Complex Diagnostic System

Manual
CDS Manual Contents

1. Contents
2 Description of the CDS Systems 2.1
2.1 Revolutionununiformity Analysis ( RUN ) 2.1
2.2 Cylinder Pressure Analysis (CPA) 2.2
2.3 Injection Pressure Analysis (IPA) 2.2
2.4 Leakage Measurement System (LMS) 2.2
2.5 Piston Ring Monitoring (PRM) 2.3
2.6 Torque Measurement System (TMS) 2.3
2.7 Performance Monitor 2.3

3. Hardware installation 3.1

3.1 Installation of the basic components 3.1
3.2 Installation of the RUN module 3.2
3.3 Installation of the CPA, IPA, LMS modules 3.3
3.4 Installation of the PRM module 3.4
3.5 Installation of the TMS module 3.6

4. Software installation 4.1

4.1 Installation of drivers 4.1
4.2 Installation of the CDS-Software 4.1

5. CDS main window 5.1

6. Basic configuration of the CDS 6.1

6.1 Engine parameters 6.2
6.2 Measuring system 6.3
6.3 Setting the static TDC 6.4
6.4 Program parameters 6.6
6.5 Settings for communication with automation control 6.7

7. Revolutionununiformity Analysis (RUN) 7.1

7.1 Necessary hardware 7.1
7.2 Calibration 7.1
7.3 Taking measurements 7.1
7.4 Presentation of the measurement results 7.2
7.5 Alarm 7.4
7.6 Menu options of the RUN module 7.6
7.7 Configuration of the RUN module 7.7

8. Cylinder Pressure Analysis (CPA) 8.1

8.1 Necessary hardware 8.1
8.2 Extension with IPA module 8.1
8.3 Extension with LMS module 8.1
8.4 Calibration 8.1
8.5 Taking measurements 8.2
8.6 Presentation of the measurement results 8.3
8.7 Menu options for the CPA module including the extension module 8.9
8.8 Configuration of the CPA module including the extension module 8.10

Version 2.0 1.1

CDS Manual Contents

9. Piston Ring Monitoring (PRM) 9.1

9.1 Necessary hardware 9.1
9.2 Calibration 9.1
9.3 Taking measurements 9.5
9.4 Presentation of the measurement results 9.6
9.5 Alarm 9.9
9.6 Menu options for the PRM module 9.12
9.7 Configuration of the PRM module 9.13

10. Torque Measurement System (TMS) 10.1

10.1 Necessary hardware 10.1
10.2 Calibration 10.1
10.3 Taking measurements 10.3
10.4 Presentation of the measurement results 10.3
10.5 Error messages 10.5
10.6 Menu options of the TMS module 10.6
10.7 Configuration of the TMS module 10.7
10.8 External interface 10.8

11. Performance Monitor 11.1

11.1 Necessary hardware 11.1
11.2 Display 11.2
11.3 Alarm 11.4
11.4 Menu options of the Performance Monitor 11.5
11.7 Configuration of the Performance 11.5

12. File Collector 12.1

12.1 Collect measurement files 12.1
12.2 Special functions 12.2
12.3 Configuration of the File Collector 12.2

Version 2.0 1.2

CDS Manual Description of the CDS

2. Description of the CDS

The complex CDS measurement and diagnostics system is an open system of modular build
for ongoing continuous monitoring and in-depth diagnosis of selected technical engine
parameters. The system was designed for slow running and medium speed diesel engines.
The diagnostics system combines the following individual modules into a unitary system.

Further to this the system can be optionally expanded with an interface to an automation
control system.
The main engine is the most valuable investment and merits particular monitoring. Damage to
the main engine could bring with it further risks to the operation, consequential damage and
economic failures.
The use of the modules with permanent measurement recording and analysis guarantees
constant information about the current state of the system variables being evaluated, with
suitable monitoring of limits, observation of trends and alarm signals. The accumulated
information and alarms can be passed on to primary automation control systems.
The basic idea of the CDS System is to use inexpensive, simple measuring systems for
ongoing monitoring of the engine installation and in the event of finding a malfunction, to use
high quality special modules discontinuously for deeper analysis of malfunctions. This is not
a matter of recognising actual malfunctions but finding the causes in order to avoid further
malfunctions.

2.1. Revolution Ununiformity Analysis (RUN)

The revolution ununiformity measurement is a system for ongoing monitoring of the load
distribution and of the torsional vibration damper of the engine. It is an economic alternative
to continual cylinder pressure analysis.
The basis for the measurements is a crank angle encoder with which the revolution ununi-
formity of a work cycle is determined. In the measurement results the following statement can
be made:

Degree of revolution ununiformity. With the degree of revolution ununiformity the current
torsional vibrations of the engine can be assessed. It can be established for
example whether the engine is running in a speed range with increased torsional
vibrations. Malfunctions on the torsional vibration damper are characterised by a
higher degree of revolution ununiformity and can thus be sensed by the system.
Load distribution. Is a measure of the uniform power output of all cylinders. A
malfunction on one cylinder, which affects the load distribution, can be detected in
this way.
Alarm. If the degree of revolution ununiformity or the load distribution exceeds limits
specified by the user, an alarm is issued. This can optionally also be given out
through the automation control system.

The RUN module, through the ongoing monitoring, allows an early recognition of
malfunctions and thus the prevention of expensive consequential damage. If an alarm occurs
repeatedly, an in-depth diagnosis should be carried out with the other modules of the CDS.

Version 2.0 2.1

CDS Manual Description of the CDS

2.2. Cylinder Pressure Analysis (CPA)

The cylinder pressure analysis is carried out cyclically by the user. For this the cylinder
pressure is measured on the engine with a manual device which is connected to the computer.
The same measurement chain is used for each cylinder, thus guaranteeing the comparability
of the cylinders with each other.
In the result of the measurement the cylinder pressure curve is shown over the crank angle.
Installing a crank angle encoder is therefore a precondition for cylinder pressure
measurement.
The aim of the CPA module is:
- Monitoring the parameters of the combustion process.
- Adhering to the engine manufacturer's specifications.
- Optimising the basic settings (long-term monitoring).
- Optimal load comparison in order to keep the loading on the engine low.
- Allows a targeted search for the cause when there are malfunctions (in-depth diagnosis).
- Determining the indicated power with the aid of the dynamic TDC correction. The
dynamic TDC correction is carried out on the basis of a highly accurate thermodynamic
model. Upon failure to take the TDC correction into account, the power error can be up
to 8% for a TDC deviation of 1° crank angle.
- Planning of the maintenance work.
The CPA module can be extended with one of the following modules.

2.3. Injection Pressure Analysis (IPA)

With the injection pressure analysis the injection pressure of each cylinder is measured in
addition to the cylinder pressure. For this each cylinder is equipped with an injection pressure
sensor. The injection pressure measurement is carried out cyclically together with the cylinder
pressure measurement. In the result of the measurement the cylinder and the injection
pressure curve are shown over the crank angle.
The measurement results of the injection pressure analysis supplement the cylinder pressure
analysis. The quality of the combustion is significantly influenced by the fuel injection. Faults
in combustion essentially arise in the fuel injection. Fault-finding is facilitated by the
knowledge of the injection pressure curve. In addition the injection parameters (start of
delivery, duration of injection) can be optimally set.

2.4. Leakage Measurement System (LMS)

Use of the LMS module is possible on all large diesel engines. A sound sensor is used for the
measurements and is simply attached on the outside of the relevant cylinder head. Due to this
it is possible to use it on engines with a common rail injection system or on engines on which
the IPA module cannot be used.
Injection process, valve impacts and leaks, among other things, give out characteristic sound
signals. By assigning the signals to the crank angle the following statements can be made:
- Determination of valve timings for the exhaust valve opening.
- Determination of the injection times (visually).
- Detecting leaks in the area of the cylinder head. Here the probability of a possible leak
is indicated. Leaks at the exhaust valve can thus be recognised early so that a repair is
still possible.

Version 2.0 2.2

CDS Manual Description of the CDS

2.5. Piston Ring Monitoring (PRM)

The PRM module is a permanent system for monitoring the piston - cylinder running pair.
The basis for the measurements is a piston ring sensor built directly into the cylinder liner of
every station above the scavenging air slot.
The signal picture arises due to the movement of magnetically effective materials (piston and
compression rings) past the sensor. The different signal levels result from different distances
of the material from the sensor. The assignment of the particular signals to the piston position
is done, as for the other modules, with the aid of the crank angle encoder. Due to the charac-
teristic signals the following malfunctions can be recognised in the sensor measuring range
and an alarm issued:

"Stuck" The level of the signal from the ring reduces as the ring is pressed into the
piston and stays there.
"Broken" The broker ring or a ring segment "rattles" in the groove. Due to this
constantly fluctuating signal levels are generated.
"Missed" Since the ring or ring segment is missing, a signal reversal occurs.
"Thermal load" If a reduction occurs in the distance from the piston to the liner (e.g. as a
result of thermal overload), the ratio of the signals from the piston ring to the
signal from the piston will change.
The piston ring sensor also contains a thermo-couple for measuring the temperature in this
area of the liner. If a limit is exceeded an alarm is also issued.
With "thermal load" or increased temperature particularly, the aim is to give warning before
damage occurs.
Furthermore assessment of the wear of the first piston ring is possible for specific ring forms.
These ring forms are coated rings or rings with a CL groove. Since the CL groove cannot be
constantly measured at the sensor, special search procedures are used which utilise the
rotation of the ring. By evaluation of the signals it can be determined when the wear limit of
the piston ring is reached.

2.6. Torque Measurement System (TMS)

The power measurement takes place through measurement of the torsion of the shaft. For this
the offset of the measuring runs in the two measurement planes of the shaft are calculated.
The measurement planes have a spacing of between 5 and 10 m. Using the material data for
the shaft, the torque, and from it the power, are calculated from the torsion angle.

2.7. Performance Monitor

With the Performance Monitor the current engine operating point and the current propeller
curve in the engine characteristics are displayed.
If the power or speed limits are exceeded or for operation with depressed speed, an error
message is issued.
Furthermore with the fuel consumption and with the availability of the speed parameters, the
run consumption can be shown.
The performance monitor can also be installed on other computers e.g. on the bridge. Only a
link (Ethernet) to the CDS database is required.

Version 2.0 2.3

CDS Manual Hardware installation

3. Hardware installation
3.1 Installation of the basic components
It is mainly modules of the CDS System that are used as the basic component and thus always
to be installed.

Crank angle encoder CAE

The control of the measurement recording is done through the crank angle. For this it is
possible to use existing signals or to install a crank angle encoder on the free end of the shaft.
There are matching versions for fitting to the respective engine types. With existing signals
(e.g. MAN ME engines) special interface modules are used.
An example of the build up and fitting of the crank angle encoder to an engine is described
below.
The crank angle encoder is fitted on the free end of the shaft. It must have a torsionally rigid
connection with the crank shaft. For certain engine types a connection shaft is available for
installation of the crank angle encoder. If necessary the connection shaft can be supplied with
a suitable flange for the shaft gland. If not available the pick up is brought out of the housing
by means of a screwed in connection shaft.
The fixture for the crank angle encoder consists of a flange which is mounted using screws
and spacer sleeves. The crank angle encoder is firmly bolted to this. The sensor shaft is
inserted into the hollow shaft of the crank angle encoder. Spacing can be equalised by
adjusting the shaft position. The connection is made with a clamping ring.
The transmission of the rotary movement from the connection shaft to the sensor shaft is
through a Paguflex coupling. Here the coupling compensates for small radial misalignments
and axial movements. The whole set-up is protected by a protective cowling.

shaft seal
connection shaft

fixture specific to the engine

Paguflex coupling

sensor shaft

crank shaft end

crank angle encoder

Figure 3.1 Sectional view through for an example of a crank angle encoder installation

Version 2.0 3.1

CDS Manual Hardware installation

Installation of the signal box.

