AVL DITEST DPM 800, User Manual

Page 1: ...USER MANUAL AVL DITEST DPM 800 ID number AT7639E Revision 02 Issued 03 2018 Data subject to alteration All data valid at time of printing FUTURE SOLUTIONS FOR TODAY ...

Page 2: ... rights reserved The contents of this publication as a whole or in part may not be reproduced in any form or passed on to third parties without the prior written consent of AVL DiTEST This publication was written exercising reasonable care AVL DiTEST can therefore not accept any liability whatsoever for any errors or omissions as well as for any possible damage ...

Page 3: ...equired safety measures when using and operating the equipment It may only be operated with the accessories and consumables supplied by DITEST or approved by DITEST Since with this product the measuring results not only depend on proper functioning of the product but also on a number of further conditions it is necessary to have the results generated by the product checked e g plausibility check b...

Page 4: ...Warnings and safety information AVL DiTEST DPM 800 II User manual ...

Page 5: ...ng high voltage Do not touch the ignition system while engine is running Danger of electric shock on vehicles with xenon headlight The lighting system with xenon headlight is under life threatening high voltage Do not touch any component while the xenon light is switched on Danger due to harmful or irritating substances Tests with engine running in closed rooms workshops test halls etc the exhaust...

Page 6: ...tion only with approved testing device Disconnect the battery when working on the airbag system When disconnecting the battery the ignition has to be switched off and there should be nobody in the passenger compartment Always store dismounted airbag unit with discharge area up or according to the storage instructions Airbag unit should never be left unattended Protect airbag unit against flying sp...

Page 7: ...r The correct choice of electrode gap substantially affects the ignition voltage required Turbocharged supercharged engines When turbocharged supercharged engines are operating at very high boost pressures the required ignition voltage is higher This can be counteracted by reducing the electrode gap approx 0 5 mm Due to the special construction of the piezo electric pressure sensing sparkplug the ...

Page 8: ...Safety information AVL DiTEST DPM 800 VI User manual ...

Page 9: ...ctivating the AVL DiTEST DPM 800 with the AVL DiScope 802 present 2 3 3 Measuring 3 1 3 1 Taking a reading 3 1 3 1 1 Setting the pressure sensor sensitivity 3 7 3 1 2 Determining TDC 3 8 3 1 3 Signal representation 3 11 3 1 4 Markings 3 11 3 1 5 Setting DC offset in bar 3 11 3 2 Tips on testing 3 12 3 3 Testing while the car is being driven 3 12 3 4 AVL DiTEST DPM 800 Connection Box 3 12 4 Care an...

Page 10: ...Contents AVL DiTEST DPM 800 VIII User manual ...

Page 11: ...e pressure progression in relation to the crankshaft position with the aid of the on board TDC engine speed sensor Measurement of the internal cylinder pressure can provide the following relative readings indicated mean pressure of the cylinder tested pmi maximum pressure of the cylinder tested pmax position relative to engine TDC at which maximum pressure is achieved in the cylinder tested pmax T...

Page 12: ...angerous risk which if not prevented leads to death Indicates an imminent danger if not prevented can result in death or serious injury Indicate a danger that may lead to moderate or light injuries Additional danger signal Danger due to electrical current Notice This text draws attention to situations or operating error that can lead to property damage or loss of data Information This text indicat...

Page 13: ...conditions Menu Menu item Selection of menu command through tapping on buttons List formats 1 2 Step by step instructions in a specified sequence Instructions consisting of only one step Listings without a specific order 1 4 Operation of PC programs This manual assumes basic knowledge of Microsoft Windows Please turn to your Windows manual for details If necessary contact your PC support system ad...

Page 14: ...General introduction AVL DiTEST DPM 800 1 4 User manual ...

Page 15: ...Installation 5 If not previously installed install Windows Installer 4 5 for your operating system Vista or XP 6 Restart the AVL DiX PC 7 Repeat steps 3 and 4 8 If not previously installed install NET Framework 3 5 9 Restart the AVL DiX PC 10 Repeat steps 3 and 4 11 Click English and then AVL DiX Installation 12 Click DiX Installation 13 Accept the licence agreement 14 Select the version for your ...

