IMES TCS-01CA-PMI User manual
Operation Manual TCS-01CA-PMI Sensor
12.02.2021
Page 1 of 21
Original operating instruction
TCS-01CA-PMI incl connecting cable
and adaptor
IMES Gmbh Phone: +49 8341 9661730
Dr.-Herbert-Kittel-Str.2 Fax: + 49 8341 9667318
Germany www.imes.de
Operation Manual TCS-01CA-PMI Sensor
12.02.2021
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1 Important information __________________________________________________ 3
1.1 Use of the operator manual __________________________________________________ 3
1.2 Copyright ________________________________________________________________ 3
1.3 Warning Notices ___________________________________________________________ 3
1.4 Address of the manufacturer ________________________________________________ 4
1.5 Obligations of the operator __________________________________________________ 5
2 Safety ________________________________________________________________ 5
2.1 Intended use ______________________________________________________________ 5
2.2 Safety notes _______________________________________________________________ 6
3 Transportation and packaging ____________________________________________ 6
3.1 Safety notes for transportation _______________________________________________ 6
3.2 Scope of delivery __________________________________________________________ 7
3.3 Packaging ________________________________________________________________ 7
4 Technical data TCS-01CA-PMI sensor _____________________________________ 8
4.1 Fault indication ___________________________________________________________ 8
4.2 Drawing __________________________________________________________________ 9
5 Installation instructions of TCS-01CA-PMI sensor __________________________ 10
5.1 Pressure sensor with adaptor and indicator valve ______________________________ 10
5.2 Disconnection of existing ABB sensor ________________________________________ 11
5.3 Mounting of IMES adaptor_________________________________________________ 11
5.4 Mounting of indicator cock on IMES adaptor _________________________________ 12
5.5 Mounting TCS-01CA-PMI sensor on adaptor _________________________________ 12
5.6 Fixing connection cable to SCU and female connector __________________________ 13
5.7 Fixing protection cover ____________________________________________________ 14
6 Advice actions ________________________________________________________ 15
6.1 Use of indicator valve______________________________________________________ 15
7 Drawings ____________________________________________________________ 16
7.1 Overview sensor components (IW-9100) ______________________________________ 16
7.1 TCS-01CA sensor (IW-6105) _______________________________________________ 17
7.2 MAN Autotuning connector (IW-4116) _______________________________________ 18
7.3 Adaptor (IW-8005)________________________________________________________ 19
7.1 Protection cover (IW-6211) _________________________________________________ 20
8 EU Declaration of Conformity ___________________________________________ 21
Operation Manual TCS-01CA-PMI Sensor
12.02.2021
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1 Important information
Please study this manual carefully, before using the
equipment. 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.
1.1 Use of the operator manual
We strongly recommend you to read the complete manual
before using the equipment.
It was our intention to structure this manual in a clear
layout, to enable you to get easy and instant access to the
information you are looking for. Please keep this manual in
a safe place where it is always available for easy access.
1.2 Copyright
These operating instructions have to be treated
confidentially. They may only be used by the persons
authorised to this effect. They may only be given to third
parties with the written consent of IMES GmbH.
All documents are protected under copyright law.
Dissemination and reproduction of documents or parts of
documents as well as the utilisation and communication of
their contents are prohibited, unless expressly permitted.
Infringements are punishable and liable to damages.
We reserve all rights to exercise industrial property rights.
1.3 Warning Notices
In the present operating instructions the following warning notices are used:
A warning notice of this risk level signals a potentially dangerous situation. If the dangerous situation is not
prevented, this could lead to death or serious injury to persons. Follow the instructions in this warning notice to
prevent the possible risk of death or serious injury to persons.
Operation Manual TCS-01CA-PMI Sensor
12.02.2021
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A warning notice of this risk level signals a potentially dangerous situation. If the dangerous situation is not
prevented, this could lead to damage to property. Follow the instructions in this warning notice to prevent
damage to property.
A note identifies additional information that facilitates the handling of the device.
1.4 Address of the manufacturer
IMES GmbH
Dr.-Herbert-Kittel-Str. 2
87600 Kaufbeuren
Germany
Tel.: + 49 8341 966173 0
Fax: +49 8341 96617318
e-mail: [email protected]
Web: www.imes.de
Operation Manual TCS-01CA-PMI Sensor
12.02.2021
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1.5 Obligations of the operator
The TCS-01CA-PMI sensor may be a source of danger if used in an improper manner or not in proper condition.
The operator is obliged to operate the TCS-01CA-PMI sensor only in proper condition. Hazard areas arising
between IMES devices and customer equipment are to be secured by the operator.
The operator must designate and instruct responsible persons:
• Only employ trained or instructed personnel.
