducer.
! Warning: Always check that the indicator cock is closed
before removing the transducer. Failure to do this can result in the
release of extremely hot combustion gasses which can severely
injure personnel.
9. Repeat step 6 to 9 until you have completed measurements on all cylin-
ders.
10. Return to the PC and stop measurements by pressing Esc. on the key-
board.
Stopping measurements displays the 'Save Manual Measurement As' di-
logue. This automatically allocates a file name to the measured data and
stores it in the directory for the current engine when the 'Save' button is
activated.
File names are assigned as indicated in the following example:
m010124_102730
where the first character 'm' indicates a measurement, the next six char-
acters the date and the last six characters the time that the measurement
was saved.
This opens the 'Open Measurement' dialogue shown in Fig. 3-3 which
lists all the measurements made with the PMI System.
The most recent pressure measurements are listed with the prefix 'm'
and have the date and time of storage as part of their designation.
e.g. m010124_102730
To view details about the measurements (see Fig. 3-4), right-click any-
where in the dialogue to actuate its quick-access menu (see Fig. 3-5)
and then select 'Details'. Alternatively, click on the corresponding but-
ton in the dialogue's toolbar.
Fig. 3-6. The 'Edit Cylinder Observations' dialogue of the PMI System
3. Check that there is one observation for each cylinder and that their
pressure curves have the approximate shape and form as indicated in
Fig. 3-6.
4. If one or more observations are missing or are not correct, then the
entire measurement should be deleted and a new measurement taken
before proceeding further with this procedure.
To delete the measurement, click the 'Close' button and then activate the
'Delete' button in the 'Open Measurement' dialogue.
5. If all cylinder observation appear correct, click the 'Close' button to
return to the 'Open Measurement' dialogue and then activate the 'Edit'
command in the dialogue's quick-access menu or click the correspond-
ing button in its toolbar.
Activating the 'Edit' command opens the 'Edit Measurement' dialogue
shown in Fig. 3-7. This allows you to rename the measurement as well
as to check whether the measurement is linked with the appropriate '0-
Diagram' and 'E-Load' reference measurements.
6. To rename the measurement, click in the measurement field and key in
a new name.
For this purpose a naming convention which preserves the date and time
of the measurement is suggested.
e.g. m_85_010124_1027
Where the first character 'm' indicates a measurement, the next three
characters indicate the engine load, the next seven characters the date
and the last five characters the time that the measurement was stored.
7. Next check that the names of the appropriate '0-Diagram' and 'E-Load'
measurement files which are to be used for TDC determination, appear
in the list-boxes immediately below the name of the measurement.
If no '0-Diagram' and 'E-Load' files are listed, then the appropriate
measurements must be made as explained in Chapter 4.
8. Finally, key in the appropriate value for the scavenge air pressure of the
engine in the 'p(scav):' data field and press the 'OK' button to close the
'Edit' dialogue and save your changes to the measurement.
Note: If no scavenge air pressure reading is keyed in, then the pro-
gram itself will automatically estimate it. For this purpose the
'p(scav):' data field should be kept at “0.00”.
After having checked and accepted a measurement as described above, it
may be examined in more detail using the 'View' menu commands which
are explained in section 2.5.2 to 2.5.5.
The 'Backup' dialogue is opened using the 'Backup' command in the 'File'
menu. To commence backup, click on the 'Make' button. The PMI System
then responds with the name and location of the new file which is to be
used for storing the backup on your hard disk. To accept the file and con-
tinue with backup, click on the 'Yes' button. The PMI System then takes a
copy of database and stores it on the hard disk.
In addition to the above, the 'Backup' dialogue has functions for restoring
the PMI System database, deleting backup files and saving them on sepa-
rate floppy diskettes. These functions are included on the 'Restore' and
'Catalogue' tabs of the 'Backup' dialogue (see Fig. 3-9 and 3-10). When
backup files are created they are stored in compressed form and are auto-
matically decompressed whenever they are used to restore the PMI Sys-
tem's database.
Fig. 3-9. The 'Backup > Restore' dialogue of the PMI System
Fig. 3-10. The 'Backup > Catalogue' dialogue of the PMI System
This chapter explains about use of the PMI On-line Setup program which
is intended for configuring the PMI System when it is first installed on
your engine plant. In this connection it allows you to make the initial setup
adjustments as well as the default and calibration measurements discussed
in section 4.1 to 4.3 of this chapter.
