AVL DITEST DPM 800 User manual

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

AVL DiTEST GmbH
Alte Poststrasse 156
A-8020 Graz / AUSTRIA
Tel: [phone] - 0
Fax: [phone] - 1460
[e-mail]
www.avlditest.com
Copyright © 2016 AVL DiTEST GMBH, all 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.

AVL DiTEST DPM 800
Warnings and safety information
User manual
I
Warnings and safety information
This equipment manual contains important warnings and safety information
which must be observed by the user.
The product is only intended for a very specific application described in the
equipment manual. Furthermore, the most important prerequisites and safety
measures required for the use and operation of the product are explained to ensure
smooth operation.
We do not accept any warranty and liability for applications other than the
application described and without observing the required preconditions and safety
measures.
Theproductmay onlybe usedand operatedby personnelthatdueto itsprofessional
qualification is able to observe the required 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 onlydepend 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) by an expert prior to implementing
further measures based on the generated measured value.
Adjustments and maintenance of live, opened devices may only be carried out by
qualified personnel trained for that purpose and that is aware of the risks involved.
The product may only be repaired at the supplying factory or by the qualified
personnel trained for that purpose.
When using the product, a specialist must ensure that neither the test object nor the
test facility can operate in such a manner that it might damage property or put
personnel at risk.

Warnings and safety information
AVL DiTEST DPM 800
II
User manual

AVL DiTEST DPM 800
Summarized of safety information
User manual
III
Summarized safety instructions
Risk of fatal injury from electric current on vehicles with high-voltage systems.
Dangerous high voltages capable of delivering fatal electric shocks are present on the HV energy
store (HV battery) and the components connected to it.
Make sure that nobody comes into contact with the connections of the HV battery, the connecting
leads or any other components connected to the high-voltage power supply.
Danger of electric shock on the ignition system
The ignition system is under life-threatening 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 emission has
to be vented to the outside and the space should be adequately ventilated!
Risk of burns due to hot components
Perform measurements at normal engine operating temperature or follow the respective test
specification!
Do not touch any hot components such as engine, engine mountings and the entire exhaust
system! If necessary, use cooling fans!
DANGER
WARNING
WARNING
WARNING
WARNING

Summarized of safety information
AVL DiTEST DPM 800
IV
User manual
Risk of injury due to rotating parts
Perform any work in the engine compartment while engine and ignition are turned off!
Do not touch any rotating parts, such as, assemblies of electric generator, radiator fan and their
drives (e.g. V belt)!
With running engine ensure a safe installation of the measuring cables!
Risk of injury due to unsecured vehicle
Apply the hand brake or place the selector lever to P (automatic transmission)!
Secure vehicle adequately against rolling!
Explosion hazard due to pyrotechnic installation and restraint system
Test and installation work should only be carried out by trained personnel!
Under no circumstances should the igniter be tested with the multimeter!
System verification 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 sparks, open fire and temperatures above 100°C!
Do not transport airbag unit in the passenger compartment!
Do not bring airbag unit in contact with oil, grease and cleaning agents!
Airbag unit that dropped more than 0.5m has to be replaced!
Dispose of untriggered airbag units!
Do not open or repair airbag unit!
Observe the applicable manufacturer's specifications when holding the cutoff speed of diesel
engines!
Always switch off the ignition first before connecting and disconnecting the OBD plugs or the
different AVL vehicle adapters!
WARNING
NOTICE
WARNING
WARNING
NOTICE