• Clearly define the responsibilities of the personnel for operation, maintenance, and repair.
• Regularly check if the personnel is working with due safety and risk awareness whilst observing the operating
instructions.
• Before starting work, the personnel assigned to work with the TCS-01CA-PMI sensor must have read and
understood the operating instructions, in particular the "Safety" chapter, as well as the applicable regulations.
• Keep the operating instructions and applicable regulations accessible to the operating and servicing personnel.
• Determine the responsibility of the user and allow him to reject all third party instructions that are in breach of
safety regulations.
• For safe operation of this TCS-01CA-PMI sensor it is required to wear safety glasses and gloves. Further
protective equipment has to be worn according to the applicable regulations of the operator.
2 Safety
2.1 Intended use
The TCS-01CA-PMI sensor may only be used for measuring combustion pressure on engines. Any other use of
the TCS-01CA-PMI sensor is impermissible. The manufacturer/supplier accepts no liability for damage resulting
from non-intended use. The risk exclusively rests with the user/operator.
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2.2 Safety notes
Observe the following notes for preventing accidents while using the TCS-01CA-PMI sensor:
• Operate the TCS-01CA-PMI sensor only in proper condition.
• Adjustment and/or maintenance work is to be carried out by authorised professionals.
• Before using the TCS-01CA-PMI sensor, check it for defects and deficiencies visible on the outside.
Immediately notify any changes (including changes in operating behaviour) to the competent staff/person. If
necessary, immediately put the device out of service and lock/tag it out!
• Keep the operating instructions near the TCS-01CA-PMI sensor to be readily available at any moment.
• Non-observance of the safety notes contained in these operating instructions may result in property damage,
injuries or even death of persons.
3 Transportation and packaging
3.1 Safety notes for transportation
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3.2 Scope of delivery
For the exact scope of supply please refer to the order documents and compare to the delivery note.
Check for completeness
Check the entire delivery for completeness based on the attached delivery note. In this context, we are referring
to our conditions of sale and delivery.
Report any damage
Immediately report to the carrier, insurance company and the delivering factory any damage to the device due to
improper packaging or transportation identified after delivery. Take action to mitigate the damage that has
occurred and prevent further damage.
3.3 Packaging
Unless an agreement was made with IMES GmbH regarding the return of the packaging material, the packaging
material remains with the customer.
The most commonly used packaging materials cardboard.
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4 Technical data TCS-01CA-PMI sensor
Measuring range pressure 0...250 bar
Over pressure static 400 bar
Frequency range 10 kHz
Thermal shock 1500 RPM pmi=9bar < +/- 0,5 bar
Accuracy < 1% Fulll scale
Temperature range of SCU -40 °C … + 75 °C
Supply voltage 18...32 VDC
SCU current consumption < 50 mA (continuous operation); 250 mA (switch-
on peak)
Output signal 4...20 mA
Sensitivity 56 µA/bar
Electrical connector Harting Han ES 10B (male) with housing Harting
Han 24B (male)
Thread M10 x 1
Dimension sensor 36.5 mm , Ø 13.5 mm
Tightening torque 15 Nm
Weight incl. electronic 1200 g
4.1 Fault indication
An output signal < 2mA indicates a fault.
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4.2 Drawing
Fig 1: Drawing TCS-01CA-PMI sensor incl. Autotuning connector
Fig.2: Drawing of adaptor
Soft iron sealings
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5 Installation instructions of TCS-01CA-PMI sensor
Apart from standard equipment, the following tools and material are required for installing the TCS-01CA-PMI
sensor and adaptor:
• A 27 mm open-ended spanner for the adaptor and indicator valve
• A 12 mm open-ended spanner for the TCS-01CA-PMI sensor for mounting on adaptor
• Copper paste or equivalent for the two threaded parts of the adaptor
The Adaptor has two soft iron sealings. One is used for sealing the indicator valve against the adaptor and one
for sealing the adaptor against the indicator flange. A set of soft iron sealings ( 2 pcs. of each size) are supplied
together with the adaptor.
5.1 Pressure sensor with adaptor and indicator valve
Fig. 3: TCS-01CA-PMI Sensor installed on adaptor
Adaptor
Indicator cock
TCS-01CA-PMI
sensor
Adaptor flange (not in
scope of supply)
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Fig.4: Overview of components
5.2 Disconnection of existing ABB sensor
Please disconnect existing ABB sensor from indicator flange and indicator cock. The connector should be
disconnected from female connetor
Fig.5: Disconnected ABB sensor incl. connector
5.3 Mounting of IMES adaptor
Install adaptor IMES adaptor with soft iron sealing on existing indicator flange. Use a 27 mm open-ended
spanner. Tightening torque 100 Nm. Use copper past or equivalent on the adaptor thread and iron soft sealing.
