Electronic Peak Pressure Indicator EPM-Peak Operating Instructions

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1 Electronic Peak Pressure Indicator EPM-Peak Operating Instructions Page 1 of 13

2 1 Introduction 3 2 The Peak Pressure Indicator EPM-Peak General Description Measure functions Scope of supply Technical Specifications 4 3 Operation Battery installation and removal Check of battery status Charge battery Operator push buttons Operating functions Operation procedure Sensor over temperature 11 4 Accuracy check Connection of EPM-Peak to pressure calibrator Generate pressure at pressure calibrator Disconnect EPM-Peak from pressure calibrator 13 5 Basic check for fault finding 13 Page 2 of 13

3 1 Introduction This operation manual provides instructions on how to use the EPM-Peak correctly and safely for the intended purpose. Please study this manual carefully, before using the EPM-Peak. Follow all safety instructions and precautionary notes in order to avoid damage to people or property during operation. This will ensure that you will receive maximum benefits from using this engine performance tuning tool with its versatile functionality and it will guarantee optimum benefits over its lifetime. Please keep the manual in a safe place where it is always available for easy access. We ask for your understanding, that we will reserve the right to change information and instructions in this manual if necessary without giving notice in advance. 2 The Peak Pressure Indicator EPM-Peak 2.1 General Description The electronic indicator EPM-Peak is a handy-, battery powered-, portable device to measure the maximum value of cylinder pressure on 4-stroke diesel engines. The cylinder pressure will be measured with the EPM- PEAK unit incl. high temperature pressure sensor at indicator cock on marine diesel engines. The EPM-Peak collect 10 consecutive pressure measurements (cycles) and calculates peak pressure and engine speed. The measured data are displayed in numerical format on the LCD screen and can be stored in memory. 2.2 Measure functions Pmax: average max. pressure of 10 cycles in bar RPM: engine speed U/min Memory: 200 data sets Application 4 stroke: RPM Measuring range: bar The battery must be recharged after approximately one hour of continuous operation. Page 3 of 13

4 2.3 Scope of supply 1x EPM-Peak unit including protection cover 1x CPS cylinder pressure sensor 1x Battery 9V E-block re-chargeable NiMh 1x Thompson adaptor W27x1/10" 1x Hollow spanner mounting tool 1x USB cable 1x Calibration certificate 1x Operation manual on CD 1x Instrument case (optional) Fig.2: Instrument case with all components 2.4 Technical Specifications Measuring range bar Accuracy < 1 % Full Scale Max. temperature at sensor measuring cell 300 C Storing capacity 200 measurements Dimension without sensor 210 x 100 x 80 mm Weight (incl. battery) 1150 g Page 4 of 13

5 3 Operation 3.1 Battery installation and removal Your device is powered by a 9-volt rechargeable battery. When the operation times are noticeably shorter than usual, replace the battery. Only use rechargeable battery E-block type ANSMANN 300 mah NiMh. Don t change the battery during charging process while EPM-PEAK is connected via USB cable to PC. Never use any battery that is damaged. Batteries may explode if damaged. Do not shortcircuit the battery. Do not dispose of batteries in a fire as they may explode. Dispose of battery according to local regulations. Please recycle when possible. Do not dispose as household waste. Take the EPM-Peak out of the protection cover. In order to replace the battery the back side cover of EPM-Peak must be opened. Press the locking mechanism and move the battery cover back. Fig.3: Open battery covers Fig.4: Re-chargeable E-block battery The battery can then be pulled out of the carrier. When installing a new battery into the carrier, make sure that the polarity matches as shown here. + Pol - Pole Fig.5: Battery polarity Then completely slide the battery cover to closed position and return the EPM-XP into the protection cover. Page 5 of 13

6 3.2 Check of battery status Push key 2/4 to check the battery status. Fig.6: Indication of battery charge state 3.3 Charge battery The EPM-Peak has a rechargeable battery. The battery charging will start automatically after the EPM-Peak unit has been connected via USB cable from USB port to PC. At first usage please connect EPM-Peak via USB cable to PC to charge battery for 2 hours continuously. Fig.7: USB-port of EPM-Peak Fig.8: EPM-Peak connected via USB cable to PC The EPM-Peak can detect the charging status and continuous charging until the battery is fully loaded. Then the charging process stops automatically. It is not recommended to interrupt the charging process before it is automatically stopped. The charging process is finished when the display message "EPM-Peak charging..." disappeared. Fig.9: Indication during charging process Fig.10: Indication charging process completed If the battery status is low, and the charging process stops after 5-10 minutes, then the user can manually force the unit to charge the battery for 120 minutes by pressing both arrows buttons coevally at the EPM-Peak for 2 seconds (forced charging mode). It is not recommended to use the forced charging mode when the battery charge condition is more than 40%, due to the risk of overcharging. Page 6 of 13

7 3.4 Operator push buttons Arrow up Start measurement Arrow down Read measurement On/Off Operation mode Fig.11: Push buttons Page 7 of 13

8 3.5 Operating functions Function Switch On/Off Battery check Sensor check Key board push button Display Notes Basic settings will be displayed after switching on: Cyl:1 = cylinder no.1 4 stroke Pmax: bar RPM: U/min Push key 2/4 to check the battery status. Also temperature at sensor measuring element will be displayed. Push key 2/4 two times to check the sensor status at 0 bar. Selection of cylinder Push arrow key change the displayed value to the number of the selected cylinder. Short-time pushing the arrow key will step forward in single cylinder steps. Continuous pushing the arrow key will step forward in 10 cylinder steps. Start measurement During measurement the following information Recording cylinder will be indicated. Display indication (1-2 s) of measured cylinder values. Then EPM-Peak switches automatically to the next cylinder. Page 8 of 13

