HORN CPM User manual

D r . E . H o r n G m b H , G e r m a n y C P M , 05/15
User Manual
C P M
-mobile Cylinder Pressure Monitoring -

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Dear Customer,
You have purchased a product that meets the highest quality and product standards. However we are
still obliged to inform you that we cannot accept any liability for the accuracy and completeness of the
contents. Although the contents may be compiled carefully and accurately we cannot accept any lia-
bility for printing and transcription errors in particular.
This manual and the hardware/software described within are protected by copyright. Any use outside
of the standard application as defined in law is forbidden without the permission of the holder of rights.
This specifically applies to copying, translation, publication (also in part), and input to electronic sys-
tems.
This manual contains the technical specifications and product information according to the latest status
before publication.
The contents of this manual and the technical data for the products may be changed without prior
notice.
All hardware and software names used in this book are the protected trademarks of the manufacturer
and must be treated as such.
Service and Support
If questions cannot be answered in our manual, please contact us:
E-Mail [email protected]
Tel.: [phone]
Address Dr. E. Horn GmbH
Im Vogelsang 1
71101 Schoenaich
Germany

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Contents
1 Introduction...................................................................................................................................................................5
2 Intended Use.................................................................................................................................................................5
3 Description of Components ..........................................................................................................................................7
3.1 Description and Technical Data ..........................................................................................................................7
4 Initial Start-Up..............................................................................................................................................................9
4.1 Charger/ Battery................................................................................................................................................10
4.1.1 Changing the Rechargeable Batteries ...........................................................................................................10
4.2 Charger..............................................................................................................................................................10
4.2.1 Changing the Plug......................................................................................................................................... 10
4.3 Connecting the Charger.....................................................................................................................................11
4.3.1 Status of Charging.........................................................................................................................................11
5 Getting Ready to Take a Measurement.......................................................................................................................12
5.1 Marginal Conditions..........................................................................................................................................12
5.2 Setting-up the monitoring device ......................................................................................................................13
5.3 Connecting the Sensors to the Measuring Device.............................................................................................13
5.4 Preparation of the Measurement Points............................................................................................................. 14
6 Carrying Out Measurements.......................................................................................................................................17
6.1 Cylinder Pressure Measurement........................................................................................................................17
6.1.1 Carrying Out Cylinder Pressure Measurements............................................................................................17
6.2 Explanations Regarding Cylinder Pressure Measurements...............................................................................19
6.2.1 Diagnosis of the Cylinder Pressure Course...................................................................................................21
6.3 Ultrasonic Measurement ...................................................................................................................................22
6.3.1 Carrying Out an Ultrasonic Measurement ....................................................................................................23
6.4 Explanation of the Ultrasonic Measurement Values.........................................................................................24
6.4.1 Two-Stroke Engines......................................................................................................................................24
6.4.2 Four-Stroke Engines .....................................................................................................................................24
7 Software......................................................................................................................................................................25
7.1 Compatibility and Prerequisites ........................................................................................................................25
7.2 Software Installation .........................................................................................................................................26
7.3 Configuring the software and the engine parameters........................................................................................26
7.3.1 Addition / Deletion of Engines to / from the Configuration ......................................................................... 29

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7.4 Software Description.........................................................................................................................................29
7.4.1 Loading Data.................................................................................................................................................29
7.4.2 Analysing the Data........................................................................................................................................ 31
7.4.3 Zoom and Move............................................................................................................................................37
7.4.4 Store Data .....................................................................................................................................................38
7.4.5 Exporting the Statistics Table.......................................................................................................................38
7.4.6 Exporting diagrams.......................................................................................................................................38
7.4.7 Print Report................................................................................................................................................... 38
7.4.8 Export engine configs ...................................................................................................................................40
7.4.9 Help...............................................................................................................................................................40
7.5 Version..............................................................................................................................................................40
8 After Use.....................................................................................................................................................................41
9 Guarantee....................................................................................................................................................................41
10 FAQ (frequently asked questions).........................................................................................................................42
10.1 Summary of the significance of the LEDs ........................................................................................................43
11 Description of the features in version 3.2.1...........................................................................................................44
12 Notes on Safety and Surrounding Area .................................................................................................................45
13 Warranty Declaration.............................................................................................................................................45
14 Ownership Information..........................................................................................................................................46
15 Copyright...............................................................................................................................................................46

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1 Introduction
Dear Customer,
Thank you for purchasing the “CPM - mobile Cylinder Pressure Monitoring” set.
Please read the instruction manual prior to use and adhere to the guidelines so that you can work with your meas-
urement device safely.
2 Intended Use
This measurement device is suitable for measuring the internal cylinder pressure and conducting ultrasonic meas-
urements of two-stroke and four-stroke engines within and during operation.
The user is liable for all damage resulting from the device being used in a way that does not comply with intended
use.
Generally accepted accident prevention regulations and the attached safety instructions must be complied with.

