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OPERATING INSTRUCTIONS PREMET
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Operating Instructions for the Electronic Indicator
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PREMET XL Edition 04.2008 subject to change without notice
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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PREMET XL Thank you for buying the LEMAG PREMET® XL electronic indicator. The technology and handling of the LEMAG PREMET® XL Indicator has been developed and designed for the future. It is easy to operate, to record, and to store peak pressure values from each cylinder for quick results, high accuracy and repeatability. The PREMET® XL can measure up to 30 peak pressures for 1-20 cylinders and calculate the statistical data. It also compensates for temperature changes prior to every measurement. The LEMAG PREMET® will provide you with essential data about your engines. The LEMAG PREMET® XL also features performances of the calculation of the mean indicated pressure, indicated power and combustion pressure and the correspondence between crank angle and pressure by using a TDC Sensor inductive or optional laser type. The standard equipment PREMET® XL includes an efficient working analysis software for Windows 9x/NT/XP. Reading the operating instructions will help you benefit from all the instruments functions. Our high quality PREMET® XL indicators can increase efficiency and will become a vital tool on board.
Safety Notice Please note that the exhausted gases are very dangerous and cause high temperatures and pressures. Therefore the connection between the indicator valve and the indicator must be absolutely gas tight. Please ensure that the connection nut on the indicator valve is completely fitted before opening. Before dismounting the PREMET® the indicator valve must be closed completely.
Temperature Range: For storage: For measuring:
-20° C up to +70° C 0° C and 50° C.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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Contents Chapter
Page
PART I 1. Switching on the Device ................................................................................................................. 4 2. Switching off the Device ................................................................................................................. 4 3. Preparing for Measurement ............................................................................................................ 5 3.1 Installing and checking the TDC-Sensor ................................................................................. 5 3.2. Installing the Optical Laser Sensor.......................................................................................... 5 3.3. Installing the Inductive TDC Sensor ........................................................................................ 7 3.4 How to test the Optical / Inductive TDC Sensor ....................................................................... 8 4. Setup Adjustments .......................................................................................................................... 10 5. Receiving SETUP from PC........................................................................................................... 16 6. Carrying out Measurements ......................................................................................................... 17 6.1. Measuring a Single Cylinder.................................................................................................. 17 6.2. Measuring all Cylinders ......................................................................................................... 18 7. Displaying Statistical Data ............................................................................................................ 20 7.1. Displaying Statistics for a Single Cylinder ............................................................................. 20 7.2. Displaying Statistics for all Cylinders..................................................................................... 21 8. Deleting Measured Values and Statistical Data of an Engine ........................................................ 22 8.1 Deleting all cylinder data......................................................................................................... 22 8.2 Deleting data for a single cylinder .......................................................................................... 22 9. Printing Statistics and Measurement Results ............................................................................... 24 10. Transmitting Statistical Data and Measured Values to a PC ........................................................ 25 11. Checking Sensor and Calibration ................................................................................................. 26 11.1 CHECK CALIB Function ....................................................................................................... 26 A) Valid only for serial no. 31000 onwards .................................................................... 26 B) Valid only for serial no. QH91E and QH91I models .................................................... 27 C) Valid only for serial no until 30999 .................................................................................... 29 11.2. NEW CALIB Function ............................................................................................... 29 11.3 TEMP CALIB Function ............................................................................................... 29 11.4 VOLTAGE CALIB Function................................................................................................... 29 12. Monitoring Temperature ............................................................................................................... 30 13. Recalibrating the PREMET® ......................................................................................................... 30 14. Internal Calibration Control ........................................................................................................... 31
PART II 1. Recharging PREMET® Batteries ................................................................................................. 32 2. Connecting the PREMET® Printer ................................................................................................ 33 3. Sending Data to the PC / receiving Data from PREMET® ............................................................ 33 4. Final Note...................................................................................................................................... 34
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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PART I 1.
Switching on the Device
Press the control button (position ON) to switch on the device. The following start-up screen will appear: LEMAG PREMET XL Vers.: 6.3x SN:12345 Press any key
- Firmware version and serial no.
Press any key to access the Main Operating Menu: SCAN ENGINE SHOW STATISTIC PRINT DATA SEND DATA TO PC
- Measurement on the engine - Display of mean values and statistics - Print out of measured values and curves - Sending measured values and statistical data to PC
Select a menu item u (↑) or DOWN (↓). Press ENTER ( ) to confirm.
2.
MANUAL SETUP RECEIVE SETUP CHECK TDCSENSOR CALIBRATE
- SETUP without PC - SETUP from PC - Check TDC Sensor - Check Calibration
DELETE DATA -----------------------------
- Delete all machine and SETUP data
Switching off the Device
Press the on / off button to switch off the device. The instrument must not be switched off during measurement or calculation, as unexpected changes of stored SETUP or measured cylinder pressures may occur. Once the device has been switched off, all SETUP values and all measured pressures are saved, even if the battery levels decrease. The instrument will switch off automatically if inactive for 5 minutes, except during measurements or checking the TDC-Sensor. The instrument should not be stored with the control button in ON position or with empty batteries. This will cause the batteries to deep discharge which can cause low capacity! Even if the instrument has not been used the batteries should be charged frequently!
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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Preparing for Measurement
3.1 Installing and checking the TDC-Sensor To determine the piston position and to relate the cylinder pressure to the crank shaft, the PREMET® XL needs a crank shaft angle sensor. There are two different types of LEMAG® sensors available: An inductive and an optic laser sensor. The inductive sensor is mostly used for permanent installation whilst the optional laser is used for mobile solutions. A laser sensor (3.2.) receives its signal as a reflection from a reflective tape on the flywheel. An inductive sensor (3.3.) receives its signal from a metallic marking which can e.g. be a screw nut.