After making these measurements you need only consult this chapter if the
Calibration Transducer or one or more of the cylinder sensors have to be
replaced, or if the triggering system is replaced or moved to another posi-
tion on the engine. In the later two instances regarding the triggering sys-
tem, you will also have to make a new set of default and calibration
measurements.
In this Chapter
• Initial Setup................................... 4 - 2 • Checking, Editing & Downloading
• System Default Measurements .... 4 - 9 Calibration Measurements......... 4 - 12
'0-Diagram' Measurements............. 4 - 9 • Sensor Replacement.................... 4 - 18
E-Load and Transducer • Calibration Transducer
/Sensor Measurements.................. 4 - 12 Replacement ................................ 4 - 20
2. Select 'Open Engine' in the 'File' menu and with the mouse or arrow
keys select the name of particular engine that you want to work on-line
with in the dialogue which is opened.
3. Click on the 'Edit' tool button to open the 'Edit Engine Data' dialogue.
Fig. 4-1. The PMI Setup 'Edit Engine Data - Torsion' dialogue
4. Select the 'Torsion' index card to open the dialogue shown in Fig. 4-1
and set the 'Trigger System' section of the dialogue as follows:
• Fore: Activate this button if the fore end of the engine crankshaft is
fitted with an Angle Encoder for triggering the PMI System.
• Aft: Activate this button if a Proximity Pickup and Trigger Ring are
mounted at the drive end (normally aft) of the crankshaft for trig-
gering the PMI System. In addition, key in the following data:
• The diameter of the drive shaft. Units: metre
• The distance of the turning wheel to the trigger ring. Units:
metre.
5. Click the 'OK' button to save your changes and exit the dialogue, and
then click on the 'Open' button to open the engine and return to the
PMI Setup program window.
The name of the appropriate engine should now appear in the title bar
of the PMI Setup program window.
6. Select 'System' in the 'Setup' menu to open the dialogue shown in
Fig. 4-2.
7. Check that the PC Communication Port to which the PMI Master Com-
munication Unit is connected matches the setting chosen in the 'System
Setup' dialogue. If not, change the dialogue setting so that it matches.
11. Check that the 'Slave Exists' check box in the 'Communication Setup'
dialogue is blank or checked according to whether your PMI System
includes both a Master and a Slave Communication Unit and then click
13. Set the 'General' section of the 'Measuring Setup' dialogue as indicated
in Table 4-1. overleaf for the particular type of crankshaft trigger sys-
tem installed on your engine.
Note: The signal output and percentage measuring range limit set-
tings given at the bottom of the 'Measuring Setup' dialogue are
fixed according to the particular cylinder sensor, calibration trans-
When triggering is stable only one count will be displayed. You can
then proceed with step 19 of this procedure.
If triggering is unstable, then the latest four counts will be listed.
See below to help determine the cause.
• No. of pulses stored for engine: The crank angle pulse count. Zero
is indicated for the first test.
• Pulse deviation (min./max): Gives the min. and max. percentage
deviation of the crank angle pulses relative to their mean repetition
time.
Large deviations normally indicate that the pickup is slipping, is
not rigidly fixed, or is damaged and needs to be replaced. See User
Guide for the particular device.
To obtain a graphic view of the trigger pulse deviation, click on the
'Display' button in the dialogue. See Fig. 4-6.
• TDC pulse relative to trigger pulse: Gives the percentage overlap
and non overlap of the crank angle pulse that is closest to the trail-
ing edge of the TDC pulse (see Fig. 4-7).
If either of the readings is less than 15 % or greater than 85 %, then
the pickup is not correctly adjusted or is defective. See User Guide
for the particular device.
TDC Pulse
18. To repeat the Trigger Test, click on the 'Repeat' button in the dialogue.
19. When a stable trigger pulse count is obtained, click on the 'Save' button
in the dialogue. This will store the count for use in subsequent tests.
After storing a count, click on the 'Close' button to close the dialogue
return to the main window.
5. Connect the Calibration Transducer to the PMI Control Box and the
multipole plug of the Control Box to the Calibration Junction Box
located in the engine room. See Fig. 1-2 and 3-2.
Caution: Always connect the Transducer to the Control Box before
connecting the Control Box to the Junction Box. Connecting the
Transducer while powering the Control Box can damage the Con-
trol Box.
6. Select 'Communication On' in the 'Communication' menu.
The status line at the bottom of the screen will now state 'Communica-
tion On'.