9 Read Pmax Delete measurements + Push Read and then the measured value for Pmax of the selected cylinder will be displayed. Push Read and at the same time for 2s to delete the currently displayed measurement. Push Read and at the same time continuous to delete all measurement. Page 9 of 13

10 3.6 Operation procedure DANGER! The indicator valve ejects hot gas under high pressure. Danger of sparks and burns. Put on suitable gloves as the adaptor will get very hot during operation. The use of safety glasses is required when operating the EPM-Peak. Hot gas and particles may be ejected from the engine. Before mounting the adaptor, please clean the indicator valve by opening (1-2seconds). The indicator valve should be blown through briefly before starting the measurement to make sure there are no condensed water, oil or soot deposits. Close the indicator valve. Mount the EPM-Peak sensor with adaptor onto the indicator valve at cylinder number 1. It is not allowed to use a hammer or equivalent tool to attach or remove the EPM-Peak from the indicator valve. The user must use the provided hollow spanner tool. Open indicator valve fully. Press On at EPM-Peak Press Measure and wait about 5-10 seconds Fig.12: Indication during measurement on cylinder Fig.13: Indication (1-2 s) of measured values from cylinder Close the indicator valve. After indication of measured cylinder values, the display switches automatically to next cylinder. Repeat measuring procedure for all remaining cylinders. The measuring period should never exceed 30 seconds per cylinder. The EPM-XP turns off automatically after 2 minutes without pressing any push button. Page 10 of 13

11 3.7 Sensor over temperature The EPM-Peak is indicating Over Temp.! if the sensor measuring cell temperature come up to 300 C. Fig.14: Indication of sensor over temperature In this case, disconnect the sensor from indicator cock and wait 5-10 minutes. 4 Accuracy check The EPM-Peak is adjusted at IMES workshop at different pressure values (0 300 bar) and temperature values (50 C- 200 C). A calibration certificate will be delivered with each EPM-Peak unit. The EPM-Peak has a very stable and long life cylinder pressure sensor. We emphasize to check calibration values of EPM-Peak at pressure calibrator by hydraulic oil once a year. 4.1 Connection of EPM-Peak to pressure calibrator Connect EPM-Peak unit with Thompson adaptor to pressure calibrator. Please check possible leakage at adaptor by generating pressure. Indication of pressure on EPM-Peak Adjusted pressure at calibrator Fig.15: Connection of EPM-Peak to pressure calibrator The pictured pressure calibrator is an example to generate pressure. At your workshop you can use your standard pressure calibrator. Page 11 of 13

12 4.2 Generate pressure at pressure calibrator We emphasize to check EPM-Peak at most frequently measured Pmax-value on engine. For example pressure values at 0 bar and between 100 bar and 200 bar. Fig.16: Example for indication of static pressure (0 bar) by generating pressure at pressure calibrator and indication of static pressure value on EPM-Peak display. Fig.17: Example for indication of static pressure (150 bar) by generating pressure at pressure calibrator and indication of static pressure value on EPM-Peak display. Checking procedure: a) Switch On by pressing operating key On/Off at EPM-Peak b) Generate pressure 0 bar at pressure calibrator c) Press 2 x operating key 2/4 at EM-Peak. The static pressure value will be displayed d) Generate pressure for example between 100- and 200 bar at pressure calibrator f) Check displayed pressure g) Compare generated pressure at pressure calibrator and displayed pressure value at EPM-Peak. The maximum acceptable difference between adjusted pressure at pressure calibrator by ambient (20-30 C) temperature and displayed static pressure at EPM-Peak is +/- 4 bar. By increasing pressure difference we emphasize to send EPM-Peak unit to IMES workshop for new adjustment and calibration. The accuracy of the EPM-Peak unit according technical data is +/- 1.0% full scale (0 300 bar) in the adjusted temperature range of 50 C- 200 C. Page 12 of 13

13 4.3 Disconnect EPM-Peak from pressure calibrator The Thompson adaptor of EPM-Peak must be dismounted from adaptor of pressure calibrator. After disconnection the Thompson adaptor incl. gas channel of cylinder pressure sensor must be cleaned from oil by using pressurized air. 5 Basic check for fault finding Before contacting your local agency or service partner, check the problem guide below. Problem Indication at EPM-PEAK Action EPM-PEAK display id black after pushing the On/Off button Recharge the battery by connecting to USB port from EPM-Peak to PC Low battery after full charging If the battery status is low and charging process finished after 5-10 minutes then the user can charge battery manually 90 min. It is not recommended to use the Forced Charging Mode when the battery charge condition is more than 40%, due to the risk of overcharging. Please see chapter 3.2 for a description how to check the charge state. Connection to USB port of PC and press 2 seconds both arrows buttons + Over temperature indication Indication after temperature of measuring cell > 300 C High offset No signal Engine speed is lower than 200 RPM or indicator cock is not opened Disconnect sensor from indicator cock and wait 5-10 minutes Sensor is defect. Please send EPM-Peak unit to IMES workshop Open indicator cock Page 13 of 13

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