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11
CD
PC
Not included in
delivery
RJ 45 Socket
6
Plug adapter
4
Charger
USB Socket
7
Key for Thomson
adapter
9
Cable for ultrasonic sensor
8
Ultrasonic sensor
1
Case
2.3b
USB-Port for
PC connection
2.2
Cylinder pressure
Sensor
(not removable)
2.4
Charging cable
port
10
Data transfer cables
USB / LAN (RJ45)
2.3a
LAN-Port for
PC connection
3
Cylinder pres-
sure sensor
2.1
Ultrasonic sen-
sor port
2.5
Reset Button

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3 Description of Components
The set consists of the listed parts below. Please check the completeness of the set upon receipt.
1 x Hard shell case
1 x Handset
1 x Cylinder pressure sensor (permanently connected to handset)
1 x Charger
1 x Battery (inside of handset)
4 x Adapter for on-shore connection/on-board supply system for charger
1 x Tool to release the cylinder pressure sensor
1 x Ultrasonic sensor
1 x Connecting cable for ultrasonic sensor/handset
Data transfer cable
1 x RJ 45 Port
1 x USB Port
1 x Software to install on PC
1 x Instruction manual
3.1 Description and Technical Data
Hard shell case: H x L x W ca. 420 x 480 x 115 mm
CPM 7.0 kg / 15,43 lbs
Humidity max. 75 %
Working temperature -20…+55 °C
Storage temperature -20…+30 °C
Do NOT store in a discharged condition !
The case is fitted with an inherently stable plastic insert for storing the entire handset.
Handset: H x W x D ca. 238 x 109 x 42 mm
To measure the internal cylinder pressure when the engine is running, the range of measurement is limited
between 0 and 300 bar; the speed of rotation limits are between min. 20 and max. 2000


.
Ultrasonic measurement, this function can measure relevant engine noise during operation.
Start button controls the following functions: Turning the equipment on and off
Deleting data memory
Initiating measurement
Terminating measurement

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Three LEDs showing the state of the measurement unit: Measurement standby
Running measurement
Measurement finalization
Low battery alert
Deleting storage
The dual-colored LEDs indicate these functions with the status ON, OFF or blinking (Table 10-1).
Power is supplied by means of the 7.4 VDC rechargeable battery provided and inserted.
Port for charger is located at the bottom (see Chapter 4.3 and page 6 graphic 2.4).
The handset has a memory that can store the measurements of at most 24 cylinders, and can be connected to a PC
for the data transmission of the measurements via an RJ 45 socket or USB (page 6 graphic 2.3).
Cylinder Pressure Sensor
Pressure range / overload: 0… 300 bar / 400 bar
Frequency: 2 kHz
Supply voltage: 18…32 VDC
Output signal: 4…20 mA
Operating temperature
Max. medium temperature: -40…+75 °C +300 °C
Protection degree (IEC 60529) IP 65
Attention!
The sensor is permanently connected to the handset. Disconnecting
the sensor from the handset will result in losing warranty!
Charger
System voltage: 100 … 240 VAC
Frequency: 50/60 Hz
Power consumption: maximal 9.62 W
Protection class: IP 30
Battery
Nominal voltage: 7.4 V
Capacity: 2200 mAh
Power: 17 Wh
Adapter
The set includes 4 adapters for the charger. These adapters fit to the most common power supply systems. There
might be some incompatibility with the power system in some countries. In such cases other adapters may need
to be used.