The signal box is the central point in the system at which all signals are brought together. The
installation location is in the engine control room close to the PC workstation. The CDS is
supplied with electrical power from here.
This box must also be connected to the connecting box. The signals for the crank angle and
the power measurement system and also the communication with the automation control are
connected here. All connections are made in accordance with the connection diagram.

PC installation.
The PC contains the measurement recording cards and is responsible for the evaluation and
display of the measurement results. The set-up is in the engine control room at a location as
free as possible from vibrations. Care must be taken to ensure adequate ventilation for cooling
of the computer. The computer can be built in if fresh-air can be sucked in from the front and
the warmed air taken out at the back.
The communication with the automation control system is likewise through the PC. This has
an extra interface card for the purpose.
The connection with the signal box is made through the connections on the rear of the
computer. For this care should be taken to ensure that the connections of the measurement
recording card (Koge 25 pin and 15 pin) are not mixed up. The connections to the PC and to
the signal box are labelled.

3.2 Installation of the RUN module

No additional hardware is required for the RUN module. With the installation of the crank
angle encoder, the signal box and the appropriate wiring all components are installed.

Version 2.0 3.2

CDS Manual Hardware installation

3.3 Installation of the CPA, IPA and LMS modules

Depending on the equipment the cylinder pressure, injection pressure or the ultrasound signal
are measured with the aid of a mobile manual unit. For this a cylinder pressure sensor and
ultrasound sensor are only attached on the indicator valve or on the cylinder head during the
measurement. The injection pressure sensors are built permanently into the injection system
and only connected to the manual unit with a suitable cable for the measurement on the
cylinder.
Also required for the module is a charge air pressure sensor in the scavenging air duct.

Connecting box.
The connecting box is installed on the engine on the control side near to the inspection
openings for the scavenging air duct. The installation place must be low in vibration. This box
is also used for the PRM module. The signals from all the sensors on the engine with the
exception of the crank angle signals are brought together here.
The connecting box is connected to a hand-held box, the charge air pressure sensor and the
amplifiers for the piston ring sensors and passes the signals on to the signal box. All
connections are made in accordance with the connection diagram.

Hand-held box.
In order to connect the manual unit to the system, the box for connection to the manual unit is
fitted close to the cylinder head station. Here care must be taken to ensure that this box is
accommodated in an easily acceptable place. This box must also be connected to the
connecting box. This connection is made in accordance with the connection diagram.

Charge air pressure sensor.

The sensor for the charge air pressure is fitted in the scavenging air duct. The pressure
connection for the sensor has a connector with an external thread (G 1/2 A). The connection
to the connecting box is made in accordance with the connection diagram.

Installing the injection pressure sensors.

An IP sensor is required on each cylinder to measure the injection pressure. The sensors are
filled with a special oil. This oil must not be removed when installing. The sensor is screwed
into the fuel line or the injection pump in place of a blanking plug, using the seal attached.
When working on the fuel line all applicable safety regulations are to be complied with.

Version 2.0 3.3

CDS Manual Hardware installation

3.4 Installation of the PRM module

For the piston monitoring module a piston ring sensor and an amplifier are needed for each
cylinder.
The sensors are built into the liner for each station above the scavenging air slot. This requires
a special drilled hole in the liner. This must already be present when fitting the liner, in
collaboration with the engine manufacturer.
In special cases the installation of the sensors can also be done in the scavenging air slots.
Due to the measurement principle it is necessary to adhere to the direction of installation and
to fit the sensors at a precisely defined depth. The distance from piston rings to sensor is to be
set to 0.7 mm.
The signal is taken through the engine block to the outside, processed in an amplifier. Sensor
and amplifier are matched to each other.
It is therefore necessary for the sensor always to be installed with the applicable amplifier.

to connecting box
cylinder liner
amplifier

piston frame passage

piston ring

linings frame
amoured cable

piston ring sensor

Figure 3.2 Installed piston ring sensor

Installation of the measurement chain

1. The piston ring sensor are mounted into the hole in the liner above the scavenge air slots
ahead the inspection opening. Before mounting the depth of this hole has to be measured
a. Turn the engine until one piston ring is behind the installation hole.
b. measure the depth with the venires caliper
pay attention to:
- the depth venire caliper has to be vertical inserted into the opening
- the bearing faces have to be clean
- the Piston Ring does not have a ring gap or a wear groove at this position
c. enter the measured depth into the calibration protocol

Version 2.0 3.4

CDS Manual Hardware installation

2. The recommended distance between the sensor and the piston ring is 0,7mm. If the
distance is too small, they have to be increased up by using the linings. The number of
linings will be calculated and entered in the installation protocol.
The installation protocol is included in the Technical Documentation and contains further
demonstrations of the installation process.

3. Now the piston ring sensor is inserted in the inspection aperture after the required number
of linings has been placed onto it. Take care not to cant the sensor during installation. The
mark TOP on the sensor has to show upward. The screws must be evenly tightened and
secured with nutlock (medium strength). Hexagon screws could be secured with tab
washers also.

4. The cables are brought to the outside by means of the frame passage. This is passed from
the inside to the outside. It is fastened on the outside by a nut. The frame passage is to
seal by a suitable sealing compound (e. g. high temperature silicone with resistance
against oil).

5. Next the amplifier housing with the mounting plate is placed on the frame passage and
secured by a second nut. If there is enough space available, the housing is fastened above
the block passage.

6. The cables of the piston ring sensor are passed into the amplifier housing using a PG
screwing; in the housing they are clamped to the amplifier according to plan. There is no
need of further adjustment of the amplifier. The basic adjustment was done during
manufacturing and must not be changed without prior consultation.

7. Finally the amplifiers are connected to the connecting box, and the connecting box is
connected to the signal box according to installation plan.
When mounting the cables all prevailing safety regulations should be observed. The
shield at the end of the cables has to insulate.

Zero point and amplification

1. Before the first measurement and after work on a piston ring sensor a zero gauging of the
measuring chain and a calibration of the amplifier have to be carried out. This adjustment
is done in the amplifier box at the cylinder.

2. The zero point calibration of a sensor is possible when the engine has to be running and
have an operation temperature. The calibration at a selected cylinder is done by means of
a small calibration screw. Follow the instructions in the cover of the box (Zero PRS). The
calibration is checked on the light emitting diode display, which is to connect with the
diagnose connector (Diag. Con.) of the box. The calibration is optimal when the flashing
diodes has the same amplitude on both side.

3. The calibration of the amplification makes sense only after the zero point calibration has
been done. The calibration takes place by means of the calibration screw according to the
description in the box (Adj. PRS). On the light emitter diode display two lamps flash
periodically. The amplification is optimal when if the two green diodes at both ends are
flashing and the red ones do not flash.

Version 2.0 3.5

CDS Manual Hardware installation

3.5 Installation of the TMS Module

cam belt

sensor 2
engine side

cam belt
sensor 4

sensor 1

sensor box A
propeller side
sensor 3

cable X
sensor box B
cable Ya amplifier

cable Yb

Figure 2.3 TMS installation

For the power measurement, measuring takes place on two planes. Sensors 1 and 3 form one
measuring plane and sensors 2 and 4 the other plane. Due to this arrangement the movements
of the ship or the shaft are compensated for.
Installation of Y stands.
First of all the Y stands are fitted. These are used to hold the sensors. To avoided relative
movements of the shaft or vibrations of the stands affecting the measurement results, these are
to be installed adequately solidly and free of vibration.
When installing the Y stands care should be taken to ensure that the sensors are at the same
height as the shaft axis and that the angle between shaft and sensor is 90 °.
The two sensor boxes are installed below the Y stands.

Installing the cam belts.

The TMS cam belts are laid loosely around the shaft and are lightly secured by the pre-
installed supports. The direction of rotation of the cam belts is correct when the "engine side"
labelling is pointing towards the engine and the "propeller side" labelling towards the
propeller.

Version 2.0 3.6

CDS Manual Hardware installation

Installing the sensors.

N.B.: the distance from the cams to the sensor head must not fall below 50 mm! A
smaller gap can lead to long-term malfunction of the sensor!
1. The TMS sensors are to be fixed to the pre-installed supports in alignment with the shaft
axis. The distance from the TMS sensors to the surface of the propeller shaft is in each
case to be set to 110 mm. Before tightening the bolts the pressure distribution plate is to
be inserted between sensor and bolts in order to prevent damage to the sensor.
2. The cam belts are now to be aligned so that they are located centrally above sensors.
Next the cam belts are to be rotated so that the cam labelled "TOP" in each case is at the
top. The shaft must not be turned between the settings of the cam belts. The belt locks of
the lobed belts are tightened with a torque of 20 Nm maximum. The connection is to be
secured against coming loose with locking tab washers.
3. Next the sensors are to be connected to the particular sensor box. To ensure a correct
evaluation of the signals, the correct sequence of the 4 sensors is to be observed with all
connections (see installation picture).
4. The connection of the TMS amplifier to the CDS signal box (cable X) is to be made in
accordance with the assignment diagrams for the CDS system. Here all valid safety
regulations are to be complied with. When wiring up care must be taken to ensure
proper insulation.

Version 2.0 3.7

CDS Manual Software installation

4. Software installation
4.1 Installation of drivers
For the correct function of the CDS it is necessary to built in special hardware into the com-
puter. These are measurement card type Koge and if necessary a RS 485 interface card. To
use the hardware special software, the driver, is necessary. Normally the system is correct
with all drivers preinstalled.
In the case of a rebuilt of the computer operating system, all driver must be installed before
setup the CDS-software. The drivers can be found on the CDS Install CD within the folder
drivers or at the OEM CDs from the hardware manufacturer.

4.2 Installation of the CDS software

The setup program starts after insert the installation CD into the computer. If the setup don't
start, the installation can be started with cds_setup.exe within the root folder of the CD.
With Start the installation begins, with Cancel the installation program will be closed.

Figure 4.1 CDS Setup Wizard

To prevent deleting a running system by a mistake, the start of a new installation is to

confirm.

Figure 4.2 Warning window

After clicking Yes the installation program close a running CDS, search for an earlier instal-
lation, save the old program files and configuration into the folder C:\Backup and delete the
old installation.

Version 2.0 4.1

CDS Manual Software installation

Before the new files will be copied, the CDS database will be installed by an separate install
program.

Figure 4.3 Installation of CDS Database

All requests of the installation program should be confirmed with Weiter and the last window
with Beenden.

After installation of the database, with Start the copying of the new files begins.

Figure 4.4 Installation of the new CDS files

After the installation the computer reboots and the CDS is running automatically.

The installation takes place in the folder C:\program files\CDS. The folder Bin contains the
program files. Data is the storage for the measurement files. Logs contains the protocol files
and Trend the CDS database files.
The CDS installation CD contains normally a configuration accordingly the engine. Anyway
it is recommended to calibrate the CDS modules. Especially the static TDC has to be set.

Version 2.0 4.2

CDS Manual CDS main window

5. CDS main window

The CDS monitor combines RUN, CPA, IPA, LMS and PRM the modules in one program
with a common user interface. The Performance Monitor and the File Collector Help program
are started from here.

start File Collector menus buttons to show the modules main window CPA alarm table

main window PRM

main window RUN

detail window CPA

status bar

Figure 5.1 CDS Summary

Menus
Many functions in the menu can also be reached through Buttons and Tabs. The menu will be
dynamically adjusted to suit the module open at the time. The generally applicable functions,
that always apply are described here. Some menu points are only available in the
Administrator mode.

File
Load file A previously saved measurements file will be loaded.
Save File Save a measurements file
Open RUN The RUN module will be brought into the foreground.
Open PRM The PRM module will be brought into the foreground.
New CPA The CPA / (IPA/LMS) module will be started
Change engine Enables the loading of another engine configuration.
(Is only used in particular applications)
Exit Terminates the CDS Monitor and if required also the Performance Monitor
and the power measurement system TMS.