AVL DiTEST DPM 800
Safety information
User manual
V
Safety information
AVL DiTEST DPM800 Piezo-electric pressure-sensing
sparkplug
Choice of piezo-electric pressure-sensing sparkplug:
Using the wrong piezo-electric pressure-sensing sparkplug can lead to electrical and mechanical
damage extending even to major engine damage.
Make sure that you choose the right piezo-electric pressure-sensing sparkplug to suit the engine
being tested.
(Physical dimensions, seal seat (tapered or flat), etc.)
Electrode gap:
The electrode gap is an important criterion for the production of a proper ignition spark. Please note
that the sparking section of the piezo-electric pressure-sensing sparkplug is a very slim design due
to the small amount of space available.
Because of that, the ignition voltages should not be as high as with normal sparkplugs in order to
prevent damage to the insulator. 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 insulation can
break down if the electrode gap is too large.)
AVL DiTEST DPM800 Piezo-electric glow plug pressure
sensor adaptor
Choice of piezo-electric glow plug pressure sensor adaptor:
Using the wrong piezo-electric glow plug pressure-sensor adaptor can lead to electrical and
mechanical damage extending even to major engine damage.
Make sure that you choose the right piezo-electric glow plug pressure sensor adaptor to suit the
engine being tested.
The glowplug adaptor is used only to hold the pressure sensor. Preheating the cylinder with the
piezo-electric glowplug pressure sensor adaptor when starting the engine is not possible.
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE

Safety information
AVL DiTEST DPM 800
VI
User manual

AVL DiTEST DPM 800
Contents
User manual
VII
Contents
Warnings and safety information................................................................ I
Summarized safety instructions................................................................ III
Safety information.......................................................................................V
1General introduction...................................................................... 1-1
1.1 General description ....................................................................................................... 1-1
1.2 Safety instructions......................................................................................................... 1-2
1.3 Typographical conventions.......................................................................................... 1-2
1.4 Operation of PC programs............................................................................................ 1-3
2Initial use........................................................................................ 2-1
2.1 Installing the software................................................................................................... 2-1
2.2 Installing the AVL DiX 2.0 software.............................................................................. 2-1
2.3 Updating AVL DiX 1.0 to AVL DiX 2.0 .......................................................................... 2-2
2.4 Activating the AVL DiTEST DPM 800 with the AVL DiScope 802 present ............... 2-3
3Measuring....................................................................................... 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
4Care and maintenance................................................................... 4-1
4.1 Visual check ................................................................................................................... 4-1
4.2 Cleaning.......................................................................................................................... 4-1
4.3 Replacing the battery .................................................................................................... 4-1
5Product specifications................................................................... 5-1
6Warranty......................................................................................... 6-1
6.1 New devices ................................................................................................................... 6-1
6.2 Exchange or loaned devices ........................................................................................ 6-1
6.3 Event of damage or loss ............................................................................................... 6-1
7Technical data................................................................................ 7-1

Contents
AVL DiTEST DPM 800
VIII
User manual

AVL DiTEST DPM 800
General introduction
User manual
1-1
1 General introduction
1.1 General description
The AVL DiTEST DPM 800 (DPM = dynamic pressure measurement) enables the progression of
the relative internal cylinder pressure to be measured using a sparkplug with an integral pressure
sensor (piezo-electric pressure-sensing sparkplug) or, on diesel engines, using a glow plug adaptor
with integral pressure sensor.
(Piezo-electric glow plug pressure sensor adaptor).
The AVL DiTEST DPM 800 includes a signal converter/amplifier which conditions the signal from the
piezo-electric pressure-sensing sparkplug (piezo-electric glow plug pressure sensor adaptor) for the
AVL DiScope 802.
The data readings are processed by the AVL DiScope 802.
When doing so, it tracks the 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/TDC)
•engine speed at which readings were taken
The product specifications also include an adaptor socket for fitting the piezo-electric pressure-
sensing sparkplug/glow plug pressure sensor adaptor.
Please note that Version 2.0 of AVL DiX is required to operate the AVL DiTEST DPM 800.
For general guidance on using the AVL DiScope 802, please refer to the AVL DiScope 802 device
manual.
Fig. 1-1
AVL DiScope
802
AVL DiTEST
DPM 800 power
supply unit
Piezo-electric
pressure-
sensing
Piezo-electric
pressure
sensor adaptor
Adaptor
socket
AVL DiTEST
DPM 800
amplifier

General introduction
AVL DiTEST DPM 800
1-2
User manual
1.2 Safety instructions
This documentation contains important warnings and safety instructions which have to be observed
by the user. Only through compliance with these requirements and safety measures it is possible to
ensure correct and safe operation.
Please note the safety instructions on the screen.
1.3 Typographical conventions
Safety instructions:
Indicates an extremely dangerous 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 indicates important information or instructions. Failure to comply with these instructions
prevents or significantly hampers a successful finalization of the operations described in this
documentation.
WARNING
CAUTION
DANGER
NOTICE
Information

AVL DiTEST DPM 800
General introduction
User manual
1-3
Standard text formats:
bold Important text/text passages, parameter
italic On screen dialogs and messages
CAPITAL LETTERS Device designation and operating 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 administrator.