3.2. Installing the Optical Laser Sensor The optical TDC laser-sensor should be mounted as close to the engine as possible to avoid errors caused by engine shaft twist. Please ensure that there is no elastic clutch between the engine and where the sensor is to be mounted. External direct light to the optic must be avoided. Do not mount the optical sensor where oil mist can occur. If necessary place a shade between the sensor and the source of oil. Fix an optical mark onto the fly wheel. It is recommended to use 5mm long strip of reflective tape. Mount the optical sensor opposite to the fly wheel. Slow turn the engine and watch the LED. The gap should be so adjusted that the LED only lights up when the mark is in front of the sensor and should be out if only the fly wheel is seen by the sensor. If necessary paint the fly wheel with black colour at the sensor position. The recommended gap between the laser sensor head and the fly wheel is 10 – 30 cm. Finally, run the engine and check the function CHECK TDC SENSOR. At this stage the PREMET® does not need to be connected to the indicator thread. The light emitting diode should flicker when engine is running. When the measurement has been completed, disconnect the laser sensor from the PREMET® XL so that the battery does not discharge over an inactive period. The advantage of the optical laser sensor over the inductive type is the larger possible gap between the sensor and the fly wheel. The disadvantage of the optical laser sensor is the sensitivity to direct light and pollution by oil. Please take this into when selecting where to install the sensor. If the sensor malfunctions (the LED is permanently on or off), clean the sensor’s optic from the outside and ensure that the cleaner does not harm the sensor housing. The optical TDC laser sensor is a direct replacement of the LEMAG® inductive type!
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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Security note: The installed laser uses a wavelength of about 670nm and has a power of <1mw. This is not normally critical for human eyes, but for health and safety reasons it is forbidden to look directly into the laser beam.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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3.3. Installing the Inductive TDC Sensor 1. Turn the engine until the first cylinder of the firing order (not always cylinder No. 1) is at the TDC (TOP DEAD CENTRE) position. 2. Mount the inductive TDC sensor close to the TDC mark/screw on the fly wheel. Please ensure that the area that sensor is to be attached does not vibrate. The distance between the TDC sensor and the TDC mark/screw should be 2 - 3mm. For high speed engines (over 500 rpm) the distance should be even smaller. We recommend marking the flywheel with a standard M6x10 Din 933 screw. The mark or screw nut must be at least 4 mm thick. 3. The trailing corner of the screw will be recognized as the TDC. 4. Connect the PREMET® XL and the TDC sensor with the provided cable. 5. When the mark es the TDC sensor the red LED will light up. Once the marking has ed the TDC sensor the light will go out.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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3.4 How to test the Optical / Inductive TDC Sensor The static test - slow turning the gear Switch on the PREMET® XL, and select CHECK TDC SENSOR, STATICALLY. following display will appear: CHECK TDC SENSOR Dynamically Statically < ESC ENTER
The
(Running engine) (Slow turning the gear)
Press ENTER to statically check TDC. The following text will be displayed briefly: STATUS OF INPUTS TDC = OFF (ON) Cancel with ESC
Once the mark is in front of the TDC sensor, ON will appear on the display. If not, check the cables and the distance of the sensor mark and sensor. Press ESC to finish the test.
The dynamic test with a running motor Select CHECK TDC SENSOR, DYNAMICALLY. The following display will appear: CHECK TDC SENSOR Dynamically < Statically ESC ENTER
(Running engine) (Slow turning the gear)
Once ENTER has been pressed the TDC will be dynamically checked. Then the rpm will be measured 3 times. CHECK TDC SENSOR PLEASE WAIT ESC ENTER
(measurement is being performed)
If the 3 measurements show a difference of > 5 % or no rpm is ed, the following warning will be shown: CHECK TDC SENSOR TDC SENSOR NOT OK ESC ENTER
(measurement was not successful)
If this message occurs please adjust the distance between the TDC sensor and the mark.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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If the sensor’s LED is permanently lit during the measurement, the distance between the mark and the sensor must be increased. If the LED does not light up at all, the distance between the mark and the sensor must be decreased. If the diode flashes sporadically, the distance is too large or the TDC sensor stand is vibrating. If the measurement was successful the following screen will appear: CHECK TDC SENSOR RPM= 127,5 ESC
The average engine speed (in this case 127,5 rev/min)
ENTER
It is recommended to carry out the dynamical test before every measurement, as the position and distance of the sensor and the mark may have changed. If you discover that your TDC mark is not in the right TDC position you can adjust the TDCSensor position in the PREMET® XL. To adjust the TDC-Sensor please switch on the PREMET® XL, select MANUAL SETUP using the arrow keys. Press ENTER for the following screen: MANUAL SETUP PARAMETERS CLOCK TDC CORRECTION
Select ”TDC CORRECTION” and confirm with ENTER To avoid unwanted changes to the SETUP the instrument will ask if changes are allowed (EDIT YES or NO) SETUP EDIT SETUP: ESC
NO ENTER
- select with UP- and DOWN keys YES or NO
Selecting YES will result in the following screen: SETUP TDC CORR: +000.0 x ESC ENTER
- 000.0 means, there is no difference between the Sensor Switch position and the TDC of cylinder no. 1
The TDC correction value must be +000.0. If the positioning of the mark is incorrect, an electronic correction can be made. Use the arrow keys to change the value. Press ENTER to change to the next figure. MANUAL SETUP PARAMETERS < CLOCK TDC CORRECTION
Confirm MANUAL SETUP with ENTER. made under PARAMETERS.