To check communication, select 'Test Connection > Master Unit/Slave
Unit' in the 'Communication' menu.
If the status line indicates no connection or communication error, check
the cabling from the PC to the PMI Communication Units and on to the
engine.
If the status line indicates too many or too few trigger pulses then select
'Test Trigger System' in the 'Communication' menu and follow the in-
structions given in step 17, 18 and 19 of section 4.1.
7. Select 'Download > Setup' to download the complete communication
and measurement setup to the PMI Communication Units.
8. Set the fuel pump index to zero (or lift the fuel pump roller guide,
depending on the type of engine) to shut off the fuel oil to the first cyl-
inder to be measured (e.g. Cylinder No. 1) and wait for approximately
20 seconds.
9. Mount the Calibration Transducer on the indicator cock of the cylinder
and open the indicator cock.
The system is ready for measurements when the 'Start' button on the
PMI Control Box is lit.
10. Press the green 'Start' button on the Control Box to start the measure-
ment.
The green light will then be extinguished for a period and then light
again when the measurement has been completed.
11. Immediately close the indicator cock when the measurement has been
completed and return the fuel pump index to its original setting (or
lower the fuel pump roller, depending on the type of engine).
12. Remove the Transducer from the indicator cock and mount it on the
indicator cock of the next cylinder to be measured.
! Warning: Always check that the indicator cock is closed
before removing the transducer. Failure to do this can result in
release of extremely hot combustion gasses which can severely
injure personnel.
13. Repeat step 8 to 13 until you have completed measurements on all cyl-
inders.
14. Return to the PC and stop measurements either by selecting 'Calibra-
tion > End' in the 'Communications' menu or by pressing the Esc. key
on the keyboard.
Stopping measurements displays the 'Save Manual Measurement As' di-
logue. This automatically allocates a file name to the measurement and
stores it in the directory for the current engine when the 'Save' button is
activated.
In the particular case of the 'Calibration' mode of the Setup program,
two sets of measurements are taken simultaneously. One set includes
observations taken with the Calibration Transducer and the other set in-
cludes observations taken with the respective sensors built into the cyl-
inder covers of the engine. These are named as indicated in the
following example:
k010121_103509
s010121_103509
where the first character 'k' / 's' indicates the type of calibration meas-
urement, the next six characters the date and the last six characters the
time that the measurement was saved.
Initially all new calibration measurements are listed with the letter 'k'
and 's' for transducer and cylinder sensor, followed by the date and time
of storage, e.g. k010122_103321, s010122_103321. See Fig. 4-8.
Fig. 4-8. The 'View Measurement' dialogue as viewed with the 'List'
function
2. Select the 'K' - 0-Diagram measurement and then activate the 'Observa-
tions' tool button in the dialogue or right-click in the dialogue.
The 'Observations...' button opens the dialogue shown in Fig. 4-9.
By clicking on the '+/-' symbol at the start of each cylinder heading you
can expand or contract a heading.
To examine an observation, click on its heading. Its pressure curve
is then displayed on the right-hand side of the dialogue.
3. Check that there is one observation for each cylinder and that their
pressure curves have the approximate shape and form as indicated in
Fig. 4-9 for 0-Diagram measurements (or Fig. 4-10 for all other meas-
urements including calibration measurements).
4. If one or more observations are missing or are not correct, then the
entire measurement should be deleted and a new measurement taken
before proceeding further with this procedure.
To delete the measurement, click the 'Close' button and then activate the
'Delete' button in the 'View Measurement' dialogue.
5. When all curves are correct, click the 'Close' button to return to the
'View Measurement' dialogue and then open the measurement by click-
ing the 'Open' button.
6. Next select 'Calculated Values' in the 'View' menu and check that the
mean indicated pressure pi for each cylinder is negative. See Fig. 4-11.
• The index has been set to zero, but leaking fuel valves result in
combustion or heating of fuel oil in the cylinder.
In each case the measurement must be repeated after correcting the most
likely cause of the problem.
7. Return to the 'View Measurement' dialogue and then activate the 'Edit'
command in the toolbar of the dialogue.
This opens the 'Edit Measurement' dialogue shown in Fig. 4-12.
10. Key in the appropriate value for the scavenge air pressure of the engine
in the 'p(scav):' data field and press the 'OK' button to close the 'Edit'
dialogue and save your changes to the reference measurements.