Page 16: ...aller 4 5 for your operating system Vista or XP 6 Restart the AVL DiX PC 7 Repeat steps 3 and 4 8 If not previously installed install NET Framework 3 5 9 Restart the AVL DiX PC 10 Repeat steps 3 and 4 11 Click DiX Installation 12 Accept the licence agreement 13 Select the version for your country 14 Select Measuring and testing 15 Confirm each step by pressing Next or OK 16 Select Update 17 Restar...

Page 17: ...system I Licence 5 Click F2 File 6 Insert the disk CD in the drive 7 Select the licence file lic for the dongle 8 Click Open 9 The screen Licence Update appears Click Transfer licence to dongle 10 Clicking Shows the contents of the dongle shows the contents of the dongle which should include the following entries LIC SCOPE XA7003 LIC DIX SCOPE DPM XA7038 11 Finish activation of the AVL DiTEST DPM ...

Page 18: ...Initial use AVL DiTEST DPM 800 2 4 User manual ...

Page 19: ...pass through the socket without being damaged Fig 3 1 4 Carefully screw the piezo electric pressure sensing sparkplug glowplug pressure sensor adaptor carefully into the engine Take care not to damage the lead 5 Carefully route the lead for the piezo electric pressure sensing sparkplug glow plug pressure sensor adaptor through the engine compartment Route the leads so that they do not come into co...

Page 20: ...sensor adaptor to the AVL DiTEST DPM 800 amplifier D see Fig 3 2 Take care not to cross the thread when screwing on the lead Fig 3 2 7 Screw the lead from the AVL DiTEST DPM 800 power supply unit SIGNAL OUT connection E to the AVL DiTEST DPM 800 amplifier D see Fig 3 3 Take care not to cross the thread when screwing on the lead Fig 3 3 C D E D ...

Page 21: ...unit using the connecting lead F see Fig 3 4 Fig 3 4 9 Connect the on board engine speed TDC sensor to connection CH2 I on the AVL DiScope 802 Wire the on board engine speed TDC sensor connection parallel i e without disconnecting the wiring loom 10 Switch on the AVL DiTEST DPM 800 power supply unit at the ON OFF switch G The PWR LED H should show blue F G H I ...

Page 22: ... test I Enginetest I Petrol if testing cylinder pressure with the piezo electric pressure sensing sparkplug or Diesel if testing cylinder pressure with the piezo electric glow plug pressure sensor adaptor see Fig 3 5 Fig 3 5 13 Select the mode Cylinder Pressure I Piezo spark plug Piezo glow plug for diesel engines see Fig 3 6 Fig 3 6 14 Click F8 Next ...

Page 23: ... offset if known and select the number of strokes per engine cycle see Fig 3 7 Only by entering the correct TDC offset can meaningful readings be obtained You can find out the TDC offset Proceed as described in Section 3 1 2 Determining TDC Fig 3 7 Information ...

Page 24: ... pressure i e essentially it is the averaged surplus pressure prevailing between 0 and 180 of crankshaft rotation see B Max pressure pmax The maximum pressure in the example 7 5 bar see C pmax TDC The crankshaft angle at which the maximum pressure occurs relative to the engine s TDC in the example 0 8 of crankshaft rotation see D RPM The engine speed while taking the pressure readings in the examp...

Page 25: ...140 BAR 16 24 pC BAR 0 200 BAR 16 25 pC BAR see Fig 3 9 Fig 3 9 2 On the results graph screen display mode see Fig 3 8 click F8 Switching 3 In the box bar mV enter the rounded figure see above in the example shown 16mV 16 24pC BAR 16mV Explanation The charge amplifier used has a signal voltage charge ratio of 1mV per pC pico coulomb If the pressure sensor produces a charge of 16 24 pC at 1 bar pre...

Page 26: ...he engine to a high speed and then releasing the accelerator On the road it is done by driving downhill with your foot off the accelerator In addition if possible you can also shut off fuel injection into the cylinder being tested by electrically disabling the fuel injector e g by unplugging the lead 2 Stop the test by clicking F2 Freeze 3 Using the button scroll back to when the cylinder was firi...