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Release Tool
The key is only intended to release the cylinder pressure sensor from the indicator cock. The adapter has to be
tightened with a maximum of 25 Nm; no mounting or fixing tool is necessary for this.
Ultrasonic Sensor
A passive sensor able to receive ultrasonic waves. The sensor is connected to the handset via a connecting cable
(page 6 graphic 2.1).
Dimensions: W x L x H ca. 38 x 136 x 22 mm
System temperature min./ max.: -50…+100 °C
Connection: 2-pole plug
Output signal: 0…10 VDC
Connecting Cable for ultrasonic sensor / handset
Cable: triaxial cable with EMV shield
Length: 1200 mm
Connection: 2-pole plug
Data Transfer Cable
The data transfer cable is required to transmit the measurement data from the handset to the PC.
Connection Port Length Reference page 7
RJ 45 2000 mm Socket 2.3a
USB 2000 mm Socket 2.3b
The end of the cable has a protective cover made of steel to prevent any damage to the plug.
Software (on CD or by download)
The software needs to be installed on a PC/Laptop/Notebook to read out, transfer and anaylse the monitored and
recorded data.
Handbook
The handbook is intended to assist you during installation, initial start up, and while measuring.
Check the scope of your delivery as regards completeness and condition!
4 Initial Start-Up
The CPM comes with a built-in battery. Charge the battery completely and monitor the state of charge as described
under 4.3 and following pages. Turn on the handset by pressing the START button (2 sec.). The LED POWER
shining green. The handset is now ready for use.

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The cylinder pressure sensor is mounted and can be used without any further measures.
The assembly of the ultrasonic sensor has to be done. To do so, see also chapter 5.3 connecting the sensors.
To install the software, see chapter 7.
4.1 Charger/ Battery
The CPM comes with rechargeable batteries for mobile use. The batteries are lithium-ion batteries, with no memory
effect, low self-discharge and deep discharge protection.
4.1.1 Changing the Rechargeable Batteries
To change the batteries, loosen both screws at the bottom and remove the lid.
Caution! The sockets remain attached to the lid. The cables are long enough
For the battery to be removed out of the casing without difficulty. Disconnect
the power between battery and handset and only use rechargeable batteries,
furnished with an identical plug, or you'll risk reverse polarity and the handset will be damaged.
Attention!
Only replace rechargeable batteries with an original spare part. Batteries
are hazardous waste and do not belong in the household waste.
4.2 Charger
Prior to use, compare the indicted data of the charger and check it corresponds to the system voltage and system
frequency available.
The charger is specially made for lithium-ion batteries, use only this charger to recharge the batteries. Prior to use,
check the bottom of the charger for proper settings, charging voltage 8.2 V (graphic 4-1), and if necessary correct
it using the yellow setting-wheel (arrow must point to 8.2 Volts).
Setting-wheel for charging voltage,
arrow must point to 8.2 Volts
Lever to release the adapter
4.2.1 Changing the Plug
Included in the delivery are 4 adapters for the charger that can be used for most common power supplies (page 6
graphic 6). Choose the most suitable one and change it by sliding the lever on the bottom part of the charger (labelled
OPEN) in the direction of the arrow (graphic 4-1).
Figure 4-1 charger

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The adapter will be ejected. The right adapter needs to be placed in the fixture and pressed down, until it audibly
clicks into place and tightly anchors to the charger. Pay attention to the mounting direction as the adapter will only
fit in one position.
4.3 Connecting the Charger
First, connect the charger by plugging the plug of the charging cable into socket 2.4 at the bottom of the handset.
The plug will only fit if the red dots on the plug and those on the socket line up. Right after that, the charger may
be connected to an appropriate socket.
4.3.1 Status of Charging
When power is supplied by mains connection, the green LED POWER at the front of the charger will glow; it
displays the functional status of the charger. The yellow LED CHARGE also comes on when charging and when
the rechargeable battery is connected. Once the battery is fully charged, the yellow LED goes out and only the green
LED shines.
Attention!
Only the right plug ensures the requisite level of safety! The charger is
made to operate only in closed rooms and should not be used outdoors.
Red dots need to be/form a line
Figure 4-2 plug connection charger for handset

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The green LED displays “Stand by” status;
the charger is connected to the power supply.
The yellow LED displays “Charge” status.
When it is ON, the battery is charging. When
it is OFF, the battery is fully charged.
Figure 4-3 Significance of LEDs of the charger
5 Getting Ready to Take a Measurement
Before beginning to measure, a few points need to be considered and addressed. This will ensure that the measure-
ments can be performed without any problem and that the measurement results are comparable and useful and to
ensure that the measurement device functions reliably and that the evaluation of the measurement data can be done
free of errors.
5.1 Marginal Conditions
Prior to measurement, ensure that the conditions are exactly the same as they were during the previous measurement.
These include:
Same engine load point
If possible, lock the governor (comply with the safety concept)
On ships, pay attention to a calm sea
No measurement during rudder motion
With power stations, pay attention to constant load decrease
Attention!
Cylinder pressure measurements should only be conducted on stationary
load points, since varying load points falsify measurement results.