Note: If no scavenge air pressure reading is available, then the pro-
gram itself will automatically estimate it. For this purpose the
'p(scav):' data field should be kept set at “0.00”.
11. Repeat items 1 to 10 first for the 'k' - E-Load measurement and then for
the 'k' and 's' transducer/sensor calibration measurements.
Note: The check in step 6 concerns 0-Diagram measurements only,
and for E-Load and other calibration measurements should be
ignored.'
In this case it is recommended that transducer/sensor calibration meas-
urements retain their original names and that the 'k' - E-Load measure-
ment be renamed as follows:
ELOAD_70_010122_1043
12. Click the 'Close' button to exit the 'View Measurement' dialogue and
then select 'Open Engine' in the 'File' menu and activate the 'Edit' but-
ton in the tabular of the 'Open Engine' dialogue.
This in turn opens the 'Edit Engine Data' dialogue shown in Fig. 4-13.
13. Open the respective 'Default' list boxes at the bottom of the dialogue
and set them to indicate the latest transducer, sensor, 0-Diagram and E-
Load measurements. See Fig. 4-13.
14. Press the 'OK' button to exit both the 'Edit Engine Data' and 'Open
Engine' dialogues and store your new default settings.
15. Select 'Download > Calibration' in the 'Communication' menu to down-
load the data to the PMI communication units.
Normally download takes several minutes or more to complete, so
please be patient.
Important Note: The communication units retain the calibration
data until the next time a new set of calibration data is downloaded.
Sensor
Cable
Cable Clips
Power Supply & Bracket
Connector
Braided
Protection Sleeve
3. Unscrew the end of the braided Protection Sleeve from the end of the
Armoured Outlet.
4. Carefully slide out the Sensor Cable from the Connection Box and Pro-
tection Sleeve.
5. Unscrew the Armoured Outlet from the Sensor bore hole and slide the
outlet over the free end of the Sensor Cable.
6. Thread the free end of the Sensor Cable through the hole inside the
Sensor Mounting Tool and use the tool to unscrew the faulty sensor.
7. Remove the faulty sensor and fit a new sensor to the end of the Mount-
ing Tool with its cable passing through the centre of the tool.
8. Insert the sensor and Mounting Tool in the bore hole from which the
faulty sensor was removed and lightly screw it fast so that it makes
contact with the end of the bore.
9. Turn the tool back (anticlockwise) one turn and connect the Sensor
Cable to the Preloading Measuring Instrument.
10. Switch the instrument ’On' and tighten the sensor until the display
shows - 40.
11. Remove the Measuring Instrument and Mounting Tool.
12. Thread the Sensor Cable through the hole in the Armoured Outlet and
screw the outlet fast.
13. Disconnect the Measuring Instrument and thread the Sensor Cable
through the braided Protection Sleeve,
14. Thread the cable back and forth between the cable clips in the Connec-
tion Box and then fasten the end of the cable in the box as indicated in
Fig. 4-14.
15. Finally replace the lid of the Connection Box and screw the end of the
braided Protection Sleeve back on the end of the Armoured Outlet.
In this Chapter
• PMI On-line Analyser .................. 5-2 • PMI On-line Setup ........................ 5 - 6
File Menu ....................................... 5-2 File Menu ........................................ 5 - 6
View Menu ..................................... 5-3 Setup ............................................... 5 - 6
Tools Menu..................................... 5-3 Communication............................... 5 - 7
Help ................................................ 5-4 Help................................................. 5 - 8
5.1.4 Help
The PMI System provides several ways of getting 'On-line Help'. You can
use either the 'Help' menu or the function key F1.
Help Menu
To help you determine which menu commands are used to access specific
topics, the respective menu commands are listed below:
• Contents: Displays the 'Help Contents'. This is the most detailed
source of information and clicking on the respective items listed pro-
vides information on the following topics:
• Using Help: How to use the Windows Help System together with
the PMI System’s 'On-line Help'. Also, includes Windows Help
Index and search engine for finding specific topics.
• Screen: The PMI System screen structure, including definitions of
its main components.
• Commands: The PMI System commands, keyboard and mouse
functions, menus and toolbar.
• Tools: The function of the different buttons seen in the 'Toolbar' of
the PMI System.
• How to...: The operating instructions for using the PMI application
software and hardware.
• Keyboard: The keys and key combinations associated with the
PMI System commands.
• Glossary: A glossary explaining the PMI System and other related
terms.