Version 2.0 5.1

CDS Manual CDS main window

Performance data
Display and settings Summary of the data provided by the automation control or by
TMS
Change Operation-DLL Enables the change of the communication with the automation
control (only in the Administrator mode)

Admin
Change admin Password Enables a change to the Administrator password
(only in the Super administrator mode)
Switch to admin mode Entry of the Administrator passwords and switch to
Administrator mode
Show (Edit) options Display (or Edit) the CDS configuration
Engine database Administration of several engine configurations
(only in the Admin mode)

Info
Info Details of the Version of the CDS Monitor, Sales, Guarantee and Rights
Owner
Licence info Display (or Alteration) of the Serial number and of the Activation key

It is fundamental for all modules that a summary of the essential diagnosis results is given
first. If a further requirement for information then exists the depth of information in the
detailed views can be increased. The ongoing RUN and PRM monitoring modules also work
when the particular summary window is not visible. If there is an alarm these windows will be
displayed and brought into the foreground.

Table for the alarm status.

Each CDS alarm is logged. This means that no alarm is lost due to other subsequent alarm
messages. Each acknowledgement of the alarm and the re-establishment of the normal state is
also registered there.

Status Line.
The bottom line of a window is the status line. It contains further information on the
measurements. In particular the measuring process itself is documented here. Depending on
the modules, continuing information such as time, status, the cylinder currently being
measured, progress of the measurement and calculation or even error messages on the
measuring process are displayed here.

Print function.
Depending on the active module, different printing forms can be selected. It is common to all
that a print preview appears before the print. The actual printing then takes place with the
print symbol at the upper edge. Depending on the module additional details can also be given
in the form. The print settings can also be selected in the preview.

Version 2.0 5.2

CDS Manual CDS main window

printer setup print report

save report
navigation open report

Figure 5.2 Print function

The company's own logo can be incorporated in the print-outs. For this a bitmap with the
company logo must be copied into the BIN folder of the CDS system under the name
company.bmp. In the next print out the logo will appear at the top left of the print out.

Measurement files.
The data as determined from the measurement recording cards are raw data. They contain all
measurement data as they were gathered by the measurement recording cards and additional
information on the measuring process itself, and are very large. The parameters for the
evaluation of the state or respectively the results data are calculated from the raw data by a
special process. Usually only the analysed data are stored. In particular cases it could be
necessary to work with raw data. This could be for better identification of unknown
malfunctions or even to compare measurements with earlier curves. The particular functions
are described in the individual modules.

CDS database.
With the CDS program there is also a database installed. The essential state parameters and
the figures passed on from the automation control are stored here. The performance monitor
accesses this database for displaying the operating point. The trend functions integrated into
the CDS monitor also utilise the database. New database tables are created for each month.

Administrator mode.
Functions which have a direct influence on the measuring system are only accessible in the
administrator mode. This particularly concerns configuration settings and calibration
functions. The administrator mode is activated in the "Admin" menu with "Switch to Admin
Mode". After entering the password the user has around 30 seconds to call up the relevant
menu point.

Version 2.0 5.3

CDS Manual CDS main window

Figure 5.3. Left: Admin menu. Centre: Entry of the administrator password. Right: Admin menu in the administrator mode

Two administrator modes are provided in the system.

Administrator - enables changes in the configuration and the calibration of the modules.
Super administrator - is reserved for the developer. In this mode important system parameters
can be altered which are of great importance to the function.
Also in this mode another administrator password can be set. If required a password to use the
Super Administrator mode can be requested from the manufacturer. This password becomes
invalid after one day. The selection of the administrator mode results from the password
query.

Presentation of curves.
To show individual sections of curves better, it is possible to zoom onto the display area. The
selected area is magnified by holding the left mouse key and pulling the mouse (to the right).
Holding the left mouse key and pulling the mouse (to the left) will once again display the
whole diagram.

Version 2.0 5.4

CDS Manual Basic configuration of the CDS

6. Basic configuration of the CDS

The configuration for the RUN, CPA, IPA, LMS, PRM modules and the commonly used
configuration data are saved centrally in one configuration. The configuration can be viewed
under the "Admin" menu point with "show config". In the administrator mode "show config"
becomes "edit config" and the data can be worked on. Data which are assigned to the modules
are explained in the operation of the individual modules. Commonly used data are listed
below.

Version 2.0 6.1

CDS Manual Basic configuration of the CDS

6.1 Engine parameters

Figure 6.1 Engine parameters

Engine name Name of the main engine

Engine type Engine type
Number of Cylinder Number of cylinders
2 Stroke / 4 Stroke 2-stroke or 4-stroke engine
Fire angle Firing angle of the particular cylinders

Speed (nom.) Rated speed

Power (nom.) Rated power
Stroke Cylinder stroke
Bore Diameter of the cylinder
Ratio Conn Rod. Con rod ratio
Compression Ratio Compression ratio
Inlet open Angle at which inlet opens
Inlet close Angle at which inlet closes
Outlet open Angle at which the exhaust opens
Outlet closed Angle at which the exhaust closes
The angle details are given in relation to TDC.

Last change Last change to the data

Version 2.0 6.2

CDS Manual Basic configuration of the CDS

6.2 Measuring System

Figure 6.2 Measuring system

Serial No. card 1 Serial No. of the Measurement recording card 1

Serial No. card 2 Serial No. of the Measurement recording card 2

The communication with the hand held unit and the alarm outputs runs though Measurement
recording card 1. This is why correct allocation is important. Card 1 is by definition the card
with the lower Serial No. and is plugged into the socket of the PC that is closer to the
processor. The Serial Nos. are on the backs of the cards and are displayed on starting the
Koge server.

Alarmpin Setting the output channel for the CDS Alarm (default 0)
on Card 1 / Card 2 Selection of the card for the alarm output (default 1)

Crank angle encoder

Crankangle Trigger Number of trigger pulses of the crank angle encoder (default 360)
TDC correction Setting of the crank angle encoder to the static TDC of cylinder 1
TDC Correction per cylinder Correction possibility for the static TDC for individual
cylinders (Used only in exceptional cases)

Version 2.0 6.3

CDS Manual Basic configuration of the CDS

6.3 Setting the static TDC

The setting of the static TDC corresponds to a virtual alignment of the TDC of the crank angle
encoder with the TDC of the first cylinder. Adaptations to the other cylinders are made
through the ignition sequence by setting the fire angle. It is therefore not necessary to
manually adjust the crank angle encoder. This value is utilised by all CDS modules, this
means that the modules operate as if the TDC of the crank angle encoder agrees with that of
the engine. It must therefore always be set before further modules are calibrated.
The setting of the TDC correction is done either with CPA or PRM. After installation of the
system or after working on the crank angle encoder this figure has to be updated again. If the
PRM module is installed, calibrating with PRM is recommended. Calibrating with CPA
provides the same result but is more time-consuming.

Calibrating with PRM.

The function for calibration of the static TDC is called up in the Admin menu with Encoder
Calibration (PRM). This function is only visible in the administrator mode.

Figure 6.3 Calibration of the static TDC with the PRM module

After selection of the cylinder for which the calibration is taking place, the calibration takes
place with Start. After the calibration is successful the new angle (CAE correction (new)) is
displayed. The value is accepted with OK.

Version 2.0 6.4

CDS Manual Basic configuration of the CDS

Calibrating with CPA.

The function for calibration of the static TDC is likewise called up in the Admin menu with
Encoder Calibration (CPA). This function too is only visible in the administrator mode.
For calibration with the CPA module, the CPA module must not be set on remote control (See
8.5 CPA module).
The calibration begins with Start. Control then passes to the hand-held unit. A measurement is
then carried out on any cylinder at will as for a normal cylinder pressure measurement. If the
calibration is successful the new correction figure (CAE correction (CPA)) and the cylinder
pressure curve will appear in the window of the selected cylinder.

Figure 6.4 Calibration of the static TDC with the CPA module

For small deviations the value determined can be corrected with CAE correction new. The
cylinder pressure curve will then be suitably displaced in the display.

The value is accepted with OK.

Version 2.0 6.5

CDS Manual Basic configuration of the CDS

6.4 Program parameters (Program)

Figure 6.5 Program parameters

Common Data Dir Path for saving measurement files (C:\Program files\CDS\Data)
TrendDB Dir Path for CDS database (C:\Program files\CDS\Trend)
Log Dir Path for saving log files (C:\Program files\CDS\Data)

Shipname Ship’s name / Forename

Autostart Automatic starting of individual modules with the Program start

Load Balance Monitoring RUN (default on)

Cylinder Pressure Analysis CPA (default off)
Piston Monitoring PRM (default on)

Version 2.0 6.6

CDS Manual Basic configuration of the CDS

6.5 Settings for communication with automation control

For the correct function of the performance monitor particularly, it can be necessary to receive
its data from the automation control. As a rule the communication for this takes place through
an RS 458 serial interface on the computer. For this a standard NMEA protocol is used. After
arrangement with automation control the communication can also take place through the
Ethernet with the ISM client (Lungsø Marine).

The setting is made in administrator mode under Menu point "Performance Data" with
"Change Operation - DLL". Here the following settings are possible.

Figure 6.6 Selection of the communications options

NMEA protocol The communication takes place through the NMEA protocol with an
RS485 interface
ISM protocol The communication takes place through Ethernet with the ISM Client
only TMS data No communication takes place with automation control. The
performance data are adopted from the TMS module.
-- no DLL -- No data at all is made available. Use of the Performance Monitors is not
possible in this case.

After setting the communication route, further settings are necessary for the NMEA protocol
and respectively for the ISM client. These are made under the menu point "Performance
Data", "Delay and Settings", and "Configuration". A range of configuration options are given
in the newly-opened window. These however differ from project to project.

Figure 6.7 Setting the transmission parameters for the NMEA protocol

Version 2.0 6.7

CDS Manual Revolution Ununiformity Analysis

7. Revolution Ununiformity Analysis (RUN)

7.1 Necessary Hardware
For the RUN module an installed crank angle encoder or the provision of crank angle signals
is necessary. The signals are prepared in the signal box before they are recorded in the
computer by the measurement recording card.

7.2 Calibration
Before the first measurement or after working on the crank angle encoder, this must be
calibrated. In the calibration the crank angle signal is assigned to the individual cylinders. If
CPA or PRM are still used along with the RUN module, a static TDC correction must take
place first with one of these modules. (See 6.3).

Before calibration the monitoring must be stopped by the administrator. The calibration is
protected by a password. For this the command RUN Calibration is called up in the menu
point Admin. The individual steps of the calibration must be confirmed.

The operating instructions from the motor manufacturer for stopping individual
cylinders must be complied with.

1. Before beginning the calibration care must be taken to ensure that there is a good load
balance between the cylinders.
2. Let the engine run. For this the engine can be run at reduced rotation speed right away.
After the confirmation the RUN module will carry out a 1st measurement.
3. The engine should now be run at reduced rotation speed.
4. For cylinder 1 the fuel feed must now be interrupted. The resulting disruption to the load
distribution is identified in a 2nd measurement by RUN and assigned to cylinder 1.
5. After this step the fuel supply for cylinder 1 is re-established and that for cylinder 2 is
interrupted. Next a check measurement is carried out by the RUN module. In this the
correct allocation of cylinder 2 is checked.

Note: Measurements with the RUN module are also possible without calibration. In that case
however if there is a malfunction of the load distribution, the correct cylinder will not be
determined.

7.3 Taking measurements

For correct functioning of the RUN module the engine should be run at operating speed (pre-
setting 60 revolutions per minute) in order to get pulses from the crank angle encoder. During
the measurement the operating state should be steady. Changes in load can lead to a
misinterpretation of the measurement values. To enable a tendency comparison with other
investigations the load point must be reproducible.

