Leutert DPI User manual

Digital Pressure Indicator DPI
Operating Instructions
Cylinder pressure monitoring
The DPI Digital Pressure Indicator measures dynamic pressures. It is
designed to analyze the internal combustion curve of large two and
four stroke diesel engines. The measurement is performed via an
indicator valve.

Digital Pressure Indicator DPI - Bedienungsanleitung
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Content
1 Safety instructions .............................................................................4
2 Product description............................................................................5
2.1 Application and function ..........................................................5
2.2 Handheld device.......................................................................6
2.2.1 Design..........................................................................6
2.2.2 Technical data ..............................................................7
2.3 Pressure sensor.........................................................................8
2.3.1 Design..........................................................................8
2.3.2 Technical data ..............................................................8
2.4 Software ..................................................................................9
2.4.1 Description...................................................................9
2.4.2 Requirements for the PC ..............................................9
3 Prepare the DPI system for use.........................................................10
3.1 Software installation...............................................................10
3.2 Prepare the handheld device for the measurement.................. 12
3.2.1 Enter motor parameters.............................................. 12
3.2.2 Transfer motor parameters to the handheld device .....14
3.3 Set date and time of the handheld device ...............................16
4 Perform measurement on the motor................................................ 17
5 Display measurement results ............................................................21
5.1 Transfer data records from the handheld device to the PC....... 21
5.2 Analyzing measurement data with the DPI software ...............23
5.2.1 Pressure Plot...............................................................24
5.2.2 TDC Correction ..........................................................28
5.2.3 PV Plot .......................................................................30
5.2.4 Bar Graph ..................................................................32
5.2.5 Data Info ....................................................................34
5.2.6 Raw Data ...................................................................35
5.3 Sending and receiving measurement data by email .................36
6 Organize measurement data in the handheld device ........................38
6.1 View data records on the handheld device..............................38
6.2 Delete data records in the handheld device.............................39
7 Maintenance....................................................................................40
7.1 Maintenance of the pressure sensor........................................40
7.2 Cleaning the pressure sensor ..................................................40
7.3 Charging the handheld batteries............................................. 41
7.4 Changing batteries .................................................................42
7.5 Setting the contrast, background lighting of the handheld device .43

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General
The operating instructions serve to ensure that the product is used properly,
effectively and safely. Please read all instructions and warnings carefully.
Follow all safety precautions to avoid personal injury or property damage
during the workflow. For damage or injuries caused by non-compliance
with the requirements, the manufacturer assumes no liability. The manu-
facturer also takes over no liability if other than original manufacturer spare
parts and consumables are used.
This operating manual is directed mainly at technically trained personnel.
In case of doubt regarding safety or operational aspects, please do not
hesitate to contact the manufacturer for assistance. Should you notice a
faulty description or depiction or if you would like to suggest points for
improvement, we are looking forward to hearing from you.
Please keep the operating manual near the product to have it available if
needed. Make sure that the manual is protected from dirt and moisture.
Explanation of symbols:
DANGER
Immediate danger is possible causing severe injury or death if you do
not follow the instructions given.
WARNING
If you do not heed the warning, dangerous situations may occur leading
to severe injury or death.
CAUTION
Follow the instructions carefully, otherwise dangerous situations may
occur leading to injury or damage to property.
NOTICE
Please follow the recommendations and instructions for a correct and
flawless operation of the device or measuring system.

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1 Safety instructions
The DPI may only be operated by trained personnel with the utmost cau-
tion and in compliance with the safety regulations for measuring large die-
sel and gas engines.
DANGER
Wear protective glasses during the measurement as hot gas or par-
ticles come out of the engine and could injure you. Wear hearing
protection during the measuring process as it can get very loud in
the engine room.
WARNUNG
Put on protective gloves before measuring because the surface of
the indicator valve and the sensor can get very hot during the indi-
cation process.
Do not operate the DPI hand-held device and the pressure sensor
above the allowed pressure and temperature ranges.
Remove the pressure sensor from the indicator connection immedi-
ately after each measurement to avoid overheating.
Use the hollow key provided.
NOTICE
Protect the DPI from moisture to prevent corrosion damage.
Do not insert any tools into the sensor bore.
Cooling the sensor with liquids is not permitted.
If the BAT indicator light on the handheld device is red this indicates
a low battery charge. There remains a measuring time of about 20
minutes. End the measurement within this time and charge the bat-
teries.
Charge the batteries via the USB connection of the handheld device
by the PC or with the associated USB charger.
When replacing the battery only use identical types.