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5.2 Setting-up the monitoring device
LED 1 = Power
LED 2 = Cycle
LED 3 = Status
Turning the device on: Press the START button for 2 seconds. Once the LED 1 is green, the handset is ready. If
LED 1 is red, this means that the battery is low. If the battery voltage drops even more, the device will switch off
itself automatically. The battery may need to be recharged prior to measurement.
Deleting memory: Press the START button for 2…5 seconds. LED 1 and 3 will indicate green. Release the START
button. Pressing the START button again confirms the delete process and LED 3 indicates red while deletion takes
place. LED 3 is off once the delete process has ended. If you do not confirm the delete process, it will stop after
about 3 seconds and LED 3 will switch off again.
5.3 Con-
necting the Sensors to the Measuring Device
Attention!
The cylinder pressure sensor is permanently connected to the handset. Disconnect-
ing the sensor from the handset will result in losing warranty!
The ultrasonic sensor is mounted to the top part of the handset (socket 2.1, page 6). The plug-connection is not a
screw, so it will latch itself. It will unlatch if you pull on the plug, but not on the cable. The same type of connection
can be found between the cable and ultrasonic sensor. Only when both red dots line up can the plugs are connected.
To
connect
To separate
Attention!
Owing to limited memory capacity and to avoid mixing up measurement data, you
have to delete the memory every time before you take the first measurement.
Note!
You can find a complete summary of the meaning of the LEDs in the ap-
pendix:
Table 10-2 Significance of the LEDs.

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Note!
The ultrasonic sensor cable is a cable especially tuned for this
particular sensor. In the event of damage, do not replace it with
another one. Please contact for assistance.
Attention!
Sensors, cables and the handset are highly sensitive measure-
ment instruments. That is why you should never pull on a cable
and why you should treat sensor, cable and handset with care!
5.4 Preparation of the Measurement Points
Before the actual measurement takes place, all metering points have to be prepared to protect the device from being
destroyed by fouling and to obtain good measurement values.
To do so, clean the threads of indicator cocks using a wire brush or some other appropriate tool and blow through
to ensure that any fouling in the indicator cock does not damage the cylinder pressure sensor when carrying out
measurements later. These preparatory measures will save you time when carrying out measurements.
Attention!
Hot gas and solid component parts will come out at high pressure when the indicator
cock is opened. Step aside before you open it,
do not hold your head right above the indicator cock, and do not look into the open-
ing as long as substances can come out of the indicator cock.
Please comply with occupational health and safety measures and wear protective
goggles and gloves while operating a running engine.
All parts within the appliance can be so hot that they may seriously injure you.
A level surface at the cylinder head is needed for the ultrasonic sensor. The surface must be free of dirt and paint.
Thanks to magnets, the sensor is self-adhesive. To obtain exact measurements, the ultrasonic sensor must be
mounted directly on the cylinder head – not on the cylinder liner and not on the engine block. A small amount of
oil, used as coupling medium, should be applied between the ultrasonic sensor and area of measurement.
Figure 5-1 Connection of ultrasonic sensor and handset

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Figure 5-2: Cutaway of cylinder head and ultrasonic
sensor. Place sensor, as shown in the picture, on top of
a level surface
Cylin er hea
Ultrasonic sensor
One by one, the measurement data are stored on a memory card. These data cannot be sorted. Therefore, it is essen-
tial to number the cylinders. The most suitable thing would be to use the cylinder numbering system offered by the
manufacturer, which is found in the engine manufacturer's manual. Begin with the first cylinder station and work
your way up, step by step, through to the last cylinder station.
Attention!
Keep to the proper sequence, beginning with the first cylinder station
all the way to the last as measurement values cannot be interchanged!