At the top of the 'Help Contents' window is a row of five keys. These
select the following:
• Help Topics: Opens the 'PMI Index and Find' dialogue, enabling
you to search for and display any topic by keying in its name or by
clicking on a topic listed in the dialogue.
Function Key F1
Whenever in doubt about any command or function that you are using,
press the Function Key F1 at the top of the keyboard. This will immedi-
ately provide you with context sensitive help information about the partic-
ular command or function that you are using in the particular situation that
you are using it.
To access context sensitive information about a menu item, you can use
either the keyboard alone or the mouse together with the keyboard.
To use the keyboard, first press the 'Alt' key and the first letter of the main
menu that you wish to examine, and then use the arrow keys to select the
particular command of interest in the menu and press the 'F1' key to acti-
vate context sensitive help.
If you use the mouse, click on the name of the main menu and while keep-
ing the mouse button pressed, select the command of interest and press the
function key 'F1' on the keyboard.
Note: Keep the mouse button pressed until you have activated the 'F1'
key.
Similarly you can also get context sensitive help on other items displayed
in the main window, e.g. views, menus, dialogues, etc. In addition, by
pointing the mouse at the buttons in the Toolbar you can obtain hints about
the purpose of the individual buttons. These are flagged just below each
button and explain what will happen when you click on a tool.
5.2.2 Setup
• System ... : Opens the 'System Setup' dialogue displaying the current
system setup. It allows you to specify the communication port, trans-
ducer calibration and trigger check and reset limits.
5.2.3 Communication
• Communication On - Off: For enabling ('' mark beside menu item)
and disabling communication between the PMI Analyser and the
engine. If the program fails to establish communication, then it is auto-
matically set 'Off-line' for viewing stored measurements.
• Test Connection: For checking communication with the master/slave
units.
• Download: Down loads the 'Setup' and 'Calibration' data for the cur-
rently open engine.
• Calibration:
• Start: Opens the 'Measurement Status' view and starts the off-line
measurement sequence for calibration.
• End: Ends the off-line calibration measurement sequence.
Shortcut: Press Escape key.
• On-line Values: Initiates reading of the current pi, pcomp, pmax, meas-
uring status, engine speed and pscav of the currently selected engine,
via its built-in sensors.
The calculated values dialogue appears when the values have been suc-
cessfully read. The dialogue displays both cylinder pressure and engine
related values.
• Capture: Initiates recording of a full set of raw pressure curves for the
currently selected engine via its built-in sensors.
5.2.4 Help
Has the same commands as the On-line PMI Analyser program. See sec-
tion 5.1 for details.
In this Appendix
• Technical Specification.................. A-2 • Care & Handling of Equipment ...A-3
On-line PMI System........................ A-2 • Technical Assistance ......................A-5
Computer Requirements.................. A-2
Hardware:
To obtain full advantage of the PMI System and its many features, MAN
B&W Diesel recommends the following minimum system configuration:
Software:
• Microsoft® Windows NT (vs. 4.0 or later), Windows 98™or later
• Handling:
Avoid hitting or dropping the transducer as this can subject it to me-
chanical shock well outside its design limits and can severely damage it.
• Mounting:
Avoid over tightening the transducer when mounting it on the cylinder
indicator cock. Always tighten it by hand without using a spanner. Also,
only open and close the indicator cock whilst the transducer is connect-
ed and always remove the transducer immediately after completing
each measurement.
Warning! Leaving the transducer permanently mounted on the
indicator cock will severely damage it.
• Connections:
The output connecter of the calibration transducer, including the corre-
sponding plugs and sockets of the connecting cable and the PMI Control
Box, should be kept clean and free of oil and grease at all times. When
not in use they should be fitted with the plastic protection caps provided.
The multipole connector used to couple the PMI Control Box to the
Junction Box should be treated with care. Whenever plugging or un-
plugging it from the Control Box, it is important to turn the outer part
of the connector so as to lock or unlock it from the Control Box. Avoid
using tools on the connector.
If the connectors need cleaning, then only use dry, chemically clean,
pressurised air, such as that used for cleaning photographic equipment.
Caution: Never use compressed air from ship or generator plant
outlets as they contain oil. Similarly, avoid using chemical cleaning
agents, as they will damage the ultra high impedance insulation of
the connectors and cable.
