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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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