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2 Product description
2.1 Application and function
The DPI (Digital Pressure Indicator) measures dynamic pressures. It serves
for Analysis of combustion processes in 2- and 4-stroke large diesel engi-
nes. The measurement is carried out via an indicator valve. This electronic
indicator is the consistent further development of the successful digital in-
dicators of the DPI range and replaces all mechanical indicators.
In order to be able to measure pressure profiles with the DPI each cylinder
of the engine must be equipped with a standard indicator valve. By means
of the Thompson adapter the DPI pressure sensor is temporarily mounted
to the corresponding indicator valve. The construction of the Thompson
adapter minimizes the risk of overheating since the heat is dissipated quick-
ly.
By using a high-resolution sensor and a very high query rate of the hand-
held device the DPI can assign a crank angle performance and create a
power calculation without the use of a TDC sensor.
The electronics of the battery-operated DPI handheld device is installed in a
robust splash-proof plastic housing. The low mass display is not pulled out
of its seat in the event of impacts as it is often the case with larger displays.
Menu texts and measurement data are shown on the LC display of the DPI
hand-held device. The menu structure is easy to grasp and enables you to
operate measuring system intuitively. The menu-driven control enables you
to use the DPI effectively after a short time.
The DPI is operated with standard AA batteries which can be replaced by
releasing a single screw.
The measurement results are displayed during the respective cylinder me-
asurement on the display of the DPI handheld device and are saved on the
device‘s internal SD card.
A data set consists of several measurements (cylinder numbers) that
amongst other things contain the following values:
– Place of measurement (ship name)
– Engine name
– Date / time
– Number of measuring cycles (cycles)
– Highest cylinder pressure (Max. Press.)
– Average cylinder pressure (Avg. Press.)
– Lowest cylinder pressure (min. Press.)
– Engine speed (RPM)
– Boost pressure

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BAT ACT
2.2 Handheld device
2.2.1 Design
Control buttons
ON / OFF button
USB socket type B
LC display with backlight,
4 lines x 20 alphanumeric characters
4-pin connection socket for pressure sensor
LED for status display of the batteries
and of the measuring process
ACT display:
– flashes blue during the measurement
BAT battery charge displays:
– lights up red: low battery charge
– flashes red: the automatic shutdown will take place shortly
– flashes green: active charging of the batteries
– glows green: batteries fully charged
All representations and mathematical calculations in the DPI software are
based on this data.
The saved measurement data can be transferred to a PC / laptop by the DPI
software to be visualized, evaluated or to be sent electronically.
The measurement data evaluation using Windows-based software gives
the ability to make complex diagnostic statements about the quality of the
combustion processes.
Every product is manufactured according to the ISO 9001 quality standard,
tested and shipped with a calibration certificate which guarantees a high
device accuracy.

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Plastic housing
Type label with CE marking
Shoulder strap
2.2.2 Technical data
Storage capacity : 50 engines with up to 24 cylinders each
Interface : USB 2.0
Power supply : rechargeable standard AA
NiMH batteries 1.2 V / 2000 mAh
Battery life : > 6 h for sensor 0 to 300 bar
Battery charging : via USB
Display : 20 x 4 alphanumeric characters, with
backlight, high contrast
Degree of protection : IP 65
Temperature range : 0 bis 55 °C
Dimensions : 211 x 100 (81) x 45 (26) mm
Weight : 430 g incl. batteries
Battery compartment for 4 x 1.5 V
batteries

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2.3 Pressure sensor
2.3.1 Design
The DPI is supplied with a pressure sensor and connection cable. By the
armored cable with plug the sensor is connected with the DPI hand-held
device.
The pressure sensor is suitable for temporary measurements on indicator
valves only (gas pressure measurements on internal combustion engines).
Measurements on hydraulic systems must not be carried out.
The quartz sensor is characterized by high accuracy, robust construction
and durability. Its calibration interval is 8000 operating hours. The cali-
bration check can only be carried out by the manufacturer. In this regard
please contact the manufacturer.
NOTE
The screw of the pressure sensor is sealed to prevent improper use
or handling. Breaking the seal will lead to loss of warranty.
2.3.2 Technical data
Pressure range : 0 to 300 bar
Speed range : 50 to 5000 rpm
Accuracy : < 0.5%
A/D resolution : 16 bit (0,0092 bar/sample)
Degree of protection : IP 65
Connection thread : W 27 x 1/10”
Temperature range : 0 to 350 °C
Dimensions : Ø = 60 mm, L = 180 mm
Weight : approx. 490 g
Connection cable
Connection thread W27 x 1/10 ”
Piezoelectric sensor
(inside)