As a rule the RUN module begins the measurements with the start-up of the CDS monitor.
Starting separately is thus not necessary (see Basic Configuration 6.4).

Version 2.0 7.1

CDS Manual Revolution Ununiformity Analysis

7.4 Presentation of the measurement results

The standard display of the RUN module is in two parts. In the upper half is the display for
the revolution ununiformity, whilst the lower half shows the load balance symbolically. As
long as the load balance is exhibiting no noticeable problems all fields are displayed green. If
there is a malfunction in the load balance the defective cylinder is shown flashing red.

open load balance window

open uniformity window open trend window

uniformity current value

display
revolution uniformity
uniformity alarm limit
alarm area

display
load balance

confirm alarm
Figure 7.1 Main window of the RUN module

The revolution ununiformity analysis work regardless of this. On the left the current value and
the set limit are displayed. In the middle of the display the degree of revolution ununiformity
is shown graphically. The degree of revolution ununiformity itself is shown as a small bar.
The limit for the alarm trigger is shown as a small bar. If the limit is exceeded by the actual
value an alarm is triggered i.e. the field on the right of the display will flash red. The alarm
must be confirmed with the "Alarm Confirm" button. The measurement will be stopped up
until this acknowledgement (see also 7.5 Giving an Alarm)
In addition it to the standard display for the RUN module, the measurement results can also be
put out in other presentation forms. The possibilities can be accessed under the menu point
Display or the buttons on the standard display of the RUN module.

Version 2.0 7.2

CDS Manual Revolution Ununiformity Analysis

The position of the measuring point in the crank star can be shown with Load Balance.

Figure 7.2 Graph of the measurement point in the crank star

With Uniformity a window with the graph of the rotation speed over the crank angle will be
shown.

Figure 7.3 Graph of the rotation speed over the crank angle

Under the point Trend Analysis the current values can be compared with earlier
measurements. There is the facility to show the History (Short History) and the trend (Trend
Analysis). In the history the last measurement values will be shown as a graph. In the Trend
on the other hand after selection of a date, the applicable values from the database will be
displayed.
In the diagram the set limits are shown with a thick line and the applicable measurement
values with a thin line. The blue lines stand for Load Balance and the red lines for Uniformity.

Version 2.0 7.3

CDS Manual Revolution Ununiformity Analysis

7.5 Alarm
Showing an alarm.
If a set limit is exceeded an alarm will be triggered and the current measurement stopped. The
alarm is confirmed by the operating engineer with the Alarm Confirm button. The engine
speed and the measuring time will be displayed so that the measurement can be allocated. The
Load Balance alarm indicates a malfunction of the load distribution. At the same time the
cylinder which is possibly defective is shown. If only the Uniformity alarm occurs, this
indicates increased torsional vibrations of the engine. The cause of this could be operation in
speed ranges with increased vibrations or problems with the torsional vibration damper.
With the confirmation of the alarm (Alarm Confirm) the measurement is continued. For
reproduction of the development of a malfunction however the result from the ongoing
monitoring must first be saved. For this reason before acknowledging a malfunction the
measurement data for the relevant cycle should be saved in a file. Regardless of this the
figures will be automatically saved in the database. Furthermore the alarms and their status
will be listed in the CDS alarm table in the main window (top right).
The limits for giving the Alarm can be changed in the Configuration (see 7.7).

Figure 7.4 Alarm in the RUN Module

Version 2.0 7.4

CDS Manual Revolution Ununiformity Analysis

Analysis
When an alarm is given the operating engineer must decide on the further steps for identi-
fication of the malfunction and determination of the cause.
Since an in-depth diagnosis is more time-consuming, the alarm should first be checked by
further measurements. This will exclude other influences such as load change or rough seas
having caused the alarm.
In addition to the standard display, the position of the measurement point in the crank star or
the graph of the rotation speed over the crank angle can be shown. More precise statements
can be made with the aid of these displays.
The position of the current measurement point is displayed in the crank star. The circle shows
the alarm threshold for this. From the graph the following statements can be made:
1. The measurement point determined for an unacceptable load balance is outside the limit
circle. The position of the measurement point in relation to the crank star indicates which
cylinder is the probable cause.
2. The distance from the co-ordinate origin is a measure of the order of magnitude of the
lack of balance.
3. Along with the current measurement point (shown red) a specified number of the previous
measurement points is shown in grey. This function is called up in the Display menu with
Trend. From the position of the points to each other an analysis can be made of whether
the state of the load balance systematically wanders out of the permitted area or whether
the malfunction was caused by a sudden event.

Recommended actions
Analysis of the alarm can lead to the following results:
1. The malfunction determined in the ongoing monitoring proves not to be true; the state
determined can be assessed as OK. The cause could have been an external load change.
After re-establishing a steady operating state the ongoing monitoring can be continued
with RUN.
2. The malfunction in the power distribution is found repeatedly, but qualitative differences
exist between the load distributions determined (e.g. for each individual measurement
different cylinders are shown to be aberrant.) The cause could be a long lasting unsteady
state in the operating point (e.g. due to heavy seas affecting the ships drive systems). In
this case the number of cycles should be increased.
3. The malfunction found in the ongoing monitoring is confirmed by repeated
measurements. The result leads to the conclusion that there are changes in the diesel
engine. To find the cause further diagnostic examinations must be carried out. The
CPA/IPA module is available for this in-depth diagnosis.

Version 2.0 7.5

CDS Manual Revolution Ununiformity Analysis

7.6 Menu options of the RUN module

In the following only the menu points with a direct relationship with RUN are listed. Menu
points with an across the board effect on the modules are explained under 6.

File
Change Engine Possibility to change the engine being monitored
Print Summary Print of the current measurement values on the standard printer. The
following are printed:
- Graphic analysis of the load balancing
- Measuring signal curve as ω(t)
Graph of the measurement point in the crank star

Measurement
Start monitoring Beginning of the measurement recording (only in the Administrator mode)
Stop monitoring End of the measurement recording (only in the Administrator mode)

Display
Load Balance Graph of measurement point in the crank star
Uniformity Graph of the rotation speed over the crank angle across one work cycle of
the engine
Trend Display of the load balancing for the last measurements and of the degree
of revolution ununiformity for the last measurements over the course of
time or switchable to specific days

Admin
RUN calibration Calibration of the crank angle encoder

Version 2.0 7.6

CDS Manual Revolution Ununiformity Analysis

7.7 Configuration of the RUN module

The basic setting can only be adjusted in the Admin Mode (see 5. CDS main window).

Figure 4.5 Configuration of the RUN Module

The following adjustments can be made:

Cycles Number of work cycles per measurement (default 3)

Monitoring Interval Time gap of the particular measurements (default 15)
Speed limit Minimum rotation speed for meaningful measurement (default 60)
N.B.: This limit also applies to the PRM module

Alarm Limit
Load Balance Alarm limit for the load balancing (default 20)
Uniformity Alarm limit for the revolution uniformity (default 10)

Recording Sensitivity
Load Balance Recording sensitivity of the CDS Database for the load balancing
(default 20)
Uniformity Recording sensitivity of the CDS Database for the revolution
uniformity (default 20)

Version 2.0 7.7

CDS Manual Cylinder Pressure Analysis

8. Cylinder Pressure Analysis (CPA)

8.1 Necessary hardware
The CPA module determines the cylinder pressure sequence through the crank angle.
Therefore, in addition to the measuring chain for the cylinder pressure, a crank angle encoder
for the cylinder pressure must also be installed and calibrated. For this, static TDC correction
must be carried out (see 6.3).
The measuring chain is connected to the diagnostic system via the handheld box at the
connecting box. The measuring chain itself consists of a high-precision pressure sensor
(handheld unit) with a Thompson adaptor for the indicator valve. The handheld unit is
connected to the handheld box by means of an armoured cable.
In order to determine the indicated performance it is necessary to know the scavenging air
pressure. For this, a pressure sensor is built into the scavenging air duct. The signal coupling
is also made via the connecting box.

8.2 Extension with IPA module

The IPA module represents an extension to the CPA module. For this, each cylinder is fitted
with a pressure sensor to measure the injection pressure. This is connected to the handheld
unit in parallel to the cylinder pressure sensor. At the same time the relevant pressure sensor is
connected to the handheld unit via a measurement cable.

8.3 Extension with LMS module

Like the IPA module, LMS represents an extension to the cylinder pressure measurement. It is
used as an alternative to IPA. In particular LMS is suitable for engines in which it is not
possible to use injection pressure sensors. The LMS sensor is a sonic sensor, connected to the
handheld unit in the same way as the cylinder pressure sensor. The sensor itself is mounted
directly onto a plane surface on the cylinder head using magnets and a coupler medium.

8.4 Calibration
In order to calculate the internal output of the cylinder it is necessary to determine the TDC
precisely. When setting up the crank angle encoder it is not necessary to align it exactly with
the static TDC. The difference between the measured and static TDC is compensated for in
the calculating technique by a correction angle (see 6.3).
Since the dynamic TDC deviates from the static TDC when the engine is in operation, this is
compensated for during operation of the engine by correcting the dynamic TDC, depending
on the load. The correction value for the dynamic TDC will be defined within the range –5° to
+5° of the crank angle about the TDC. If the value lies outside this range, the message “TDC
correct failed” will appear in the status window of the remote measurement unit. In this case,
static TDC correction must be carried out (see 6.3). If this should fail, the following
parameters of the engine must be checked: advance angle, idle stroke, connecting rod ratio
and compression ratio.

Version 2.0 8.1

CDS Manual Cylinder Pressure Analysis

8.5 Taking measurements

Basic requirements
- All measurements should be taken under reproducible conditions.
- Wherever possible, all measurements should be taken at the same load increment in order
to ensure good comparability between the measurements.
- Since, as a rule, engine calibrations relate to the normal load-bearing point, measurements
should not be taken at a load of less that 50%. When using LMS, measurements at a load
of less than 70% should be avoided, as it can happen that the characteristic acoustic
signals of the normal engine operation will not appear in the expected form and as a result
it will be impossible to evaluate the results.
- By increasing the number of measuring cycles, the curve representation is improved by
averaging. In our experience, good results are achieved with 10 cycles.
- Before an evaluation is carried out, the measured values should be saved. The program
will suggest a name for the file.
- The handheld unit already contains the electronics for processing the signal. It should
therefore be handled with care and the temperature at which it is kept should not exceed
60°C.

Changing over the measuring chains

When the measuring chains are changed over, all the relevant Health & Safety guidelines
must be complied with. In particular care should be taken
- not to stand in the way of the air outlet from the index opening,
- to take precautions against burns,
- to wear safety goggles,
- to close the indicator valve before removing the sensor.
In order to maintain the accuracy of the measurements, the sensor must be protected against
contamination. It is therefore recommended that the index channel should be blown out by
opening the valve for a short time. The cylinder pressure sensor is screwed onto the indicator
valve. After the pressure sensor has been firmly screwed in place, the indicator valve must be
opened completely in order to charge the sensor with the full pressure. The length of time for
which the indicator valve is opened should be limited to the duration of one measurement (1 –
2 min) in order not to put an unnecessary thermal load on the sensor and the valve.

To analyse the injection pressure, the corresponding signal line is plugged into the IP sensor
on the cylinder.
If the module is fitted with LMS, the sonic sensor is connected to the handheld unit. The sonic
sensor is fixed to a level, clean metallic surface of the cylinder head. Here care should be
taken to ensure that the sensor is attached using a coupler medium (oil, silicone grease).
Without the coupler medium it is not possible to take meaningful measurements.
If no IPA or LMS is used, the signal line remains unassigned.