General introduction
AVL DiTEST DPM 800
1-4
User manual

AVL DiTEST DPM 800
Initial use
User manual
2-1
2 Initial use
2.1 Installing the software
To install the software you must have administrator permissions.
You must have Version 2.0 of AVL DiX installed on your AVL DiX station.
If necessary, update AVL DiX to Version 2.0.
2.2 Installing the AVL DiX 2.0 software
1. All connected modules must be switched off
(set AVL DiLink 480 master switch on rear panel to "0") as the current drivers are not
available at the point of installation.
2. Insert the DVD "AVL DiX 2.X BO7340" in the DVD drive.
3. The screen "AVL DIX SETUP" appears.
(If the screen does not appear, start Windows Explorer, right-click on your DVD drive and
click Autoplay (WIN XP) or Install or run program (Win Vista/Win 7)).
4. Click English and then AVL DiX 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 country.
15. Select Measuring and testing.
16. Confirm each step by pressing Next or OK.
17. Restart the AVL DiX PC.
18. After completing installation, switch on all AVL DiX modules.
(Set power switch on back of AVL DiLink 480 to "1".)
19. Plug the AVL DiX dongle (silver) into a USB socket.
20. The operating system will automatically detect the new hardware and install the appropriate
drivers.
Click OK when asked to confirm installation of unsigned drivers.
The summary of the system update is then displayed.
Press F8 Confirm to finish the system update.
Information

Initial use
AVL DiTEST DPM 800
2-2
User manual
2.3 Updating AVL DiX 1.0 to AVL DiX 2.0
1. All connected modules must be switched off
(set AVL DiLink 480 master switch on rear panel to "0") as the current drivers are not
available at the point of installation.
2. Insert the DVD "AVL DiX 2.X BO7340" in the DVD drive.
3. The screen "AVL DIX SETUP" appears.
(If the screen does not appear, start Windows Explorer, right-click on your DVD drive and
click Autoplay (WIN XP) or Install or run program (Win Vista/Win 7)).
4. Click English and then AVL DiX 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 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. Restart the AVL DiX PC.
18. After completing installation, switch on all AVL DiX modules.
(Set power switch on back of AVL DiLink 480 to "1".)
19. The operating system will automatically detect the new hardware and install the appropriate
drivers.
Click OK when asked to confirm installation of unsigned drivers.
The summary of the system update is then displayed.
Press F8 Confirm to finish the system update.

AVL DiTEST DPM 800
Initial use
User manual
2-3
2.4 Activating the AVL DiTEST DPM 800 with the
AVL DiScope 802 present
1. Restart the AVL DiX PC.
2. Start AVL DiX.
3. The screen “Licence Update” appears.
4. Click Extras I Update 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 800 by clicking Next.

Initial use
AVL DiTEST DPM 800
2-4
User manual

AVL DiTEST DPM 800
Measuring
User manual
3-1
3 Measuring
3.1 Taking a reading
1. Switch off the vehicle's engine.
2. Unscrew the sparkplug (glow plug).
3. Carefully feed the lead for the piezo-electric pressure-sensing sparkplug (glow plug pressure
sensor adaptor) through
the adaptor socket (A).
In the adaptor socket there is a slot (B) through which the lead can 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 contact with any hot parts
- are not close to any hot parts (radiant heat)
- do not come into contact with any rotating parts
- are not kinked or damaged
(B)
(A)
NOTICE

Measuring
AVL DiTEST DPM 800
3-2
User manual
6. Carefully screw the lead (C) for the piezo-electric pressure-sensing sparkplug (glow plug
pressure 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)