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2.4 Software
2.4.1 Description
After measuring the engine the measuring values saved in the handheld
device are transferred to the PC and can be displayed with the DPI soft-
ware and evaluated in detail. To analyze the engine data different visu-
alization modes are available (pressure diagram, PV diagram, bar graphs,
tabular information).
To operate the DPI software you can use the commands in the menu bar,
the four tabs for selecting the display mode and various buttons.
The software enables data export, report generation or sending of the
data by email with just a few clicks.
In addition the software is used for comfortable configuration of the hand-
held device.
Since the software is in English language basic knowledge of English is fa-
vorable but not a requirement. In the manual you get a detailed description
for each command which enables you to work with the program without
any foreign language skills.
Menu commands
Tabs to select the display mode
Command buttons
LED shows connection of
handheld device on the PC
Display area

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2.4.2 Requirements for the PC
In order to be able to run the DPI software, your PC should meet the fol-
lowing requirements:
– A free USB port for data transfer between the handheld device
– and PC
– approx. 15 MB free space for the installation of the software and the
– documentation
– Windows 7 and higher
– minimum screen resolution 1024 x 768, recommended 1280 x 1024
– Color 16 bit or higher
– Printer, color printer recommended
This manual was created for software users who have basic knowledge
of computer skills. You should be familiar with the typical Windows fea-
tures like menus and command buttons since these elements are not ex-
plained here.
Menu “File”
Opens a data record from the PC’s hard drive
Data export as a dpz file on a PC or by email Imports a
dpz file from the PC hard drive
Exports the opened data record to an xls file Create a
report for printing or as a PDF file
Exit the program, also with Alt + F4
*) A dpz file is a measurement data record in DPI for-
mat and to be read with the DPI software only.
Menu „About”
Display of software version and manufacturer
Find and install updates available online
Link to the manufacturer’s homepage
Menu „Settings”
Selection of the display colors for the 24 cylinders
Enter the company name, address and logo for the report
Menu „Handheld”
Imports a data record from the handheld device into the PC
Exports the engine data
Synchronize the date/time of the handheld device with the
PC
Menu commands

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3 Preparation of the DPI system for use
3.1 Software installation
The software is stored in the handheld device’s memory upon delivery
and must be copied and installed on the PC before use.
1) Connect the DPI handheld device with a Windows PC using the sup-
plied USB cable. The DPI automatically turns on and is recognized by
the computer as a drive. Additional device drivers do not need to be
installed.
2) Open the newly recognized drive ‘DPI’. Select the file ’Installer DPI
(version no.). Exe’ and copy it to the PC, for example on the desktop.
NOTICE
DO NOT start the installation directly from the DPI drive!
3) Start the software installation on the PC by double-clicking to the
file ‘Installer DPI (version no.). exe’.
4) Confirm the license conditions and continue with [Next>].

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5) Follow the further installation instructions. Finally the DPI and a pro-
gram group appears in the Windows start menu and Desktop icon
for the DPI software.
If a previous version of the DPI software is already set up on your PC,
you can update it. You will receive updates e.g. electronically..
Start the installation of the new software as described above. Here the
installation program searches for existing versions and automatically selects
their installation path.
During the update the program files are updated as well.
The directory with the measurement data remains unaffected.
NOTICE
The measurement data and program settings are saved on the
System drive C under your user name \ My Documents \ DPI. Please
back up this data regularly. Please be aware that a reinstallation of
Windows will overwrite the directory `My Documents` and the data
could be lost.