In order to begin the measurement, the CPA module must be started. This is done by selecting
New CPA in the File menu. Then the Remote control command is called up in the
Measurement menu.
- The program is now ready to start measuring. All other entries are made on the handheld
unit.
- “CDS basic” will appear on the display of the handheld unit.
- Fix the measuring chains to the corresponding cylinder. Whilst doing this, all the relevant
safety advice must be followed.

Version 2.0 8.2

CDS Manual Cylinder Pressure Analysis

- Press the CLR button on the handheld unit, then type in the number of the cylinder to be
measured and confirm by pressing Enter.
- After confirmation is given, the measurement process begins. During this time the word
Operate will flash on the display, indicating one individual measurement operation at a
time, beginning with the measurement of the scavenging air pressure and then the
individual measurements of the cylinder pressure.
- When the measurements are complete, the measuring chains can be changed over, and
then the next cylinder number may be entered.
- The measured values should then be saved.
- During the measurement by Remote Control a protocol is run on the computer which
documents the individual steps and process sequences and can be referred to if there are
any problems.

In this way it is possible to measure the cylinders in any order. If one cylinder is measured
more than once, only the last measurement can be saved.
After all the measurements have been completed, the handheld unit and measuring chains
should be packed back into the case – the measuring chains must first be left to cool down.

8.6 Presentation of the measurement results

The main screen of the CPA / IPA or CPA /LMS module displays the power output of the
whole engine. The power output of each individual cylinder is shown in the form of a bar
chart. It also shows the type of engine, number of measurement cycles, speed and total engine
output.

revolution and indicated power of the engine

open detail window display indicated power of each cylinder

status bar

Figure 8.1 Main screen of the CPA module

Version 2.0 8.3

CDS Manual Cylinder Pressure Analysis

A new window can be opened be pressing the Details button. This window is divided into two
sections, allowing better comparison of the measured values. By selecting Alignment in the
menu, it is possible to change the view. Three different views are possible:

- Two windows Æ screen divided into two sections

- Top windowÆ only the upper diagram is displayed
- Bottom window Æ only the lower diagram is displayed

Above the two diagrams are the tabs for the cylinders and the engine. Click to select the
required display.
The display for the whole engine is shown in the form of a bar chart. A selection of the
measured values is displayed on the right-hand side. A selection can be made by clicking, and
the appropriate value will then be displayed for the whole engine and the cylinders. The
measured values adjust to the relevant measurement (IPA or LMS). By selecting Mode it is
possible to change the form in which the bar chart is displayed. It is only possible to select
Compare if all the cylinders were measured.
When an individual cylinder tab at the top of the diagram is selected, a diagram opens to show
the exact sequence of the cylinder pressure (blue). In addition, during IPA the injection
pressure or during LMS the acoustic emission is shown in red.
The individual measured values for the cylinder are shown on the right-hand side of this type
of graph. Below the measured values is the More detailed icon, with the help of which it is
possible to display additional measured values.

Given characteristic values

CPA statistical values
power indicated output
max. cylinder press. maximum cylinder pressure
angle max. cyl. press. crank angle at maximum cylinder pressure
press. increase relation pressure increase ratio
mean indic. press. mean indicated pressure
compression pressure compression pressure
expansion press. expansion pressure
scav. air press. scavenging air pressure

IPA statistical values

pres. at beg. of supply pressure when supply begins
angle at beg. of supply crank angle when supply begins
press. start of injection pressure at start of injection process
angle start of injection crank angle at start of injection process
max. injection press. maximum injection pressure
angle max. inj. press. crank angle at maximum injection pressure
angle end of supply crank angle when supply ends
angle end of injection end crank angle at end of injection process
angle injection duration duration of injection in °KW

LMS statistical values

prob. of leakage probability of leakage

Version 2.0 8.4

CDS Manual Cylinder Pressure Analysis

CPA / IPA

Figure 8.2 Details screen showing bar chart and curve progression of cylinder pressure and injection pressure

Additional functions
In the detailed view it is possible to call up an additional menu by clicking with the right
mouse button. You can choose from the following options:

Clip
Clip Chart Copy the current chart
Clip Screen Copy the current screen

External reference
Load cylinder reference Load a reference to an external cylinder
Load engine reference Load a reference to an external engine
Save cylinder as reference Saves the current cylinder status as reference

Print
Cylinder Report Prints the Cylinder Report: it is possible to print the graphs for individual
cylinders by selecting the individual cylinders in the Print menu
Summary Report Prints the whole report

Display
Compress Degree Range Displays the compression range
Control angles of valves Displays the control angles of the valves
Show IPA Values Displays the IPA values (red)
Show Theoretical Curve Displays the compression graph, not including combustion (yellow)
Internal cylinder reference Displays the changes of pressure in the engine and the IPA values of the
other cylinder station (grey)

Save raw data Saves raw data

Load raw data Loads raw data

Version 2.0 8.5

CDS Manual Cylinder Pressure Analysis

CPA / LMS
Probability of leakage
In this window, all the cylinders are shown and evaluated in the form of a summary.
The probability of leakage is given as a percentage for each cylinder. The maximum
permissible values for the display are laid down in the AE parameters.
The level of probability is an indicator of the probability of leakage. It says nothing about the
size of a possible blow-by.
The probability of leakage in a cylinder is broken down into three areas:

green very low probability of leakage

yellow there is a possibility of leakage, but this is not certain
red very high probability of leakage

Figure 8.3 Details screen showing bar chart and curve progression of cylinder pressure and LMS acoustic signal

Figure 8.4 Signals of LMS with leakage

Version 2.0 8.6

CDS Manual Cylinder Pressure Analysis

If a high probability is indicated during several consecutive measurements, then the affected
cylinder should be checked.
Most leakages occur on the exhaust valve.
In addition, leakages may also occur in the following places:
- injection nozzle
- inlet valve
- starting-air valve
- cylinder head gasket
- sealing face of the outlet valve cage
- leaky safety valves / indication valves
(If this is the case, the temperature of the valves is mostly high compared to normal
operation.)

The information from the LMS module is very much dependent on the quality of the
measured signals. In particular the connection and the place where the measurements are
carried out have a big influence on the quality. Thus leakages should be confirmed by
repeating the measurements. If a number of malfunctions occur at the same time, the set-up
values should also be checked.

When the engine is started up following a repair to the cylinder head, a check / measurement
of the leak tightness of the fit of the injection nozzle and safety valve is recommended.

The individual ultrasonic signals for the individual cylinders can be shown by clicking on the
detailed display for the relevant cylinder (see picture). The sequence is shown through the
crank angle. The blue line represents the pressure sequence and the red line the acoustic
emission.
In the lower window, headed Details, there is the option to select additional functions using
the right mouse button (see additional CPA / IPA functions).

Furthermore, the measured values can be displayed by selecting the menu options Display Æ
display statistics (see picture), Display Æ Cylind. pressure value (see picture) and Inject.
pressure value (see picture).
When Display statistics is selected, the mean, maximum and minimum for the relevant
measured values are displayed within the 10 measurement sequences. When the cylinder
pressures and injection pressures are displayed, the measured values of the averaged trends
are shown per degree of the crankshaft angle.

Version 2.0 8.7

CDS Manual Cylinder Pressure Analysis

Figure 8.5 Display statistics

Figure 8.6 Cylind. pressure value

Evaluation

Once he has the results of his evaluation, the plant engineer must make the necessary
decisions regarding the continued operation of the engine and its maintenance. In doing so he
should make use of all the options for displaying the measurement results. Various options for
printing out the data are available in the File menu:

Version 2.0 8.8

CDS Manual Cylinder Pressure Analysis

- Cylinder Report
In this type of valuation, data sheets are drawn up for each individual cylinder with the
maximum, minimum and mean of the following measured values:
engine output, maximum indicated pressure, angle at maximum cylinder pressure, start of
combustion, pressure increase, compression pressure and expansion pressure.
One page is printed for each cylinder. Individual pages may be selected in the printer set-
up.
- Summary Report
The Summary Report gives a complete overview of the whole of the main machine.
The opening dialogue asks for performance data. If the figures are available in the
database, they are entered in the corresponding fields. The user can check and alter these
values.

8.7 Menu options for the CPA module including the extension module
Only those menu options which relate directly to CPA, IPA and LMS are listed below. Menu
options which affect the whole module are explained in section 6.
File
Save CPA file Saves the measured values file
New CPA Starts pressure measurements for a new cylinder
Print Summary Prints a summary
Print Cylinder Prints the cylinder data
Print bar graph Prints the bar graph
Exit Ends the program

Measurement
Remote Measurement Switches to control by means of the handheld unit and activates the
protocol function
Stop Measurement Ends the measurements

Display
Display Details Displays the details
Display Statistics Displays statistics
Cylind. pressure Displays the measured cylinder pressures
value
Inject. pressure value Displays the measured injection pressures

Admin
Change admin Changes the administrator password
password
Switch to admin Switches to administrator mode
mode
Edit options Set-up
Engine database Main data for the engine

Version 2.0 8.9

CDS Manual Cylinder Pressure Analysis

8.8 Configuration of the CPA module including the extension module

CPA parameters
The following set-up parameters may only be changed in administrator mode. As a rule, the
configuration is pre-set. Changes should only be made by arrangement with the Servicing
department.

Figure 8.7 Configuration of the CPA module

TDC correction Activates the dynamic TDC correction (default on)

To determine the static TDC (see 5.2.2), must the TDC
correction be switched off?
scav. air measurement Measures the scavenging air pressure (default on)
Injection Process analysis Selects the IPA or LMS auxiliary module (AE)
Cycles Number of measurement cycles (default 10)
Angle comp. pressure Angle to determine the compression pressure
for retarded ignition 0 (combustion begins after TDC)
for advance ignition e.g. -10 (combustion begins before TDC)
Cylinder Pressure
Cylinder Cylinder number for the following values
Sensor No Serial number of cylinder pressure sensor
ADC channel Measuring channel for cylinder pressure (default 0, in older
systems 8)
Calib. value (MPa/V) Calibration value for cylinder pressure sensor (see data sheet)
As the same pressure sensor is used for all the cylinders, the
settings are the same for all cylinders.

Version 2.0 8.10

CDS Manual Cylinder Pressure Analysis

Scavenging air pressure

Channel Measuring channel for scavenging air pressure (default 1, in
older systems 12)
Calibration Calibration value for scavenging air pressure (default 0.04)
Offset Zero point balancing for scavenging air pressure (default 0)

In the CPA parameters menu it is possible to choose whether no IPA should be carried out
(No IPA), whether an IPA should be carried out (Pressure Analysis) or whether an LMS
(Acoustic Emission) should be carried out (see picture).

Figure 8.8 Setting up the injection measurements

IPA parameters
If Pressure Analysis is selected, it is possible to open the following window (see picture). In
this window you can see the parameters for the injection pressure analysis. The set-up options
are as follows:

Figure 8.9 Configurating the IPA module

Version 2.0 8.11

CDS Manual Cylinder Pressure Analysis

Injector opening pressure Pressure during opening of the injection valve

Begin of supply min. Beginning of search range for start of injection (degrees relating
to TDC)
Begin of supply max. End of search range for start of injection (degrees relating
to TDC)

Injection pressure
Sensor No Serial number of the corresponding sensor
ADC channel Measurement channel for injection pressure (default 0, in older
systems 10)
Calibration Calibration value for the respective sensor (see data sheet)
Press. pipe Pressure of permanent connection (relative pressure
measurement only)
0 MPa (absolute pressure measurement only)

Two different types of IPA sensor are used. First, there are pressure sensors which make
relative measurements. They determine the change in pressure compared to that of the
permanent connection. Therefore in this case it is necessary to enter the pressure of the
permanent connection.
The other type of sensor measures the absolute pressure. Hence they also measure the
pressure of the permanent connection. Entering the pressure of the permanent connection
would lead to a mistake here. The value must therefore be set to zero.
These different types of sensors cannot be used together as they work on different measuring
principles. They are also operated using different amplifiers which are to be found in the
handheld units. The user can differentiate between the handheld units by the different
coloured seals used in the handheld units themselves.