Page 27: ...dent negative pressure following gas expansion after TDC see Fig 3 12 Fig 3 12 5 Activate TDC detection by clicking Green colour indicates reference marker detected and related to TDC Red colour indicates reference marker not detected reference marker could not be related to TDC TDC detection could not be completed If the reference marker is detected and related to TDC the internal cylinder pressu...

Page 28: ...L DiTEST DPM 800 3 10 User manual By selecting the option box you can display cursors marking the maximum pressure and the detected reference marker position of the on board engine speed TDC sensor signal Fig 3 13 ...

Page 29: ...marking the maximum pressure and the detected reference marker position of the on board engine speed TDC sensor signal 3 1 5 Setting DC offset in bar Starting from the results screen display mode see Fig 3 8 proceed as follows 1 Click F8 Switching to change to settings mode The default setting is 31 8 bar it is based on an amplifier offset voltage of 500 mV and an average pressure sensor sensitivi...

Page 30: ...n The throttle losses are different when the engine is idling as the intake air flow is much more dynamic The maximum cylinder pressure drops to a substantial degree e g 5 6 bar 3 3 Testing while the car is being driven Risk of injury Never take readings when driving the car alone Driver drives passenger takes readings Route the leads through the car so that they do not come into contact with any ...

Page 31: ...daptor the adaptor socket and all leads for damage and dirt contamination 4 2 Cleaning Before cleaning the AVL DiTEST DPM 800 disconnect all leads and switch off the AVL DiTEST DPM 800 amplifier Only clean the AVL DiTEST DPM 800 with a dry cloth Do not use any cleaning agents or solvents 4 3 Replacing the battery 1 Switch off the AVL DiTEST DPM 800 Connection Box at the ON OFF switch K 2 Unscrew t...

Page 32: ...ery cover N on the back of the AVL DiTEST DPM 800 Connection Box downwards Fig 4 2 4 Take out the battery O and disconnect the terminals P Connect a new battery and insert it in the AVL DiTEST DPM 800 power supply unit Fig 4 3 5 Carefully replace the cover see Section 3 Fig 4 2 N P O ...

Page 33: ... Connection Box not including 9V PP3 battery BO7725 Battery 9V PP3 E HI0001 AVL DiTEST DPM 800 amplifier GG1407 Adaptor socket to fit piezo electric pressure sensing sparkplug or glow plug pressure sensor adaptor ordered E g GG7405 or WG0140 or WG0200 Piezo electric pressure sensing sparkplug or glow plug pressure sensor adaptor ordered Lead BNC 0 5m black RG 58 EX7528 DiX software CD BO7340 DiX m...

Page 34: ...Product specifications AVL DiTEST DPM 800 5 2 User manual ...

Page 35: ...tration of moisture e g water oil acids etc External intervention e g repairs carried out by non authorized people Improper operation e g control of touch screen with sharp or pointed object cleaning with compressed air Improper storage care and maintenance e g cleaning the device with solvent based cleaners 6 2 Exchange or loaned devices The agreements with your supplier apply For the execution t...

Page 36: ...Warranty AVL DiTEST DPM 800 6 2 User manual ...

Page 37: ...ssure sensor manufactured to customer specifications Order form AT7656D E Adaptor socket Adaptor socket Adaptor socket for fitting the piezo electric pressure sensing sparkplug with slot for the pressure sensor lead AVL DiTEST DPM 800 Connection Box Dimensions WxHxD 60x120x20mm Weight Approx 500g Operating temperature 5 35 C Transportation temperature 25 60 C Power supply 9V PP3 battery supplied C...

Page 38: ... length x dia 131x13 8mm Plug M12 Connections Input Piezo electric pressure sensing sparkplug glow plug pressure sensor adaptor Outputs AVL DiScope 802 CH1 or CH2 CE mark CE mark The manufacturer hereby declares that the AVL DiTEST DPM 800 complies with the provisions of the EC Directives cited below including all relevant amendments EN 61010 1 Safety Requirements EN 61326 1 EMC 2006 95 EC Low vol...