Any adjustments to the measurement can be
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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4. Setup Adjustments You must set up the PREMET® XL according to the actual engine data for measuring. The instrument will retain these settings until the operator makes new adjustments. It is possible to set up the instrument directly without a PC (MANUAL SETUP) or by ing a SETUP from PC (RECEIVE SETUP) MANUAL SETUP RECEIVE SETUP CHECK TDCSENSOR CALIBRATE
- Adjustment of PREMET® XL on the device - Take over adjustment of PREMET® from PC - Check TDC Sensor - Check Calibration
To set up the device select the menu item MANUAL SETUP from the Main Operating Menu and confirm with ENTER. Then select PARAMETERS, confirm with ENTER and then follow the menu. MANUAL SETUP PARAMETERS < CLOCK TDC CORRECTION
- selected item
On the next screen you can check the SETUP parameters or edit them. SETUP EDIT SETUP ESC
NO ENTER
- Change between YES or NO by using the UP and DOWN buttons
Select the measuring units for pressure on the following screen. Units are: for pressure p = bar ESC
- select bar/psi/Mpa or kg/cm² with the arrow keys ENTER
Select the unit and press ENTER. To select the measuring unit for indicated power: Units are: for power p = kW ESC
- select between kW and hp by using the arrow keys ENTER
Please select the unit and press ENTER. Select the charge air pressure value Pscav: SETUP Pscav = 0,0 bar * ESC ENTER LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
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OPERATING INSTRUCTIONS PREMET
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Use UP or DOWN to change the value of the charge air pressure. Press ENTER to save the charge air pressure value currently displayed on the screen. Background Information The PREMET® XL device relates all dynamic pressure readings (peak pressure and pressure curve, but not the pressure gauge readings) to the entered value for charge air pressure. Now select- 2- or 4- stroke-engines u or DOWN: SETUP 2/4 stroke: ESC
2 ENTER
Press ENTER to save the value currently displayed on the screen. The following screen will appear: LINE ENGINE YES ESC ENTER
- NO means V-engine, selection by using the arrows keys
Press ENTER to save the value currently displayed on the screen. If you select NO for the V-engine the following picture will appear: SETUP V-ANGLE 000.0 ESC
: x ENTER
Use UP or DOWN to change degree of V-angle. The X indicates which decimal is being altered. Press ENTER to move the X. Confirm with ENTER. Once you have entered the V-angle or selected “YES” for an in-line-engine the following display will appear: SETUP NO OF CYL: 06 ESC ENTER
Select with arrows keys between 1 to 20 cylinders
Press ENTER to save the value currently displayed. Press ESC to interrupt the SETUP procedure and return to the Main Operating Menu. Background Information The number of cylinders is required to determine mean engine values and to automatically assign readings to the appropriate cylinder
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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Once the number of cylinders has been confirmed with ENTER, you can enter the number of power strokes to be measured: SETUP NO OF WORKSTROKES : 10 ESC ENTER
Select with arrows keys between 1 to 30 work strokes
Press ENTER to save the value currently displayed. If the number of power strokes to be measured has been confirmed with ENTER, you can enter a limit value for the statistical calculation. This limit value sets a limit above and below the peak pressure of the cylinder. The statistics function calculates the percentage of measured power strokes which are within these limit values. SETUP DEV FROM MEAN Pmax=05.0 bar ESC ENTER
Select with arrows keys in steps of 0,5 bar
Press ENTER to save the value currently displayed. The following display will appear: TDC SENSOR ESC
YES
- Measurement with TDC-Sensor (YES or NO) Selection with the arrows keys
ENTER
If NO TDC Sensor is selected, the instrument will only measure the firing pressure over time without the option of calculating indicated power PIND and mean indicated pressure MIP or any other function in relation to the crank-angle. If you select “NO” and confirm with ENTER, the following screen will appear and give several PRINT variations: SETUP PRINT STROKES +< PRINT CURVES +< ESC ENTER
Printout of the measured pressure strokes Printout of the P/alpha curve over time
The mean average will automatically set NO when the TDC-sensors are deactivated. If YES is selected the following display will appear: FIRING ORDER POS. CYL-NO 1 1 ESC ENTER
-select the cylinder which appears at what position in the firing order with the arrows keys
The built in formula that calculates the position of each individual cylinder’s TDC assumes that cylinder No. 1 is first in the firing order and that the TDC-Sensor transmits a signal precisely at cylinder No. 1’s TDC position.