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3.2 Prepare the handheld device for the measurement
3.2.1 Enter engine parameters
At first use of the device you have to enter the engine parameters once for
each engine.
NOTICE
Pay attention to correct entries so that the DPI gives you correct
measurement results.
1) Start the DPI software on the PC. Open the command [Open Data-
base] in the menu [File].
2) Select [Create Ship]. Place the mouse pointer on the line ‘ANewS-
hip’ and enter the name of the ship / power plant or similar. Under
‘Description’ you can write down additional information. Save the
entries with [Save].
3) Mark the ship’s name and click on [Create Engine] to set up an en-
gine for this ship.

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4) Enter the engine-specific parameters in the ‘Create new Engine’
window.
Dataset
Engine name : Name of the engine
Stroke length : stroke length
Correction rod length : length of the connecting rod
Piston diameter : piston diameter
Engines : engine manufacturer / type
Handheld
Default boost pressure : charge air pressure (standard)
Default meas. cycles : measuring cycles (standard)
Default meas. cylinder: no. of cylinders (standard)
Default strokes : 2- or 4-stroke engine
NOTICE
When determining the length of the connecting rod the dis-
tance between the large end and the small end has to be
considered and not the total length of the connecting rod.
The DPI is able to measure the TDC based on the pressure curve
showing the course of combustion. This is the basis of the power
calculation. For engines with premature combustion for reduction
of nitrogen oxide emissions some peculiarities result regarding the
automatic detection of the TDC. In these cases the check box [NOx]
can be ticked to determine the TDC.
Use the DPI‘s ability to prevent interfering influences on the mea-
surement result by selecting certain measurement settings, e.g. the
number of measurement cycles as basis for averaging. This gives you
results which enable you to compare the measurement data of the
individual cylinders to each other.
5) Save the entries with [OK]. Repeat this step for more engines if nec-
essary.
During the indication process the DPI uses the current measuring settings
for each engine. These will be saved until they are redefined.

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3.2.2 Transfer engine parameters to the handheld device
1) Connect the handheld device to the PC by means of the USB ca-
ble. The handheld device switches on automatically and the battery
charging process begins.
2) A green LED symbol in the status bar of the DPI software indicates
that the handheld device is connected to the PC.
NOTICE
If the handheld device is connected to the PC or the battery
charger via USB button operation is not possible.
3) Open the [Export Engines Data] command in the [Handheld] menu.
In the upper ‘Setup’ area the datasets are displayed which are al-
ready stored in the handheld device. If you mark an engine with the
mouse you will see the assigned “parameters” in the lower window
area. If no engine data has been saved yet in the handheld device
the following window would be empty.
4) Click the [Add Engine from Database] button.

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5) Mark the desired engine and click on [To Handheld]. After success-
fully transferring the engine parameters to the connected hand-held
device the new engine appears in the list. The handheld device is
now ready for the measurement.
NOTICE
You can enter and save the parameters of a maximum of 50 engines
in the DPI.
6) Close the window with [Close] and disconnect the handheld device
from the PC.

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PMI
Connected to USB
Recharging . . .
---}----------------
3.3 Set the date and time of the handheld device
The correct value of time and date is necessary to ensure an exact temporal
assignment of the measurement results.
The date format is month / day / year, the time is displayed in
hours:Minutes:seconds.
The date / time setting of the handheld device is done in the DPI software
by synchronization with the PC settings, provided the PC is set up correctly.
1) Connect the handheld device to the PC using the USB cable. The
handheld device switches on automatically and the battery charging
process begins.
2) Start the DPI software on the PC.
3) Open the menu [Handheld] and [Sync. Time].
4) Click the button [Synchronize Time to Handheld] button. The date
and time settings of the PC are transferred to in the handheld device
and saved there.
5) If necessary, disconnect the handheld device and PC. The handheld
device switches off automatically.

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4 Perform measurement on the engine
DANGER
Wear protective glasses during the measurement as hot gas or parti-
cles come out of the engine and could injure you.
Wear hearing protection during the indication process as it can get
very loud in the engine room.
WARNING
Put on protective gloves before indicating because the surface tem-
perature of the indicator valve and the sensor can get very high
during the indication process.
Do not operate the DPI handheld device and the pressure sensor
above the allowed pressure and temperature ranges.
NOTICE
Ensure that the load and the speed is as constant as possible during
the measurement in order to get comparable results.
If the sensor cable is not connected to the sensor, insert the orange contact
into the pressure sensor and secure the contact by screwing on the knurled
nut. Pull it hand tight. The plugs of the connection cable have a “nose /
slot” connection identifier. Please pay attention to correct insertion.
Plug the sensor cable into the 4-pin connection socket of the handheld
device. Please make sure that the red marking point shows towards the
display of the handheld device and the plug is not turned.
1) Before installing the pressure sensor, clean the relevant indication
channel by fully opening the indicator valve briefly while the engine
is running in order to blow out the channel. You thus avoid the sen-
sor membrane being contaminated or damaged.
2) After blowing out close the indicator valve completely.
3) Then attach the pressure sensor to the indicator connection of the
Engine.
NOTICE
First hand-tighten the cold sensor to prevent it from seizing.