Black seal: relative pressure sensor. Blue seal: absolute pressure sensor

Version 2.0 8.12

CDS Manual Cylinder Pressure Analysis

LMS parameters
When Acoustic Emission / LMS is selected, the following window can be opened. The
parameters given below may be set for this type of analysis:

Figure 8.10 Configuration of the LMS module

Amplification
Calculation range 1 Measurement range before TDC
Calculation range 2 Measurement range after TDC
Limit noise Noise limit
Limit standardisation Standardisation limits for the noise level (measurement range
1/2)
Diagnosis weight Weighting of the measurements (measurement range 1/2)
Warning limits Limits for the alarm (default 40, 80)
first figure for the green range 0 - 40
second figure for the yellow range 40 - 80
red range begins 80 - 100

ADC channel Measurement channel (default 0, in older systems 10)

Calibration Calibration value (default 1)

Version 2.0 8.13

CDS Manual Piston Ring Monitoring

9. Piston Ring Monitoring (PRM)

9.1 Necessary hardware
The PRM module determines the signals in relation to the crank angle. Therefore, in addition
to a piston ring sensor in the cylinder barrel, a crank angle encoder must also be installed and
calibrated. For this, a static TDC correction must be carried out (see 6.3).

9.2 Calibration
With the help of the calibration, all the parameters necessary for the recording of the
measured values are determined and stored in the configuration. Before calibration it is
necessary to build in and wire up the sensors correctly and calibrate the engine parameters. In
the case of the engine parameters, particular care should be taken to give the ratio between the
piston stroke and connecting rod correctly.

Calibration can only be carried out in administrator mode and is selected in the Admin menu
by clicking on PRM calibration.

Figure 9.1 Calibration dialogue: start window

Before starting the calibration, the cylinder that to be measure (Cylinder), number of
compression rings (Num rings) and number of values ( Num values ) has to be set. If it is
possible, the calibration is to carry out at cylinder 1. An another cylinders is to use if the
sensor at cylinder 1 is defect or the signal is unserviceable. The number of values should be
set to 2000.
The values should only be changed after consulting the manufacturer.

Version 2.0 9.1

CDS Manual Piston Ring Monitoring

Step 1
The button step 1 starts the calibration. One measurement is carry out and the position of the
signal to the crank angle will be detected. After measurement the detected values for
Starttrigger and Num trigger will be taken over. Then the signal is shown in the diagram.

Figure 9.2 calibration dialog: step 1 is carried out

Step 2
After step 1 is successful, step 2 can be carried out. This measurement works with the
parameter detected in step 1 and convert the signal to the piston stroke. The signal area, which
is important for the evaluation, will be detected. The parameter is enter Range begin and
Range end.
In the diagram the converted signal for upstroke and downstroke is shown. If the conversion
successful, both signals are similar.

Figure 9.3 calibration dialog: step 2 is carried out

Version 2.0 9.2

CDS Manual Piston Ring Monitoring

Step 3
Step 3 is searching for the areas for piston entry and piston leave. The essential parameter for
it is the Search level. Especially by an very low maximum of the piston entry it is possible
that the area is not to be found. In the case the values for Begin or End is probably not
plausible. It is recommended to increase the Search level step by step until the areas are
found. The parameters are entered in the table at Entry and Leave.
piston entry ring 1 ring 2 ring 3 ring 4 piston leave

Figure 9.4 calibration dialog: search areas of piston entry, the rings and piston leave at the signal

Alternatively the values can be set manually in the table. According to the example ( Fig. 9.4 )
the following values should be enter in the table:

Entry Begin 0.490 End 0.560

Leave Begin 1.240 End 1.280

The values can be different a little bit. It is important, that the in both areas the maximum
(entry) and the minimum (leave) are complete within the area and other signals outside.

Version 2.0 9.3

CDS Manual Piston Ring Monitoring

Step 4
After finding piston entry and piston leave, the search for the piston ring areas ( step 4 ) is
started. The value for Topring height is enter in the dialog first. This value can be read from
the signal ( Fig. 9.5). For better read it is recommended to zoom the area of the first ring. By
dragging the mouse from top left to bottom right with the left button pressed zooms to the
selected area. Dragging a window in the opposite direction returns to the normal display. The
parameter is the distance between the maximum and the minimum of the first ring.

Figure 9.5 calibration dialog: detection of the parameter Topring height

This value ( in the example ca. 20 mm ) is enter in the dialog and then the step 4 is to start. At
this step the areas of the piston rings will be searched and entered in the table. By selecting
the value in the table by mouse click, the corresponding area in the diagram is highlighted (
Fig. 9.5 ). If the areas are not found correctly, the parameter Topring height should be
changed step by step and the step 4 carry out again.
If required the changes or adjustments of the piston ring values can also do by manual input
analog to step 3.

Figure 9.6 calibration dialog: display of the area of the second ring

Under circumstances it is possible that the ring gap is in the area of the sensor. In this case the
signal deviate from the figures in this manual. The step 2 have to be carry out again. An
undisturbed signal is required for correct calibration.

After calibration the values will be accepted by clicking OK.

Version 2.0 9.4

CDS Manual Piston Ring Monitoring

9.3 Taking measurements

It is only possible to take measurements while the engine is running. As measurements taken
when the rotary speed is low lead to errors in the results, measurements are not carried out at
rotary speeds below a minimum permissible value which can be set as required (default 60
rpm). The revolution limit is calibrated with the other settings in the RUN module and taken
over after the CDS has been restarted.
Calibration must be carried out before measurement can begin.

Monitoring
When Start CDS is selected, the PRM module is automatically started. During monitoring all
the cylinders are measured. After a given time this measurement is repeated. If a fault is
detected, it is shown on the display and appears on the machine monitoring system. The
monitoring is stopped and the measurement is saved automatically. After the alarm has been
confirmed, the measuring continues automatically.

Manual measurement
In addition to monitoring, measurement of all cylinders can be started by selecting Manual
measurement.
Manual measurements are treated like normal monitoring measurements with regard to
recognition of malfunctions and alarm management.

Wear measurement
In addition to monitoring, a separate wear measurement is started. This is taken at quite long
intervals. Here only one cylinder is measured in the course of one measurement interval, the
next cylinder being measured after the next measurement interval. Measurement of wear
continues until there is a definite result or the maximum time duration for wear measurement
has been exceeded.
During wear measurement the signal characteristics are not evaluated and no alarm is given.
During wear measurement the detailed window displays Wear measurement.

Version 2.0 9.5

CDS Manual Piston Ring Monitoring

9.4 Presentation of the measurement results

revolution and number of measurement cycles
open details, statistics and trend symbolic view of piston and piston rings

thermal load and temperature confirm alarm

status bar alarm area

Figure 9.7 Main window of the PRM module

The main window of the PRM module shows the appropriate cylinder and the piston rings
relating to it. The piston rings are shown as either
green OK
red faulty
or grey suspended.

Beneath the diagram of the pistons there is a percentage display and a temperature display.
The percentage display is a measure of the thermal load on the piston. It is a ratio derived
from measured values for the piston rings and that of the piston. When the piston is
undergoing thermal expansion, the piston signal becomes bigger, whilst the rings continue to
be compressed into the grooves and give off a smaller signal. In this case the percentage
becomes greater.
The temperature display shows the value for the sensor temperature.

Below the piston displays is the alarm field. When there is an alarm this flashes red and the
faulty components are shown in red. The alarm must be acknowledged by double-clicking on
the Alarm Confirm button.

Status bar
Section 1 File name of a measurements file
Section 2 Current data and time
Section 3 Status display for piston ring monitoring
Section 4 Status display for wear measurement

Version 2.0 9.6

CDS Manual Piston Ring Monitoring

Details

Figure 9.8 Details window

Diagram
The diagram shows the signal sequence from one measurement run. The signal sequence is
recalculated to the piston stroke; the amplitude is displayed in volts. The individual
measurement runs are shown in different colours.

It is possible to zoom in and out on the diagram.

To zoom in, hold down the left mouse of the button at the top left of the selected area and
drag down to the bottom right. Drag the window in the opposite direction to return the display
to normal size.

Symbol diagram
Below the chart the pistons and compression rings are displayed in the form of symbols.
Normally the piston is black and the piston rings green. If a distorted signal is detected, a
yellow display box appears. If the malfunction is confirmed after further measurements, the
corresponding component is shown in red.
Suspended piston rings are shown in grey.

Value display
This shows the most recent measured values and status.
Speed: Rotational speed
Ring condition: Shows the status of the piston rings
(okay, stuck, broken, missed or unknown failure)
Thermal load: Value for the thermal load on the piston at the time of measurement
Sensor temperature: Temperature of the sensor at the time of measurement
In the event of breakdown, the right side also displays
thermal overload, high temperature, PR sensor failure, temp sensor failure

Version 2.0 9.7

CDS Manual Piston Ring Monitoring

Raw data

Figure 9.9 Context menu and display of raw data

A right click on the Details window below the values display opens a context menu.
By selecting Display raw data, the measured data can be displayed as it is measured and
before it is recalculated to the stroke and evaluated. In particular, problems with the
measurement can be detected and rectified with the help of this raw data. By selecting Save
raw data the raw data run can be saved.

Statistics
Selecting the button PRM statistics in the overview window allows all the cylinders to be
displayed in a single table showing the status of the piston rings, pistons, thermal load and
sensor temperature.

Figure 9.10 Statistics window, cylinder 1 ring 1 is stuck

Trend
The Trend button opens a display showing the trends for the temperature and thermal load
values.

Version 2.0 9.8

CDS Manual Piston Ring Monitoring

9.5 Alarm
When monitoring is switched on, any malfunctions that are detected are displayed as an alarm
and an alarm sounds on the machine. The monitoring is stopped automatically and the most
recent measurements are saved. If an alarm sounds, it must be acknowledged by clicking on
Alarm confirm. After this acknowledgement the monitoring continues automatically. If the
alarm sounds again, the corresponding ring should (if need be) be excluded from the
measurement process until the malfunction has been corrected (see 5.4 Configuration).
Suspended rings are shown in grey in the symbol diagram and are given the status suspended.
Any malfunction detected during manual measurement will only be displayed as an alarm: no
alarm will sound on the machine. No acoustic alarm will be given for acknowledged
malfunctions.
No alarm will be sounded during wear measurement.

Figure 9.11 Statistics window, cylinder 1 ring 1 is stuck

The following statuses can be determined:

Therm. load
An alarm sounds immediately. The piston in the symbol diagram and the value for the thermal
load are displayed in red.
There is too little play between the piston and the bush, and there is a danger of the piston
jamming.
In order to give warning of the pistons jamming, the distance is monitored between the piston
crown with the highest thermal load and the cylinder barrel. The signal aspect for piston entry
becomes exponentially greater as it approaches the cylinder barrel. If the set limiting value is
exceeded, this sets off an alarm.

Temperature
An alarm sounds immediately. The figure for the sensor temperature is shown in red.
The temperature in the area of the sensors is too high and there is danger that damage will
occur.

Version 2.0 9.9

CDS Manual Piston Ring Monitoring

Broken ring
The Broken ring malfunction is first shown in the detailed window as Probably broken. Only
after this has been confirmed by further measurements does an alarm sound. The
corresponding ring is shown red in the symbol diagram. The ring status for the corresponding
ring shows Broken ring.
The signal sequence of a broken ring shows clear irregularities. As a result of the loss of the
internal stress when the piston ring breaks into two or more pieces, these pieces may move
around loosely in the piston ring groove. As a result, the effective mass changes constantly, so
that it is possible to observe a continually changing stress amplitude over several
measurement runs. The piston ring “rattles” in the signal response during the measurements.