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Example 1: 4-Cylinder-Engine: Firing order: POS. 1 POS. 2 POS. 3 POS. 4
1-4-3-2 CYL-NO 1 CYL NO 4 CYL NO 3 CYL NO 2
Example 2: 6-Cylinder V-Engine: Firing order: A1-B1-A3-B3-A2-B2 It is not possible to distinguish between the engines A- or B- banks. The cylinders are therefore numbered as follows: A-Bank cylinder A1=1, A2=2, A3=3 then B-Bank B1=4, B2=5, B3=6. So in our example you must complete the following setup: POS. 1 POS. 2 POS. 3 POS. 4 POS. 5 POS. 6
CYL NO 1 (A1) CYL NO 4 (B1) CYL NO 3 (A3) CYL NO 6 (B3) CYL NO 2 (A2) CYL NO 5 (B2)
Press ENTER to save the firing order you have selected. The following screen will appear: DO YOU WANT AUTOMATIC CALC OF TDC DEVIATION OF ALL CYL. : NO
The TDC deviation of each cylinder compared to cylinder 1 is calculated based on the firing order. - Select YES/NO with the arrow keys:
If YES is selected the instrument will calculate the TDC position of each cylinder according to the firing order and the TDC position of cylinder No. 1 (TDC sensor mark). The programmed formula is correct for most 2/4 stroke in-line/V-engines. If the firing gap between the individual cylinders is not constant, a manual correction must be carried out. On some V-engines the formula does not correct values for the B-bank, so a manual correction must be carried out again. Confirm with ENTER. The following screen will appear: Then the individual TDC deviation for each cylinder starting with cylinder No. 1 (unit equals degree of crank angle) can be observed and changed: TDC DEVIATION for Cyl.. 01 000.0 x
- TDC deviation of single cylinder compared to reference cylinder 1 in crank angle degree - Enter value of deviation by using arrow keys
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When all cylinders have ed, the following screen will appear: SETUP BORE: ESC
0311 mm x ENTER
- Bore of the cylinder
Once the last decimal place has been entered, press ENTER to save the values currently displayed. The following screen will appear: SETUP STROKE: ESC
0320 mm x ENTER
- Stroke of the cylinder
Enter the correct value using the same procedure as above and confirm with ENTER. Now you can enter the length of the ROD (piston rod) in mm. SETUP ROD: ESC
0450 mm x ENTER
- Length of the ROD from small-end hole to big-end hole
Confirm this value with ENTER to set the PRINT DATA functions for the optional PREMET® PRINTER. The following print options with the TDC Sensor will appear: PRINT P/ALPHA +< PRINT P/V + PRINT STROKE + PRINT MIP + ESC ENTER
- Pressure curve - Closed pressure curve - Peak pressure diagram - MIP analysis (future function)
Using the arrow keys you can mark (+) or exclude ( - ) the different types of curves and diagrams. We recommend marking every option, which will ensure that all the different diagrams are available after the measurement. Press ENTER to confirm and return to the Main Operating Menu. Under MANUAL SETUP, in the submenu CURVE AVERAGE (mean average), you can activate the mean average with YES. The mean average diagram will then be calculated according to the strokes. The single stroke will not change. If the mean average is deactivated with NO, the diagram will be calculated according to one stroke. If you are not able to activate this function with YES please check if the parameter TDC-SENSOR YES/NO on the MANUEL SETUP places YES. The submenu CLOCK programs the internal real time clock: MANUAL SETUP PARAMETERS CLOCK < TDC CORRECTION
- selected item confirmed by using the ENTER button
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The following display will appear: SETUP SET DATE DAY: 02 ESC
ENTER
Use UP or DOWN to change the day. Press ENTER to save. Follow the same procedure to program the MONTH, YEAR, HOUR (24h) and MINUTE. Press ENTER to save. Press ENTER after the minutes have been saved to return to the Main Operating Menu. Press ESC to interrupt the SETUP procedure and return to the Main Operating Menu. You can now start performing measurements on the engine.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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Receiving SETUP from PC
It is also possible to prepare the engine SETUP in the WPREMET® PC-Software and it to the instrument. To the SETUP into the PREMET® XL select the menu item RECEIVE SETUP from the Main Operating Menu: MANUAL SETUP RECEIVE SETUP < CHECK TDCSENSOR CALIBRATE
- Receive SETUP from PC
Press ENTER for the following screen: RECEIVE SETUP ? ESC ENTER
Press ENTER. The PREMET® XL is ready to the SETUP from the PC. The following screen will appear: RECEIVE SETUP IN PROGRESS ESC
During transmitting in the end of this line there is a flickering sign.
ENTER
Now select TRANSMIT in the WPREMET® Software, submenu XL SETUP. If the was successful, the following screen will appear: RECEIVE SETUP SUCCESSFUL ESC ENTER
If the was not successful the following screen will appear: RECEIVE SETUP NOT SUCCESSFUL ESC ENTER
In this case check the cable connection and repeat the transmission. The PREMET® XL must display IN PROGRESS before the transmission from the PC can start! The following SETUP values will not be changed by ing a SETUP: • • •
Real time clock Print Options Engineering units for pressure and indicated power!
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
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XL
Carrying out Measurements
Select the menu item SCAN ENGINE from the Main Operating Menu SCAN ENGINE
<
- Measurement on the engine
SHOW STATISTIC PRINT DATA SEND DATA TO PC
Press ENTER to activate this menu item: SCAN ENGINE ALL CYLINDERS < SINGLE CYL ESC ENTER
Measurement of all cylinders as per SETUP Measurement of a single cylinder
Use UP or DOWN to select whether a single cylinder, individual cylinders (SINGLE CYL), or the complete engine from the first to last cylinder (ALL CYLINDERS) should be measured. Press ENTER to confirm the selection. Press the ESC key to return to the Main Operating Menu. Background Information: When the instrument was designed, we had to consider that the temperature of the Sensor increases during the measurement. We simulate this temperature increase during works calibration but it is also necessary for the instrument to recalibrate itself. This is carried out automatically whilst measuring the first cylinder. The time it takes to measure the first cylinder is therefore approx. twice as long as normal.