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Sensor warm up
Time left: 00:48
Cancel
PMI
SN: 9757
Version: 1.03.31
» Main menu «
Measure engine
Show data
» Measure engine «
Main Engine
AUX Engine 1
}

}

» Measure engine «
Main Engine
AUX Engine 1
AUX Engine 2

}

}
Measure engine
AUX Engine 1
Cylinder no: 01
No Yes
Cylinder no: 01
Cylinder no: 01
} }
AUX Engine 1
Measure entire eng.
or redo single cyl.?
Cylinder Engine
Overwrite
AUX Engine 1
Cylinder no: 01?
No Yes
AUX Engine 1
Overwrite prev.
Measurements?
No Yes
}
}
}
}
}
}
4) Press the button for 1 second to switch on the handheld device.
The serial number and the firmware version appear on the display
for a short time.
5) In the main menu you can now use the arrow keys or to
change the lines. Confirm with the button if the line `Measure
engine` is marked by the }arrow.
6) Scroll with the vertical arrow keys or , until the motor to be
measured is marked on the display with the }arrow.
8) Start with . The sensor warm-up phase begins. A cancellation is
possible with the button , the display changes back to the main
menu.
NOTICE: Do not turn off the DPI before the measurement is
terminated otherwise you would have to wait for the pres-
sure sensor to warm up again before each measurement.
7) Open the indicator valve completely.
9) The engine to be measured appears after the warm-up phase. Below
that the cylinder number appears as a flashing digit. If necessary change
the cylinder number with the arrow keys or . Confirm by .
NOTICE: The series of measurements automatically starts
with cylinder 1 at the beginning of a new measurement. Oth-
erwise the system is counting up starting from the last mea-
surement.
10) If data for this cylinder is already stored in the handheld device, de-
cide here whether you want to repeat the complete measurement
series of the engine by or only that of the cylinder by .
10.1) If the existing cylinder data should be overwritten please confirm
with Button and go to step 11. If canceled with button the
display changes back to the main menu.
10.2) Use the arrow key to confirm overwriting the existing engine
data and go to step 11. If canceled with button the display
changes back to the main menu.

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Measure engine
AUX Engine 1
Cylinder no: 01
Cycles: 010
Measure engine
AUX Engine 1
Cylinder no: 01
Boost: 0,50
Cycles: 010
Cycles: 010
Boost: 0,50
Boost: 0,50
Cycles: 010
Boost: 0,50
Boost: 0,50
Measure engine
Start measurement?
No Yes }
}
Measuring engine ...
AUX Engine 1
Cancel
Measuring engine ...
AUX Engine 1
RPM: 240
Cancel
Measuring engine ...
AUX Engine 1
Calculating ...
}
}
Measurement finished
1.Close valve!
2.Disconnect sensor!
3.Hit key to confirm
11) The number of measuring cycles can be adjusted with the arrow
keys or . Confirm the value by .
13) Start the measurement with the key . During the measurement
the ACT display flashes blue.
12) In the following display the boost pressure can be adjusted with the
or button. Confirm with the key .
After the measurement is finished the results are calculated.
14) Close the indicator valve completely.
15) Unscrew the pressure sensor. Due to expansion of the sealing cone in
the pressure sensor the hollow key may be required for unscrewing.
CAUTION
After completion of the measuring series, remove the pres-
sure sensor from the indication bore in order to avoid overhe-
ating.
NOTICE
If the pressure sensor does not come loose, open the indi-
cator valve for a short time to achieve a loosening through
the combustion pressure. Close this valve immediately after
removing the pressure sensor from the indicator valve.
16) For security reasons confirm the correct performance of steps 14
and 15 by the key .