• Calibration:
If at any time the transducer has to be replaced, then the PMI System
must be readjusted in accordance with the sensitivity of the new trans-
ducer. See Chapter 4 for details.
Glossary of Terms
Adjustment Limits:
Preset 'Edit Engine Data' defining the maximum pressure adjustment
limits of an engine selected with the 'Open Engine' command in the
'File' menu of the PMI Setup program. The data can be viewed using the
'Open Engine' – 'Edit' function. The properties indicated are:
p(i): The maximum acceptable positive or negative deviation in mean
indicated pressure allowed between any two cylinders. Units: bar.
p(max): The maximum acceptable positive or negative deviation in
maximum pressure allowed between any two cylinders. Units: bar.
Balance Plot:
A histogram displaying balance values, e.g. cylinder pressure data, etc.
Bore:
The diameter of the cylinder. Units: metre.
Calculated Values:
Values derived on the basis of PMI System measurements, e.g. effective
engine power, pressure deviations and proposed adjustments.
Communication Setup:
A 'Setup' dialogue available with the 'Setup' menu of the PMI Setup pro-
gram. It gives the master/slave input/output addresses, as well as links
cylinders to communication unit channels. The settings are:
Input/Output Addresses: For setting up the Block Command, Ready
to Measure Lamp, Error Lamp and Start to Measure Button addresses
on the Master and Slave Communication Units.
Link Cylinder to PMI Unit/Channel: For setting up which engine cyl-
inders are linked to channels 1 to 6 of the Master Communication Unit
and channels 1 to 8 of the Slave Communication Unit if connected.
Channels 7 and 8 of the Master Unit are reserved for p(scav) and calibra-
tion box signals.
Activating 'Default' selects the settings applicable for the specified en-
gine at the time of installation of the On-line PMI System. Normally,
these settings should not be changed.
Compression Pressure:
The pressure developed in a cylinder at TDC. Units: bar
Connecting Rod:
The rod coupling the piston with the crankshaft. The length of the rod
is defined as the distance between the centres of the bores at either end
of the rod. Units: metre.
Crank Angle:
The angle in degrees turned by the crankshaft.
Crank Angle: The angular position of the end of a search band for the
TDC’s of the respective cylinders of the engine.
As rule of thumb, this end position lies ((360 / 2* number of cylinders)
+ five) degrees after the nominal position of the cylinder’s TDC.
Firing Order: The sequence in which the respective cylinders of the
engine fire.
Effective Power:
The power developed by an engine minus the power loss due to friction,
etc. Units: ekW or bhp.
E-Load:
Pressure diagram based on pressure measurements on each cylinder tak-
en under stable conditions at an engine load of 50 to 75%, equally dis-
tributed on all cylinders.
The E-Load diagram is used for torsion correction when determining
the TDC of each cylinder.
Engine Properties:
Preset 'Edit Engine Data' defining the general properties of an engine se-
lected with the 'Open Engine' command in the 'File' menu of the PMI
Setup program. The data can be viewed using the 'Open Engine' – 'Edit'
function and lists the following properties:
Bore: The diameter of the engine cylinders. Units: metre.
Stroke: The length of travel of the piston. Units: metre.
Connecting Rod: The distance between the centres of the cross pin and
crank bearings at either end of the rod. Units: metre.
Kpcomp/pscav: The ratio of cylinder compression and scavenge air pres-
sure.
Ploss: The mean pressure loss due to friction in the engine. Units: bar.
Engine Speed:
The rotation velocity of the crankshaft, expressed in revolutions per
minute. Units: rpm.
Firing Order:
The sequence in which the cylinders fire.
Index (Adjustment):
A value used to express the amount of fuel oil injected into an engine
cylinder for adjusting the pi.
Measuring Settings:
A 'Setup' dialogue available with the 'Setup' menu of the PMI Setup pro-
gram. It allows you to specify the trigger and transducer system require-
ments, etc. The settings are:
Trigger Type: PMI system triggers on the rise (low/high), decay (high/
low) or both rise and decay (double) slope of the trigger signal from the
crank angle pickup.
TDC Type: PMI system triggers on the rise (High/Low) or the fall
(Low/High) of the TDC trigger pulse.
No. of Pulses: The number of crank angle pulses detected per work cy-
cle. Depends on 'Trigger Type' and type of crank angle pickup used for
triggering the system.