6.1. Measuring a Single Cylinder Pre select the desired cylinder: SCAN ENGINE SINGLE CYL SELECT CYL: 01 ESC ENTER
- Measurement of a Single Cylinder - Selection of the Cylinder to be measured
Use UP or DOWN to pre select the cylinder number to be measured between 1 and the highest number entered during the SETUP procedure. Press ENTER to confirm the desired cylinder. Press ESC to return to the Main Operating Menu. If the cylinder is selected the screen will display the following message: SCAN ENGINE PREPARE CYL: 01 ESC ENTER
- Measurement on the Engine - Prepare for Measurement on Cylinder 1
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Mount the PREMET® XL on the indicator cock, open the indicator valve (please note our Safety Instructions, page 2) and connect the TDC sensor with the PREMET® XL if you want to take measurements with the sensor. Press ENTER to start the measuring procedure. The screen will display PLEASE WAIT during the measuring process: SCAN ENGINE SCANNING CYL: 01 PLEASE WAIT ESC ENTER
- Measurement on the engine - Measurement on Cylinder 1
If no diesel engine pressure signal is received after a given period (30 seconds), the procedure will automatically shut down and the following message will appear: SCAN ENGINE NOT SUCCESSFUL no Cyl pressure ESC ENTER
- Measurement on the engine - reason for failure
Press any key to return to the Main Operating Menu. If the measurement was successful, the following message will appear: SCAN ENGINE CLOSE VALVE PROCESSING DATA ESC ENTER
- Close the indicator valve - The results will be calculated
While the results are being calculated, close the indicator valve and dismount the PREMET® XL. Confirm with ENTER. Once the measuring data has been calculated, the following display will appear: CYL:-NO: PMAXMEAN: PMAXMAX: PMAXMIN:
01 123 127 121
- Number of the measured cylinder - Peak Pressure Mean Value in bar - Maximum Peak Pressure Value - Minimum Peak Pressure Value
Press any key to return to the Main Operating Menu and close the indicator cock.
6.2. Measuring all Cylinders Start with cylinder 1 and end with the highest cylinder number as entered during SETUP. The screen will display a message for each cylinder: SCAN ENGINE PREPARE CYL: 01 ESC ENTER
- Prepare cylinder 1 for measurement
Press ENTER to start the measuring procedure.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
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The screen will display PLEASE WAIT during the measuring process: SCAN ENGINE SCANNING CYL: 01 PLEASE WAIT ESC ENTER
If no diesel engine pressure signal is received after a given period (30 seconds), the procedure will automatically shut down and the following message will appear: SCAN ENGINE NOT SUCCESSFUL no Cyl. pressure ESC ENTER
Press any key to stop the measurement. If the measurement was successful the device will display the following: SCAN ENGINE CLOSE VALVE PROCESSING DATA ESC ENTER
- Close the indicator valve
While the instrument is calculating the data, close the indicator valve and dismount the PREMET® XL from the cylinder. Confirm with ENTER. After a successful calculation the following picture will appear: CYL: NO: PMAXMEAN: PMAXMAX: PMAXMIN:
01 123 127 121
- Number of the measured cylinder - Peak Pressure Mean Value in bar - Maximum Peak Pressure Value - Minimum Peak Pressure Value
The following screen will appear if any key is pressed: SCAN ENGINE PREPARE CYL: 02 ESC ENTER
- Prepare next cylinder for measurement
Now prepare the next cylinder as described above and carry out the measurement. Once the last cylinder has been measured, press any key to return to the Main Operating Menu. If the VOLTAGE of the battery decreases during the measurement, the light at the back begins to flicker. Finish the measurement and recharge the battery (see PART II, Chapter 1).
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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7.
XL
Displaying Statistical Data
The device offers statistical evaluation of measured peak pressures. As well as calculating mean peak pressure values for each cylinder from the pre-selected number of power strokes, maximum and minimum values for each cylinder are calculated and stored. In addition the percentage of power strokes per cylinder with peak pressure above the mean value is calculated, as is the number of power strokes whose peak pressure lie within the specified limits above and below the mean value for the cylinder. The mean value of peak pressure is calculated for the engine as a whole and the percentage deviation in the mean values of individual cylinders from the overall mean value for the engine is calculated. Select SHOW STATISTIC to display these values: SCAN ENGINE SHOW STATISTIC < PRINT DATA SEND DATA TO PC
- Display of mean values and statistics
Press ENTER to confirm. The following screen will appear: SHOW STATISTIC ALL CYLINDERS < SINGLE CYL. ESC ENTER
- Display statistics for all cylinders - Display statistics for one cylinder
Use UP or DOWN to display data for only either one cylinder only or for each cylinder in turn. Press ENTER to confirm. Press ESC to interrupt the function and return to the Main Operating Menu.
7.1. Displaying Statistics for a Single Cylinder The following menu will appear: SHOW STATISTIC SINGLE CYL SELECT CYL: 01 ESC ENTER
- Display of statistic of one cylinder - Selection of the desired cylinder
Press UP or DOWN to select the desired cylinder. Once the selected cylinder has been confirmed the statistical display will appear: 1st. Screen. CYL:-NO: 01 01.02.1999 18:35 10 WORKSTROKES
- Date of measurement - Time of measurement - Selected number of power strokes
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OPERATING INSTRUCTIONS PREMET
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Press any key for the second statistic: 2nd. Screen CYL:-NO: PMAXMEAN: PMAXMAX: PMAXMIN:
01 123 127 121
- Number of cylinder measured - Mean peak pressure value - Maximum peak pressure value - Minimum peak pressure value
Press any key for the third statistic: 3rd. Screen CYL:-NO: 01 PMAX>MEAN: 50% PMAXINLIM: 100%
- Number of cylinder measured - *1 - *2
*1 -
Number of power strokes (as a percentage) with peak pressure higher than the mean peak pressure for this cylinder
*2 -
Number of work strokes (as a percentage) with peak pressure within the set limits for peak pressure.
Press any key for the fourth statistic: 4th. Screen CYL:-NO: PMEANENG: DEVOFCYL: RPM:
01 123,5 +05,5 720
- Number of cylinder measured - Mean peak pressure for whole engine - Deviation * - Engine speed
* of peak pressure of current cylinder from the mean peak pressure of the whole engine Press ENTER for the 5th screen: 5th Screen CYL:-NO: 01 MIP: + 18,3 Bar Pind: + 167 kW ESC ENTER
- No. of the cylinder measured - Mean indicated pressure of the cylinder - Indicated power of the cylinder
7.2. Displaying Statistics for all Cylinders The same 5 screens are used to display the statistics of all the cylinders in turn, starting with cylinder 1 and ending with the highest cylinder number entered during SETUP.