Stuck ring
The Stuck ring malfunction is first shown in the detailed window as Probably stuck. Only
after this has been confirmed by further measurements does an alarm sound. The
corresponding ring is shown red in the symbol diagram. The ring status for the corresponding
ring shows Stuck.
The piston ring sticks and can no longer move freely in the ring groove, so that it remains in
the position that it takes up with the smallest diameter in the ring groove. As a result, this
leaves a gap between the piston ring and cylinder barrel in other piston positions. This
condition is shown in the signal sequence by a smaller amplitude in the range of the affected
piston ring compared to earlier measurements.

Figure 9.12 Detail window, cylinder 1 ring 1 is stuck

Version 2.0 9.10

CDS Manual Piston Ring Monitoring

Missed ring (-segment)

The Missed ring malfunction is first shown in the detailed window as Probably missed. Only
after this has been confirmed by further measurements does an alarm sound. The
corresponding ring is shown red in the symbol diagram. The ring status for the corresponding
ring shows Missed ring.
If the piston ring or a section of it is missing, an inversion of the signal occurs. After a piston
ring breaks, pieces of the ring may fall out of the ring groove. If an “empty” piston ring
groove passes the sensor, the sequence of the magnetic mass is reversed compared to the
normal status. Instead of a piston ring increasing in mass, when it enters the sensor area there
is first a decrease in mass as a result of the ring groove. As a result, the signal is inverted and
a negative amplitude is produced in the signal sequence instead of a positive one. If the ring
groove leaves the sensor area, a positive amplitude is produced as a result of the increase in
mass.

ring failure
If a malfunction occurs that does not coincide with the described malfunctions, an unknown
failure is indicated in the detailed window. Only after this has been confirmed by further
measurements does an alarm sound. The corresponding ring is shown red in the symbol
diagram. The ring status of the corresponding ring shows ring failure.
The cause of this type of malfunction message may, for example, be a temporary jarring of
the ring.

TDC correction failed

If a measured signal cannot be evaluated because it is not possible to correct the TDC, this
does not set off an alarm. Since in this case no evaluation takes place, the piston rings are
shown in grey in the overview window. The message TDC correction failed appears in the
detailed window.

Sensor failure
If a sensor does not supply a signal, this sets off an alarm. The corresponding component is
shown in red. In this case the sensor should be checked. If the malfunction appears for the
majority of cylinders, a new set of measurements should be taken.

Version 2.0 9.11

CDS Manual Piston Ring Monitoring

9.6 Menu options for the PRM module

File
Load File Loads a saved measurements file (*.pra)
Save PRA file Saves the most recent measurements, suggests a file name:
Factory name_Date_Time.pra
Open RUN Opens the RUN module
Open PRM Opens the PRM module
New CPA Opens the CPA module
Change Engine Loads another configuration (*.cfg)
Print summary Prints the summary
Print cylinder Prints the cylinder data
Exit Ends the current program

Measurement
Start Starts the monitoring
monitoring
Stop Stops the monitoring
monitoring
Start wear Starts the wear measurement
measurement
Stop wear Stops the wear measurement
measurement
Manual Starts monitoring
measurement

Display
Display details Opens the window with the detailed view
Display Opens the window with the statistics
statistics
Trend Opens the trends window

Admin
change admin Changes the administrator password
password
switch to Switches to administrator mode
admin mode
Edit options
engine Changes the engine to be tested
database

Help
Info

Licence info

Version 2.0 9.12

CDS Manual Piston Ring Monitoring

9.7 Configuration of the PRM module

Piston parameter

Figure 9.13 Configuration of the PRM module - piston parameters

The majority of these configuration values originate from the calibration and as a rule do not
have to be changed.

Trigger start Trigger impulse at the start of measurement

Number values Number of measured values in the measurement range
Meas Trigger Number of triggers to determine the measurement range
Wear meas Select functions for wear measurement
Possible set-ups:
None No wear measurement
Plasma Wear ring is plasma coated
Slot 0 Wear ring is slit above the perimeter
Slot 45 Wear ring is slit at an angle of 45°
UpStroke/DownStroke Selection of measurement sequence to be evaluated
Meas Temperature Switch temperature measurement on / off

Piston parameters Number of piston rings

Range begin Start of measurement range (recalculated to strokes[m], also
applies to the following values)
Range end End of measurement range
Entry Piston entry (start and end of the signal)
Ring 1-n Rings 1 to n (start and end of the signal)
Joint Joint (as a rule, signal is not needed)
Leave Piston exit (start and end of the signal)
Monitoring parameter

Version 2.0 9.13

CDS Manual Piston Ring Monitoring

Monitoring parameter

Figure 9.14 Configuration of the PRM module - monitoring parameters

Meas Interval Measurement interval

Wear interval Wear measurement interval
Breaktime Abort time for wear measurement
Suspended Cylinders Selects a cylinder to suspend individual functions
Ring 1 - Ring 4 Suspends monitoring of individual rings
Temperature Suspends temperature monitoring
Thermal Load Suspends monitoring of piston expansion

Alarm Limits
Limit therm. load Limit value for thermal load (piston expansion)
Limit broken ring Limit value for broken piston ring
Limit missed ring Limit value for missing piston ring
Limit temperature Limit value for temperature
Limit stuck ring Limit value for stuck piston ring

Reset wear param Reset wear parameters for plasma-coated rings

Because of the non-magnetic plasma layer, plasma-coated wear rings give a smaller signal
than the other piston rings. The removal of this layer of wear is monitored by means of the
wear measurements.
If the wear ring or sensor is changed, the wear parameters must be reset; otherwise – because
of the way in which the measurements are taken – it is not possible to detect either any stuck
rings or if the 1st ring of the cylinder is stuck permanently.

Version 2.0 9.14

CDS Manual Torque Measurement System

10. Torque Measurement System (TMS)

10.1 Necessary hardware
The TMS module determines the signals through the crank angle. Therefore a crank angle
encoder must also be installed and calibrated. For this, static TDC correction must be carried
out (see 6.3).
For the measurement of the signals TMS needs 4 sensors, they work in to two measurement
levels. The signals from the sensors will be boosted with the TMS amplifier.

10.2 Calibration
The sensors will be delivered preadjusted. Normally it is not necessary to change the
adjustments of the sensors.
Checking the signals and the adjustment of the sensors takes place at running engine. It is
important that the sensors have the correct distance to the shaft (see 3.5 hardware installation).
To see the signals the signal window will be opened with show signals at the menu options
(see 10.4 display). If the TMS program starts, it begins with a continuous measurement.
The signal curve of a sensor should be disturbed symmetrical around the zero point (offset). If
the curve is as whole too high, the offset has to be decreased. If the curve is as whole too low,
the offset has to be increased. The offset is set for every single sensor.
The maximum amplitude of the signals should be between 2 to 6 V, the minimum amplitude
of the signals should be -2 to -6 V. In other cases the amplification has to be increased or
decreased. The amplification is set for every single sensor.

Figure 10.1 normally signal curve sensor 1 and 3

There won't be any trouble no problem, if the signal amplitude of sensor 1 and 3 or 2 and 4
differ. But if there are differences between the outlook of the signal curves, it is recommended
to contact the manufacturer. Therefore it is recommended to save a measurement (see 6.
measurements).
The unit is calibrated by an external comparison measurement of performance or of torque.
This must take place simultaneously at the same load point. According to the procedure
chosen, the torque on the propeller shaft or the effective performance can be used. Load
changes during calibration lead to a false result.

Version 2.0 10.1

CDS Manual Torque Measurement System

The basic calibration should take place at nominal power and rotation direction ahead. After
this the system is ready for measurements. The rotation direction ahead will be set with this
calibration measurement.
A calibration measurement takes longer than an normally measurement. To increase the
accuracy of the measurement, an average value will be determined by several single
measurements.
A calibration measurement will to be started with the calibration command in the options
menu. Calibration takes place in 6 steps, each step being confirmed with Ok. By clicking
cancel calibration is cancelled and the measured values will be lost.

1. The engine must be running at constant load.

2. TMS calibration measurement is started.

3. The comparison measurement (e.g. indexing with CDS)

is here selected and executed.

4. Rpm in the comparison measurement is sampled. This

sample serves to check plausibility.

5. The measured value of the comparison measurement is

entered.

6. Calibration is completed and the determined calibration

values are accepted with Ok and saved in the
configuration.

Figure 10.2 calibration window

Is an error occurring during the calibration the measurement will be stopped. A new
calibration is recommended.
Repeated measurements (max. 10) increase the accuracy of the calibration. These can also be
carried out at a later point. Up to 10 calibration points will be assessed.
Calibration needs to be carried out again after any work on the TMS cam lobes or
sensors.
Before re-calibration, the previous calibration values must be reset. This takes place at the
menu options with configuration. With the button reset calibration values all calibration
values will be set to start values. To prevent deleting by a mistake, the resetting of calibration
values is to confirm.

Version 2.0 10.2

CDS Manual Torque Measurement System

10.3 Taking measurements

A single measurement can be carried out with manual measure in the measure menu.
Continuous measurement is started in the same menu with start measure, and can be stopped
again with stop measure.
It is possible to carry out a measurement without any calibration. In this case the values for
torque and power are wrong. An error message is also possible. An measurement without
calibration allows to test the sensors by showing the signal curves.
The rotation direction ahead will be set with the first calibration measurement. The rotation
direction backwards will be shown as negative revolution. Until the rotation direction is
saved, all measurements will be assessed as rotation ahead. In this case a backward rotation
results in wrong values for torque and power. With save ahead direction the rotation direction
ahead will be defined. Before that a measurement in direction ahead has to be carried out.

After a manual or a continuous measurement it is possible to save a measurement file. By

clicking save in the file menu, a saving dialog is opened. The suggested file name is
composed of date and time of the measurement. Measurement files can be opened with open
at a later time.

10.4 Presentation of the measurement results

The effective torque, effective performance and rpm are displayed as figures in the TMS
window. The status bar shows the time and date of the last measurement. The right side
represents the status of the measurement.
Other displays can be selected in the options menu.

Figure 10.3 Main window

Display of the signals

Show signal in the options menu shows the current signal curve of all four sensors, allowing
functional irregularities to be spotted. Normally all sensors are shown. For a clear
presentation, the signal of each sensor can switch off or on.
This window can stay open during the measurement. The signal curves will be made topical
with every other measurement. Freeze signals stops the changing of the signal curves.
If there is an another window open at the signal display no action is possible.

Version 2.0 10.3

CDS Manual Torque Measurement System

If freeze signals chosen, the display can be switched to the raw data view. With right click on
the signal curves opens a context menu. There it is possible to save or load the raw data. Raw
data can help to solve problems with the measurements.
If there is an another window open at the same time, no action is possible into the signal
display.