Fig.6: Installed IMES adaptor at MAN flange
Adaptor
TCS-01CA-PMI
sensor
SCU of TCS-
01CA-PMI sensor
Protection cover Connection cable (3m)
incl. Harting connector
and ITT Canon connector
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5.4 Mounting of indicator cock on IMES adaptor
The indicator valve must be placed directly on the top of the adaptor. Otherwise,
the extra volume added between the pressure transducer and the indicator valve might have
influence on the measured pressure. Use a 27 mm open-ended spanner.
Use copper paste or equivalent on the Indicator valve thread and iron soft sealings.
Tightening torque 60 Nm.
Important note
5.5 Mounting TCS-01CA-PMI sensor on adaptor
a.) Before assembling, lubricate the threads on the TCS-01CA-PMI sensor, the engine adapter
and the indicator valve and the surfaces of all sealing with copper paste or equivalent.
This facilitates future disassembly.
b.) Use a 12 mm open-ended spanner for to mount sensor on adaptor
c.) Mount the TCS-01CA-PMI sensor on the adaptor. Tightening torque 15 Nm.
d.) Bend away the cable between sensor head and SCU carefully when mounting the TCS-01CA-PMI
sensor
Fig.7: TCS-01CA-PMI sensor and indicator installed on adaptor
When mounting (or dismounting) the TCS-01CA-PMI sensor on the adapter, the cable between sensor head and
SCU must rotate along with it or else the cable will get damaged by the forced twist. This means that the
electronic unit and cable must be loosened when fastening/unfastening the TCS-01CA-PMI sensor.
Warning
Keep a safe distance to the blow out bore on the indicator valve of the Pressure
Transducer, because of the risk for particles and very hot gases coming out of the bore if
The indicator valve should normally not be opened when the engine is running in order to minimize the risk for
indicator valve leakage. It is normally sufficient to open the valve during slow turn in order to clean the
indicator bore as well as the pressure transducer and indicator valve.
However, when running the engine continuously for longer times, we recommend to open
the indicator valve for a few strokes once a week.
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the indicator valve is open.
5.6 Fixing connection cable to SCU and female connector
The connection cable (3m) incl. Harting connector to MAN PMI system.
Fig.8: Connecting cable (3m)
The SCU of TCS-01CA-PMI sensor should be connected via ITT Canon connector of connection cable (3m).
Fig.9: SCU connected to connetion cable (3m)
The Harting connector should be locked to existing female connector
Fig.10: Harting connector and female connector
ITT Canon connector
for connection to SCU
Harting connector for connection to
MAN PMI system
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The Harting connector is locked to female connector.
Fig.11: Harting connector to female connector locked.
5.7 Fixing protection cover
Please mount protection cover on SCU of TCS-01CA-PMI sensor to reduce vibration level.
Fig.12: Installation on engine
The SCU of TCS-01CA-PMI sensor is
placed in protection cover and connected to
sensor connecting cable (3m) which is
mounted on MAN PMI system.
Please fix protection cover with cable strips.
Sensor connecting cable 3m incl. Harting
connector to MAN PMI system.
TCS-01CA-PMI sensor installed on adaptor
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6 Advice actions
6.1 Use of indicator valve
Blowing through the indicator valve for more than one engine revolution or a leaking indicator valve may lead to
faulty measurements, reduced lifetime of the sensor and even sensor failure.
In general, it is recommended only to open the indicator valve while the starting valves are open and the engine
is turned by air. Indicator pipes and valves clogged with exhaust/soot deposits should be cleaned manually
before starting the engine.
Do not to blow through the indicator valve right before taking a manual calibration measurement. If clogging is
suspected, blow through the indicator valve at low load for maximum 1 engine revolution. Disassemble and
clean the valve manually if it is still clogged. Wait for minimum 10 minutes after the indicator valve has
been blown through, before mounting the handheld pressure transducer to take a calibration.
It is important to note that when cleaning the indicator pipe arrangement, the sensor element should not be
dissembled from the sensor block for cleaning of the sensor itself. A thin layer of soot on the sensor membrane
does not influence the measurement result, and it is therefore not necessary to dissamble it. Only heavy exhaust
deposits should be removed, for example by dissolving the deposits in sparkling water.
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7 Drawings
7.1 Overview sensor components (IW-9100)
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7.1 TCS-01CA sensor (IW-6105)
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7.2 MAN Autotuning connector (IW-4116)
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7.3 Adaptor (IW-8005)
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7.1 Protection cover (IW-6211)
Table of contents