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OPERATING INSTRUCTIONS PREMET
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8. Deleting Measured Values and Statistical Data of an Engine To delete the following data for a single cylinder, select DELETE DATA: • • • •
individual peak pressure the mean, maximum and minimum peak pressure values the measured pressure curves the speed value
The SETUP values "Number of Cylinders", "Number of Power Strokes" and "Charge Air Pressure" are not affected by this procedure. Select DELETE DATA from the Main Operating Menu and confirm with ENTER. following screen will appear: DELETE DATA ALL CYLINDERS < SINGLE CYL ESC ENTER
The
- Delete data of all cylinders - Delete data of single cylinder
Select with UP or DOWN and press ENTER 8.1 Deleting all cylinder data If ALL CYLINDERS is selected, the instrument will give a security warning DELETE DATA All cylinders ? ESC ENTER
- Delete data of all cylinders
To retain data press ESC. To delete the data of all cylinders press ENTER. The following message will appear: DELETE DATA All cylinders DATA DELETED ESC ENTER
Press ENTER to return to the Main Operating Menu.
8.2 Deleting data for a single cylinder DELETE DATA ALL CYLINDERS SINGLE CYL < ESC ENTER
- Delete data of single cylinder
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OPERATING INSTRUCTIONS PREMET
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Select SINGLE CYLINDER u or DOWN and press ENTER DELETE DATA SELECT CYL : CYL NO : 01 ? ESC ENTER
- Delete data of single cylinder
Select the cylinder to be deleted with UP or DOWN. Confirm with ENTER. Press ESC to return to the Main Operating Menu. If a cylinder is to be deleted, the following safety prompt will appear: DELETE DATA CYL-NO: 01 ESC ENTER
Press ENTER to delete the cylinder. The following message will appear: DELETE DATA CYL-NO: DATA DELETED ENTER
01 - Delete data of Cyl. No. 1 is finished
Press ENTER to confirm. Press any key to cancel and return to the Main Operating Menu.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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OPERATING INSTRUCTIONS PREMET
9.
XL
Printing Statistics and Measurement Results
Before you can PRINT DATA you must prepare the PREMET® and the PREMET® printer as described in PART II, Chapter 2 –”Connecting the PREMET® Printer”. Select menu item PRINT DATA to execute a print out on the optional PREMET® printer. Please connect the printer to the PREMET® using the supplied connecting cable. Press ENTER to activate this menu item. The following safety prompt will appear: PRINT DATA? ESC ENTER
- Print-out of measured values and statistical data?
Press ENTER to confirm and start the print-out. The printing procedure can be interrupted by pressing ESC. The items selected under MANUAL SETUP (PART I, Chapter 4.1) will be printed. During the printing process the following display will appear: PRINT DATA PLEASE WAIT
When this procedure is finished the following message will appear: PRINT DATA FINISHED ENTER
Press any key to return to the Main Operating Menu
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10. Transmitting Statistical Data and Measured Values to a PC Before you can transmit the data you must prepare the PREMET® and the connected PC as described under PART II, Chapter 4 – ”Sending Data to the PC / receiving Data from PREMET®” Now start the software on the PC and select RECEIVE. Then select the COM-port on the PC where the PREMET® XL is connected. The following message will appear: ”Receiving data from PREMET®” Select menu item SEND DATA TO PC to transmit the stored SETUP values, statistical data and measured values to a connected PC. Press ENTER to activate this menu item. The following safety prompt will appear: SEND DATA TO PC ESC ENTER
- Transmission of measured values and statistical data?
Press ENTER to start transmitting. Press ESC to return to the Main Operating Menu. During transmission the following message will appear: SEND DATA TO PC PLEASE WAIT ESC ENTER
During transmission you can follow the in the rising bar-graph on the monitor. To interrupt the transmission press ESC. Once the transmission has finished the following message will appear: SEND DATA TO PC FINISHED ENTER
Press any key to return to the Main Operating Menu.
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OPERATING INSTRUCTIONS PREMET
11.
XL
Checking Sensor and Calibration
Select CALIBRATE on the Main Menu to check the sensor calibration or carry out a new calibration. The following screen will appear: CALIBRATE CHECK CALIB. NEW CALIB. TEMP CALIB.
<
Use UP or DOWN to pre-select the desired menu item. Press ENTER to confirm. Press ESC to return to the Main Operating Menu.
11.1 CHECK CALIB Function
A)
Valid only for serial no. 31000 onwards
This is a pressure-gauge function with simultaneous display of battery voltage. In this case a rapid pressure drop is being evaluated. It is vital for the accuracy of this measurement that the pressure drop is carried out faster than 4 sec. Carry out the following steps: • •
Ensure the instrument has a starting temperature of 18° - 23°C and is rising (not falling!) from below 18°C up to max. 23°C Allow the sensor to self-test for 2 minutes; otherwise the function cannot be carried out accurately.
Press any button to reactivate the screen. Press ENTER to start the check calibration mode: CHECK CALIB. apply test pressure ESC
ACK
Apply a steady pressure as required, preferably with a dead weight tester or if not available with any hydraulic pump. The maximum pressure allowed is 230 bar! The following screen will appear after pressing Enter (ACK): CHECK CALIB. Ubat= 7.49 Volt Apply 0 bar press ACK
Now the rapid pressure drop to 0 bar has to be carried out within 4 seconds
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OPERATING INSTRUCTIONS PREMET
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The following screen will state the actual pressure reading as measured by the PREMET® CHECK CALIB. p = 200,6 bar press
ACK
If the pressure to be tested was >50bar the PREMET® will ask for storage of the obtained data as follows: Do you want to Keep this result As calib. check ? ESC=NO ACK=YES
B)
Valid only for serial no. QH91E and QH91I models
This is a pressure-gauge function with simultaneous display of battery voltage. The following screen is displayed: CALIBRATE CHECK CALIB. APPLY 0 bar ESC ENTER
Carry out the following steps: • •
Ensure the instrument has a starting temperature of 18° - 23°C and is rising (not falling!) from below 18°C up to max. 23°C Allow the sensor to self-test for 5 minutes; otherwise the function cannot be carried out accurately.