Trigger Timeout: The minimum elapse time, when there is a loss of
trigger signal, required to activate a 'Trigger Timeout' warning. Units:
ms, i.e. milliseconds.
p(scav) Limit: The maximum measurement range of the scavenge air
pressure sensor. Units: Bar
Cylinders / Transducer / p(scav): Selects type of signal output by the
cylinder sensors and their charge amplifiers, the calibration transducer
and the scavenge air pressure sensor, i.e. PMI 0 – 5 V, ± 5 V, 0– 20 mA
or 4 – 20 mA (Default 4 – 20 mA).
High/Low set upper and lower limit of measuring range as a percentage
of the max. signal output of the cylinder sensors and the calibration and
scavenge air transducers/amplifiers.
MIP:
Abbreviated term referring to mean indicated pressure p(i) or pi
O-Diagram:
Pressure diagram based on pressure measurement on each cylinder tak-
en at an engine load of 50 to 75% without fuel injection (hence without
combustion) in the cylinder.
The 0-diagram is used when determining the TDC of each cylinder.
p(i) Adjustments:
Preset 'Edit Engine Data' defining the index adjustment properties of an
engine selected with the 'Open Engine' command in the 'File' menu of
the PMI Setup program. The data can be viewed using the 'Open Engine'
– 'Edit' function. The properties indicated are:
p(max) Adjustment:
Preset 'Edit Engine Data' defining the index adjustment properties of an
engine selected with the 'Open Engine' command in the 'File' menu of
the PMI Setup program. The data can be viewed using the 'Open Engine'
– 'Edit' function. The properties indicated are:
bar/Shim: The change in maximum pressure caused by inserting or re-
moving one shim to increase or decrease the Fuel Pump Index.
Rotation of Link:
The number of turns required to obtain a certain displacement of the in-
dex rod.
PT Diagram:
Pressure vs. time diagram (draw diagram) showing the change in cylin-
der pressure as a function of the angular position of the cylinder's TDC.
PV Diagram:
Pressure volume diagram (indicator or working diagram, banana curve,
etc.) showing the change in cylinder pressure as a function of the rela-
tive cylinder volume. The relative cylinder volume is 0% at TDC and
100% at BDC.
Shim Adjustment:
The number of shims to be added or removed in a fuel pump for adjust-
ing pmax.
Stroke:
The length of travel of the piston from TDC to BDC. Units: metre.
System Setup:
A 'Setup' dialogue available with the 'Setup' menu of the PMI Setup pro-
gram. It allows you to specify the communication port, transducer cali-
bration and trigger check and reset limits. The settings are:
Communication Port: 1, 2, 3 or 4, depending on which port of the PC
is coupled to the Converter Box of the PMI System.
Transducer Value: The calibration transducer sensitivity at 20 - 23 ° C
and 250 bar, as specified on the calibration chart supplied with the
transducer.
Averaging Period: Sets the number of work cycles over which meas-
urements are averaged. Should normally be set for averaging over 10
work cycles.
Check Limits: 'High' and 'Low' range limits as a percentage of the max-
imum output signal, above and below which the pressure signal is
classed as being out of range.
Threshold: The minimum measurable pressure signal expressed as a
percentage of the difference between the maximum and minimum out-
put signal.
Reset Limits: Maximum and minimum limits within the check limit
range, above and below which the pressure signal is automatically reset.
Torsion:
The state of strain set up in a body by twisting or applying a torque.
Units: nRad/Nm.
Torsion Coefficients:
Preset 'Edit Engine Data' defining the torsional deflection properties of
an engine selected with the 'Open Engine' command in the 'File' menu
of the PMI Setup program. The data can be viewed using the 'Open En-
gine' – 'Edit' function. The properties indicated are:
Torsion Coefficient: The torsion coefficients of each section or group
of sub sections of the crankshaft, starting from the fore end of the crank-
shaft to cylinder No. 1 (i.e. ->1), between cylinder No. 1 & 2 (i.e. 1->2),
cylinder No. 2 & 3 (i.e. 2->3), cylinder No. 3 & 4 (i.e. 3->4) etc., up to
the turning wheel (i.e. -> Turn). Units: nRad/Nm.
The values stated are fixed and are based on MAN B&W Diesel's own
mechanical design and measurement criteria.
VIT (Adjustment):
Variable Injection Timing. A method of controlling the timing of fuel
oil injected into an engine cylinder for adjusting pmax.
Work Cycle:
On two-stroke engines a work cycle is normally defined as one full rev-
olution of the crankshaft.