Figure 10.4 signal display, display and save raw data

Version 2.0 10.4

CDS Manual Torque Measurement System

10.5 Error messages

No Error Cause / recommended action

E10 measuring blocked by Koge card is being used by a CDS module:

CDS no action necessary
E11 measuring failed single measurement failed
no action necessary
E20 revolution low rpm to low:
no action necessary, measurement is running again at a higher
revolution
E21 sensor 1: no signal maximum amplitude of a signal < 1V:
check signal path and power supply of sensor
E22 sensor 2: no signal

E23 sensor 3: no signal

E24 sensor 4: no signal

E25 sensor 1: too high the measured signals are too high:
signals check the signal curve,
E26 sensor 2: too high decrease the amplification / adjust offset,
signals check the distance of the sensor from the shaft, (increase
E27 sensor 3: too high sensor distance)
signals
E28 sensor 4: too high
signals
E29 measurement 1: low correlation of the signal curves of sensor 1 and sensor 3 is too
correlation low:
check setting of cam lobes and sensors
E30 measurement 2: low correlation of the signal curves of sensor 2 and sensor 4 is too
correlation low:
check setting of cam lobes and sensors
E31 calculation not plausible curve evaluation does not deliver plausible values:
no or wrong calibration values (see 5. Calibration),
rotation direction not detected (see 6. Measurement),
a signal curve is disturbed,
if problem recurs contact the manufacturer

Version 2.0 10.5

CDS Manual Torque Measurement System

10.6 Menu options for the TMS module

File
open Open a measured value file (*.tmm)
save Save the current measured values (*.tmm)
(only during manual measurement)
load config from Save the current configuration for the registry
registry
save config to Save the current configuration into the registry
registry
load config from Load a configuration file (*.cfg)
file
save config to file Save the current configuration (*.cfg)
save config to txt Save the current configuration as Textfile (*.txt)
exit Exit the program
Measurement
manual measure Carry out a manual measurement
start measure Start continuous measurement
stop measure Stop continuous measurement
Options
calibration Carry out calibration measurement
save ahead Rotate direction of the last measurement is set as direction ahead
direction
configuration Show calibration values
show signal Show signal curves
info Show version information

Version 2.0 10.6

CDS Manual Torque Measurement System

10.7 Configuration of the TMS module

With Configuration in the options menu the setting of TMS can be changed.
The modification are accepted with Ok and saved in the configuration. Cancel discards all
changings.
With the button reset calibration values all calibration values will be set to start values. To
prevent deleting by a mistake, the resetting of calibration values is to confirm. After resetting
the system needs to be re-calibrated.
Calibration needs to be carried out again after any work on the TMS cam lobes or
sensors.

General

Figure 10.5 Configuration General

Channel A measurement channel level A

Channel B measurement channel level B
Trigger per Revolution count of the trigger impulses from the crank angle encoder per
revolution
Measuring interval delay time between the single measurements
Number of values count of the measurement values per measurement
Number of calibrations count of the single measurement at the calibration

Revolution Minimum limit for revolution to be measured

Correlation Minimum limit for error messages E29/E30 correlation low
Amplitude Minimum limit for error messages E21/E22/23/E24 no signal
Signal Maximum limit for error messages E25/E26/27/E28 too high signal

AutoStart starts the measurement with starting the program

AutoSaveDate all 5 days a measurement will be saved automatically
AutoSaveError measurements with the error message E31 (calculation failed)
will be saved automatically
ResultTxt a logfile with measurement results and error messages will be
written

Version 2.0 10.7

CDS Manual Torque Measurement System

Calibration

Figure 10.6 Configuration Calibration

Zero Angle offset of the measurement

Calibration Value correlation between torque and torsion of the shaft
(will be calculated from the geometrical data of the shaft)
Calibration Correction correction of the calculated calibration value by measurements
Power MCR nominal power, exceeds the measured power this value plus 15 % the
error message E31 (calculation failed) appears.

At the diagram the current calibration values and the calibration line will be showed.

Serial

Figure 10.7 Configuration Serial

The external interface of TMS will be set here. The parameter are preadjusted and should not
be changed.

Version 2.0 10.8

CDS Manual Torque Measurement System

10.8 External interface

RS 485 NMEA Protocol
Optional the measurement values can put out with the NMEA protocol. The protocol is send
over the RS 485 data bus. A free RS 485 COM interface at the computer is necessary.

construct description format

characteristic sign (comma between characteristic sign and list) $SNTMS

list of parameter timestamp [time_t] (seconds from 01.01.1970 1:00 integer

GMT)
revolution speed [rpm] floating point
(comma after each torque [kNm] floating point
parameter) power [kW] floating point
error code 1 integer
error code 2 integer
internal use floating point
torsion angle [rad] floating point
correlation value [%] floating point
direction of revolution [-1 backwards, 1 forward, 0 integer
n. a.]

asterisk checksum checksum hexadecimal

The protocol will be send each 2 seconds with following settings:

bits per second 9600
data bit 8
parity no
stop bit 1

External display
Optional an external display will be connected at the RS 485 data bus or at the RS 232 COM
interface.
Following values are shown:

line 1 Time of the measurement error number of an occurs error

line 2 torque at the crankshaft [kNm]
line 3 effective power [kW]
line 4 revolution speed [rpm]

Version 2.0 10.9

CDS Manual Performance Monitor

11. Performance Monitor

11.1 Necessary Hardware
For the Performance Monitor especially hardware is not necessary. For the display functions
the CDS trend database will be used. All applied data will be delivered by the automation
control or the module TMS in varying volume. The settings for the communication is
described in the manual chapter 6.5.
Depending on the available data the Performance Monitor offers the following functions:

- entering of present data for the values

engine revolutions n [U/min]
effective engine power Pe [MW]
engine filling F [%]
fuel consumption Bh [t/h]
ship’s speed v [sm/h]
- Calculation of the characteristic values
specific fuel consumption be [g/kWh]
fuel consumption per seamile Bs [kg/sm]
- Graphic display of the engine maps
engine map specific fuel consumption be = f(n, Pe)
engine map cruise consumption Bs = f(n, v)
engine map ships´s speed
- Display of the current operational point in the engine maps. The position of the
operational point in the engine map allows a quick visual assessment of the optimisation
potential. In addition the propeller curve for the present state of operation is entered. The
operational point would move along this curve if the engine revolutions were changed.
- In the engine maps the values of the characteristic can be obtained by mouse click on any
operational point.
- Apart from their graphic display the values of the characteristics can also be presented
numerically. Furthermore date and time of the last measurement or entry are displayed.
- In the engine map be = f(n, Pe) the limits of the characteristics of the engine can be
displayed (layout diagram, load diagram, overload diagram, optimal propeller curve).
Each measurement or manual entry is checked against the border values of the load
diagram. If they are exceeded an alarm is set off.

Version 2.0 11.1

CDS Manual Performance Monitor

11.2 Display

changing the engine maps

current operating point

specific fuel consumption

start Pe counter

start Bh counter
date and time of
the last parameters

operating hours and

revolution counter

confirm alarm button

next values in x sec open a detail window with all parameters
delivered by the automation

Figure 11.1 main window of the Performance Monitors

Engine maps
The current operating point of the propulsion engine appears in the engine map as a blue
square. It is the intersection point of the revolutions per minute and the power, and it
characterises the current fuel consumption or the ships´s speed.
In addition as propeller curve for the current operating point is entered. The operating point
would move along this curve, if the number of engine revolution per minute is changed.
The current position of the operating point in the engine map allows a quick overview of
potential optimisation measures to be taken.
The engine maps are limited by the operation limits of the propulsion engine (or its turbo
loader):
- maximum number of revolutions for continuous operation
- maximum power for continuous operation
- threshold mean effective pressure
- threshold torque/revolutions per minute

These engine maps are available:

- Be, specific fuel consumption Be = f(n, Pe), [kg / kWh]
- Bs, cruise consumption Bs = f(n, v), [kg / sm]
- v, ships´s speed [sm / h]

Version 2.0 11.2

CDS Manual Performance Monitor

Cursor display
The data of the current values can be obtained at any operating point with a mouse click.In
this field the corresponding values for the revolutions (n), the effective engine power (Pe) and
depends on the choosen characteristic field the specific fuel consumption (be), the
consumption per saemile (bs) or the speed (v) can be read depending on the cursor position.

Apart from their graphic display the current data of the operation values and the characteristic
values are also shown numerically on the right side of the screen.
Counter
With cklicking Start the Pe counter starts and begins to add the power. The elapsed time is
displayed on the right. Clicking Stop reset the counter.
The second counter works as same as the Pe counter.
Additionally date and time of the most recent measurement or input are displayed below the
counters.
Below the time the operating hours and the revolution counter will be displayed.
By clicking the button Details a separate windows will be shown. It contains all data
transmitted by the automation.

Figure 11.2 detail window

Version 2.0 11.3

CDS Manual Performance Monitor

11.3 Alarm
Each measurement or manual input is checked for the observation of the limits of the load
diagram. If this threshold is exceeded an alarm is set off.

Figure 11.3 main window with alarm

The Performance Monitor can only continue work when the alarm display has been
confirmed.

Version 2.0 11.4

CDS Manual Performance Monitor

11.4 Menu options of the Performance Monitor

Monitoring
Stop Monitoring Stops the reading of data
Manual Input Manual input of values
Exit Close the Performance Monitors

Analysis
Time Series Open a window with time series of the values

Settings
Monitoring Interval for reading the data from the CDS trend database
Frequency
Diagram Layout Allows the adjustment of the diagram
Options Settings of the Performance Monitors (see 11.5)
Alarm suspended Allows the switch of / switch on of the alarm of the Performance Monitor
to the CDS Alarm
Test CDS Allows the output of a CDS alarm for testing the function die Ausgabe
alarmpin eines CDS Alarms. Diese Funktion dient zum Testen des Alarms.

Help
Info Open a window with information according the Performance Monitor

11.5 Configuration of the Performance Monitors

The configuration of the Performance Monitors follows 2 ways.

The showed engine maps will be developed to match with the engine / type of ship. The
engine maps will to be trained. During the starting time it is possible to customise the engine
maps.
Single parameters will be put in into the menu settings with options. With delivery of the
performance monitor, these parameters are preadjusted. As with the engine maps, it is
possible to customise the parameter during the starting time.

Version 2.0 11.5

CDS Manual File Collector

12. File Collector

12.1 Collect measurement files
The File Collector is a tool to manage the measurement files. By the help of the File Collector
it is possible to collect measurement files and to copy these file into an assigned folder. The
files will be compressed and if necessary split to enable the transmission by email. If the files
are split it is most important to send all packages.
In general the collected files will be saved in the folder C:\email. There a new folder with the
name CDS_ZIP+date will be created. This folder contained all related files. The file search
will be started with the ZIP button. During the search a new windows is opened, who can put
in additional information e.g. changing of piston rings.

Figure 12.1 File Collector main window

The measurement files will be searched within the CDS install folder in the folders Data,
Logs and Trend. The File Collector is preconfigured. However it is possible to customise the
File Collector.
At first the timeframe can be changed. There are 4 possibilities who can chosen.

last month search files from the last month

current month search files from the current month
last xx days search files from now on the last xx days
Date from xx to yy search files from date xx to date yy

Furthermore the selection of the type of files can be changed. For that reason on the right side
there is a list of checkboxes for special types of files.
Select a checkbox to search a type of file. Especially in case of problems it is important to
send raw data of measurements.

Version 2.0 12.1

CDS Manual File Collector

12.2 Special functions

Save CDS information
With Save CDS information in the menu Files important information about the CDS will be
collected.

File version list of file version of the CDS program files

CDS tree save the folder index of the CDS
Log files save log files from the folder Logs
ISC-Client file configuration of the ISM client from Lungsø Marine

Registry settings as *.reg save the whole configuration of the CDS

If there is a problem with the CDS, it is helpfully to solve the problem, to send the
information request together with the list of file version, the log files and the configuration of
the CDS. A lot of questions could not be to answered without the current configuration.
For another thing this with function it is possible to back up the configuration.

Figure 12.2 Save CDS information window

After clicking OK a new windows is opened, who can put in additional information. The
result of this function is a compressed file with the name cds_info+date.zip. The file is also
located in the folder C:\email.

Manual ZIP selection

If the possibilities of settings are not enough to find the desired files, these files can be collect
manual. This function will be started with Manual Zip selection in the menu Files.

Unzip file
Also in the menu Files the function Unzip file is located. A compressed file before therewith
can opened and decompressed

12.3 Configuration of the File Collector

The presettings can be changed with Edit data settings in the menu Setting. The single
elements of the list can be chosen by the right mouse click. In the context menu the changes
can be taken place. The button Set to default reject all changes.
Version 2.0 12.2
 18119 Rostock / Friedrich-Barnewitz-Str. 3
Germany
Tel.: +49 381 5196171/ Fax: +49 381 5196172
E - Mail : maridis@maridis.de