Press any button to reactivate the screen. Press ENTER to start the check calibration mode: (Please ensure no pressure is applied during this phase) CHECK CALIB. #1 Ubat= 7.49 Volt APPLY 0 bar Keep for 30 sec
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OPERATING INSTRUCTIONS PREMET
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The following screen will appear after 30 seconds: CHECK CALIB. #1 Ubat= 7.49 Volt Waiting 1 min Keep for 60 sec
The following screen will appear after 60 seconds: CHECK CALIB. #2 Ubat= 7.37 Volt Waiting 1 min Keep for 30 sec
The following screen will appear after 30 seconds: CHECK CALIB. #2 Ubat= 7,37 Volt Waiting 1 min Keep for 60 sec
The following screen will appear after 60 seconds: CHECK CALIB. #3 Ubat= 7,29 Volt Waiting 1 min Keep for 30 sec
The following screen will appear after 30 seconds: CHECK CALIB. #3 Ubat= 7,29 Volt Waiting 1 min Keep for 60 sec
Please ensure no pressure is applied during this phase. The following screen will appear after 60 seconds: CHECK CALIB. P= 0.1 Bar Ubat= 7,31 Volt max. 30 sec
During the following 30 seconds apply pressure as required and compare the PREMET® values to the reference manometer. The maximum pressure allowed is 230 bar.
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OPERATING INSTRUCTIONS PREMET
C)
XL
Valid only for serial no. up to 30999
This is a pressure-gauge function with simultaneous display of sensor temperature. NB! Before the function CHECK CALIB can be carried out, the following prerequisites are necessary: •
The instrument must have a starting temperature of 18° - 23°C and must rise (not fall!) from below 18°C up to max. 23°C
•
Increase the test pressure gradually 5 times up to > 100 bar and < 230 bar in a short time to simulate the dynamically changing pressure.
Press ESC to leave menu item CHECK CALIB and press ENTER to restart. The sensor now has the correct 0 bar offset. CHECK CALIB can now be carried out. The maximum pressure allowed is 230 bar. CALIBRATE CHECK CALIB. APPLY 0 bar ESC ENTER
- Checking Sensor calibration - The operator is prompted to enter a pressure of 0 bar
Confirm with ENTER. The sensor will execute an internal zero reset. Once the sensor is reset the following screen will appear: CHECK CALIB. TEMP = 21°C PRESS =123,5 bar Ubatt = 7,25
- Sensor temperature - Pressure at Sensor
Press ESC to leave this function.
11.2. NEW CALIB Function This function calibrates or recalibrates the sensor. This function is -protected and disabled. 11.3 TEMP CALIB Function This function calibrates the sensors internal temperature measurement. This function is -protected and disabled. 11.4 VOLTAGE CALIB Function This function is -protected and disabled.
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OPERATING INSTRUCTIONS PREMET
12.
XL
Monitoring Temperature
If the maximum sensor temperature of 75°C is exceeded the following message will appear: !!ATTENTION!! SENSOR TEMPERAT !!TOO HIGH!! DISCONNECT
This message only extinguishes if the sensor temperature falls below 75°C. The sensor possesses a very high thermal time constant, this message can therefore only occur if the sensor is left on the indicator cock for too long. The maximum permissible installed time varies according to the engine type, exhaust gas temperature, engine speed and fuel injection setting. If the warning appears, remove the sensor immediately from the engine. If possible, allow the sensor to cool down as it is possible for the internal temperature to rise further once removed.
13.
Recalibrating the PREMET®
To comply with ISO regulations, the PREMET® must be returned to Lehmann & Michels after 1 year for recalibration and an upgrade. This process takes 3-4 working days upon receipt of the instrument. The PREMET® will then be returned with a new certificate of calibration.
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OPERATING INSTRUCTIONS PREMET
14.