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MAN
Exhaust Side
CCS CS
Control Side
Wärtsilä
Exhaust Side
CCS CS
Control Side
V-Engines MAK / Caterpillar
Side A
CCS CS
Side B
Figure 5-3 Counting methods for MAN, Wärtsilä and MAK engines
Special Features of V Engines
For measurements using a V-engine, begin on bank A at the cylinder station 1 and then measure the entire bank.
Only then should you start to carry out measurements on bank B in the same order.
2
1 3 4 5
1
2
3
4
5
6
7
8
9
10
4
5 3 2 1

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6 Carrying Out Measurements
6.1 Cylinder Pressure Measurement
Cylinder pressure measurement is an essential diagnostic tool to monitor the status of the engine and its individual
cylinders. To do so, the march of pressure of all strokes is measured and represented.
The measured data is transferred into a diagram with cylinder pressure over the degree of the crank angle [°CA]. It
represents a curve, from which the following points regarding supervision and state-based maintenance can be an-
alyzed:
Start of compression
Slope of compressibility curve
Height of compression pressure
Start of combustion
Maximum cylinder pressure
Opening and closing of valves
6.1.1 Carrying Out Cylinder Pressure Measurements
For a safe and rapid measurement, it is necessary that the measurement point preparations as outlined in chapter 5.4
have been completed and the handset has been prepared. The measurement begins at the first cylinder station and
is to be conducted according to the following structure:
-Check that the battery is charged (see Chapter 4.3).
-Attach sensors to the handset (see Chapter 5.3).
-Delete memory (see Chapter 5.2).
-Determine cylinder station number 1 (see Figure 5-3).
-Using the belt, hang the handset over your shoulder so you will have one free hand.
-Position yourself in front of the cylinder head in such a way that you can safely reach the indicator cock.
-Screw the cylinder pressure sensor clockwise (hand-screwed max.). If the sensor is screwed on too tightly, it will
be damaged. If the sensor is too loosely, it can come off and shoot off owing to the cylinder pressure of the
indicator cock. This constitutes a serious risk of injury! Position yourself next to the indicator cock, not in front
of it and not above it!
-Turn on the handset by pressing the START button for 5 seconds. LED 1 will glow green.
-Fully open the indicator cock, using the appropriate tool. No gas must be permitted to escape from between sensor
and indicator cock.
-Wait approx. 15…20 seconds with the first cylinder to ensure that the sensor can warm up.
-Briefly press the START button (LED 1 and 2 will glow green).
-Measurement begins (If you briefly press the START button, you can manually terminate this measurement.).
-When LED 2 switches off, the measurement has finished and the data is recorded.

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-The device is ready for the next measurement, if LED 1 only is green.
-Close indicator cock.
-Unscrew cylinder pressure sensor. You may have to use the tool provided. Do not hit it with a hammer or a similar
object.
-Repeat step 6 to 16 for all remaining cylinder stations.
-Turn the device off after all measurements have been completed. Press the START button for little more than 6
seconds or until all LEDs have gone out.
Attention!
While measuring, make sure you are safely positioned. The rule of thumb of "one
hand for the ship, the other hand for me" applies here.
Position yourself next to the indicator cock and not in front of it or above it.
Comply with health and safety procedures and accident prevention regulations!
Attention!
Write down the charge air pressure as it needs to be entered into the software by hand.
LED 1 and 2 indicating green light, means that the device is measuring the cylinder pressure. The measurement
time depends on the engine and rotational speed. There is an overview of the measuring time in Table 6-1.
Rotational Speed [1/min] Engine Total Time of Measurement [s]
20 2 stroke 88
150 2 stroke 20
250 4 stroke 22
1000 4 stroke 13
1500 4 stroke 12
2000 4 stroke 12
Table 6-1 Times and Cycles to Determine Sampling Rate

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6.2 Explanations Regarding Cylinder Pressure Measurements
Figure 6-1 Cylinder Pressure Curve
Description of Figure:
Cylinder pressure, in bar (1 bar = 100,000



= 0.1 MPa), is located on the vertical axis, on the left-hand side. The
piston path is displayed in degree of crank angle [°CA] and is located on the horizontal axis, lower limit. The curve
shows an open p/αdiagram.
Conversion of crank angle to path:
 1
412
s = piston path r = upstroke radius
λ= connecting rod ratio α= crank angle
1 2 3 4 5

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With 2-stroke engines, the pressure range of –180 °CA to +180 °CA is displayed. This corresponds to 360 °CA =
one engine revolution = charge exchange + compression stroke + power stroke.
EO = exhaust valve opens
EC = exhaust valve closes
IO = inlet opens
IC = inlet closes
TDC = top dead centre
BDC = bottom dead centre
Valve Timing Diagram, Two Stroke Engine
TDC 0°
BDC -180° / 180°
= power stroke
0...180 °CA
= compression stroke
–180…0 °CA
= injection duration
= charge changing
Power Stroke Diagram, Two Stroke Engine
EO
IO
TDC
BDC
IC
EC
Rotational
direction
90°-90°
PMS
0/°