XL
Internal Calibration Control
The electronic indicators PREMET® are designed with long term accuracy as a precondition. However, during operation they face very harsh environmental conditions e.g. rapidly changing pressures and temperatures as well as chemical and mechanical affects. This can lead to reduced accuracy over time, depending on the operating conditions. Because decisions to readjust the engines can be made based on measurements performed with the PREMET® one must ensure the readings from the instrument are accurate. Periodically checking the device’s accuracy is strongly advised. To check the accuracy the PREMET® performs a built in CHECK CALIB routine. This enables a known pressure to be compared with the PREMET® measured result of the. If the measuring error is within the accepted range of the PREMET® (1.6% of the measuring range of 230 bar), no further action is necessary. To the the PREMET® also has a built in calibration control routine. Every time the power is switched on this routine checks how many work strokes the PREMET® has been exposed to and the elapsed time since the last calibration or CHECK CALIB. After either 15 months or 160000 pressure cycles the PREMET® will display the following message: You should perform a CHECK CALIB Press any key…
This message can be acknowledged by pressing ENTER. The PREMET® will continue to function as normal. This message will appear every time the PREMET® is switched on until the performs a CHECK CALIB with a pressure exceeding 50 bar. The same message will appear again after another 12 months or 160000 pressure cycles. A CHECK CALIB with a pressure exceeding 50 bar will once again clear this message. After another 12 months or 160000 pressure cycles the PREMET® will display the following message: Instrument should be re-calibrated Press any key…
It is strongly advised to send the instrument to LEHMANN & MICHELS or an authorized dealer when this message appears for a deep calibration check and possibly re-calibration or replacement of sensor parts. The PREMET® contains no potentiometer for changing the gain of the instrument. The sensor is calibrated using different pressures and temperatures. This task can only be performed by LEHMANN & MICHELS and selected authorized dealers. LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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PART II 1. Recharging PREMET® Batteries The PREMET® is equipped with Ni-MH batteries. If the battery is fully charged, you can carry out measurements for approx. 3 - 4 hours. Ni-MH batteries have no memory effect as known from Ni-Cd batteries, but they have higher self discharge characteristics. Before charging the PREMET®, ensure that the device is switched off, as it is not possible to charge the batteries when the PREMET® is switched on. Connect the battery charger to the mains and to the PREMET®. The red LED „Charge“ lights and indicates the charging process. During the testing cycle the green LED „Ready“ flashes also but goes out after around 1 minute when the test phase is over. After termination of the fast charge the charger switches automatically to trickle charge. The red LED „Charge“ is off and the green LED „Ready“ is constantly on for approx. 2 minutes. After around 2 min. the indicator changes to green flashing. The battery pack can be removed at this time or left connected to keep topped up until use. If the green LED „Ready“ flashes immediately after connecting the battery pack and the red LED „Charge“ lights up sporadically, this means that the polarity (+/–) at the charging cable is not set correctly. Please reverse the polarity. If both LED’s are still flashing after changing the polarity and the steady light „Ready“ does not light permanently, the battery pack is defective and cannot be recharged at all. In this case the pack has to be replaced. LED red „Power“: Steady light shows that the charger is ready for use. It lights once the charger is plugged in. LED red „Charge“: Steady light indicates the fast charging process after connecting the battery pack. LED green „Ready“: Steady light indicates the battery pack is fully charged. After approx 2 minutes it switches to flashing, which indicates trickle charging. Once the battery pack is connected, the testing cycle is initiated and the green LED flashes for around 1 minute. If it carries on flashing and the red LED “Charge” does not light, it indicates that the battery pack is not connected properly and maybe has an incorrect polarity. LED yellow „Discharge“: Steady light indicates the discharging process after pressing the yellow button. The LED „Ready“ flashes for approx. 1 minute indicating the testing cycle. For maximum service life and service performance of the PREMET® batteries we recommend pressing the ”discharge” button on the charger after connecting it to the PREMET®. Pressing ”discharge” initiates the automatic discharge / recharge cycle of the charger, prolonging the service life of the battery-pack. Without this initiation, the charger will recharge the batteries only, which eventually will shorten the service life and charge holding capacity of the battery pack. After discharging and after a power interruption the charger automatically switches over to charging. LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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Connecting the PREMET® Printer
2.
Connect the printer (25 pins) to the 7 pin PREMET® plug-box using the supplied standard cable (serial). Connect the power unit to the printer (5V DC) and to the 230 V. AC mains. The printer is now online. The printer has two LED’s on the right hand side. The LED's indicate the printer status: • •
If both LED's are lit the printer is ready (online) to print out the data from the PREMET®. If only one LED is lit the printer is in the status paper feed. If you press the right hand button on the printer the paper feed function is working. Press the SEL button to stop the paper feed and print data again.
Only the original PREMET® printer is compatible with the instrument. Please note that the printer can only print the data as specified in SETUP (PART I, Chapter 3). E.g. If PRINT CURVE is not selected during SETUP, the printer cannot print the draw card. Now you can print on the PREMET® printer (see PART I, Chapter 9: Printing Statistics and Measurement Results).
3.
Sending Data to the PC / receiving Data from PREMET®
The normal scope of delivery includes the PREMET® Software package. With this software it is possible to send all measured data from the PREMET® to any PC. It is also possible to transfer the SETUP from the PC to the PREMET®. Therefore it is necessary to connect the PREMET® with the PC. 3.1 How to connect the PREMET® with the PC? Use the standard data transfer cable(serial) which is supplied together with the instrument to connect the PC on the serial COM port 1 or 2 (normally 9 or 25 pins) with the plug-box (7pins) of the PREMET®. If necessary, use the delivered PC adapter to do so. If your PC does not have a serial COM port, which is more and more common with new PCs, use our special USB adapter which is separately available to connect your PC with the PREMET®.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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The picture is to clarify how to connect which cable for the system to work properly:
Serial Data Transfer Cable
USB Adaptor
Please note: it is not possible to use any other adapter for this purpose! It is necessary to install a special driver for this adapter before it is ready for use. See “Software instructions for the electronic indicator PREMET® for MS-WINDOWS 9x/NT/2000/XP” for detailed information. The driver is also on the CD which is delivered with the PREMET®. The computer is now able to receive SETUP (Chapter 4.2 –Receive a SETUP from PC) or transmit measured data (Chapter 10. -Transmission of statistical data and measured values to a PC) How to work with the WPREMET® software is described in the ”SOFTWARE INSTRUCTIONS for the electronic indicator PREMET® for MS-WINDOWS 9x/NT”
4.
Final Note
We hope this instruction book will help you use our electronic indicator PREMET® to its full potential. We are sure that you will soon discover how easy it is to handle our instrument and discover how essential the engine data is. Please do not hesitate to us if you have any questions, requests or suggestions. Your knowledge and experience is vital to us.
LEHMANN & MICHELS GmbH Sales & Service Center Siemenstrasse 9 • D-25462 Rellingen • Tel. +49 4101 5880 0 • Fax +49 4101 5880 129 e-mail:
[email protected] • visit us at www.lemag.de
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