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(1*,1(,167580(17$7,21 $9//,67*0%+ +DQV/LVW3ODW] $*UD]$XVWULD 7HO )D[ KWWSZZZDYOFRP ,GHQWQXPEHU $7( 5HYLVLRQQXPEHU (GLWLRQ -DQXDU\ 61BBBBBBBBBBBBBBBBBBBBB 6XEMHFWWRDOWHUQDWLRQ 3ULQWHGLQ$XVWULDE\ $9//,67*0%+*UD] 2SHUDWLQJ,QVWUXFWLRQV 7'&6HQVRU Copyright 2002 AVL List GmbH, all rights reserved The contents of this document may not be reproduced in any form or communicated to any third party without the prior written consent of AVL. While every effort is made to ensure is correctness, AVL assumes no responsibility for errors or omissions which may occur in this document. This manual contains important warning and safety instructions to be observed by the user. This product is only intended for one certain area of application which is described in the instructions. Furthermore the most important necessary prerequisites for application and operation as well as the safety measures are explained to ensure smooth operation.No warranty or liability will be granted if the product is applied in areas others than those described or if the necessary prerequisites and safety measures are not met. The product is to be operated and used only by qualified personnel capable of observing the required safety measures. Only accessories and supplies either delivered by AVL or approved by AVL are to be used with the product. Due to the operating principle of this product the accuracy of measurement results which it produces do not only depend upon its correct operation and function, but also upon a variety of boundary conditions beyond the control of the manufacturer. Therefore the results obtained from this product must be subjected to careful examination by an expert (e.g. for plausibility) before action based upon the results is undertaken. Adjustment and maintenance of instruments when open and under voltage are only to be carried out by a professional technician being aware of the dangers involved. Protect instruments powered by the mains from humidity. Repairs on the product are to be carried out by the manufacturer or qualified service personnel only. Upon application of the product an expert is to ensure that neither the object of examination nor the testing equipment are operated under conditions that my lead to damage or injury. List GmbH Important Notice! Important Notice Important Notice! Important Notice Safety Instructions Any connected equipment that uses higher voltages than 50 V AC or 75 V DC must satisfy the requirements of the 73/23/EEC Directive. Only shielded cables may be used with appropriately shielded connectors in order comply with the 89/336/EEC Electromagnetic Compatibility Directive. Mains connections with standardised connectors and the exceptions mentioned do not need to be shielded. This device must not be used in any environment where there is a danger of explosion. The device must not be exposed to rain or permanent humidity or moisture. The device may only be opened by qualified personnel. If a foreign body or liquid gets inside the device, disconnect it from the mains and have an expert check it before using it again. Make sure that the device is supplied with the correct supply voltage. The device must not be connected to a direct voltage power supply network. Use the appropriate power supply unit. TDC-Sensor Content Operating Instructions I 1 Operating Instructions in Brief 1 1.1 General .1 1.2 Measurement Principle 1 1.3 Design 1 1.4 Procedure Determining TDC 2 2 Application Area 3 3 System Components 5 3.1 Scope of Supply 5 3.1.1 TDC-Sensor 428 =TI0428A.01= 5 3.1.2 TDC-Sensor Set 428 =TI0428SETA.01= 5 3.2 Optional Accessories 6 3.2.1 Sensor Probes 6 3.2.2 Adaptor for Standard-Probe 428.10 6 4 Sensor Design 9 4.1 Sensor Electronics with Connection Cables and Balancing Unit .9 4.2 Probe with Clamping Set .9 4.3 Adaptors 9 5 Operation Principle 11 5.1 TDC-Sensor 428 11 6 Preparing the Measurement 13 6.1 Selection of Measurement Bore 13 6.1.1 Installation Position - Measuring Position 13 6.1.2 Typical Installation 14 6.1.3 Adaptor Design 17 6.2 Installing the Sensor Probe 20 6.2.1 Gap between Piston and Probe 20 6.2.2 Adjusting the TDC-Sensor Probe 21 6.3 Electrical Connections 23 6.3.1 Connection Probe and Sensor Electronics 23 Content TDC-Sensor Operating Instructions II 6.4 Electrical Balancing . 24 6.4.1 Purpose of Balancing 24 6.4.2 Prerequisite 24 6.4.3 Balancing Unit 25 6.4.4 Checking the TDC Signal Amplitude 26 6.4.5 Checking the TDC Signal for Interference 26 7 Measurement Procedure 29 7.1 Cylinder in Non-fired Operation . 29 7.2 Measurement with AVL Indicating Equipment 29 7.3 Typical Signal Curves . 30 8 Errors and Remedies 31 8.1 Possible Damage 31 8.2 Signal Influence at Gas Exchange 32 8.3 Typical Signal Signifying Touch with Piston . 33 8.4 Sensor Probe Soiling 34 8.5 Sensor Probe Damage . 34 8.6 Damage to the Sensor Probe Head 34 9 Technical Data and Dimensions 35 10 Appendix 39 10.1 CE Compliance . 39 10.2 List of Figures . 39 TDC-Sensor General Description Operating Instructions 1 1 Operating Instructions in Brief 1.1 General In the thermodynamic evaluation of pressure curves measured in internal combustion engines, the exact determination of the top dead centre (TDC) position is of great importance (e.g. in IMEP-measurements). Since the rigid construction of internal combustion engines is not ideal, a statically determined TDC can involve uncertainties. 1.2 Measurement Principle The capacitive TDC-Sensor 428 is used to determine TDC dynamically in a motored IC engine or partially firing IC engine (the cylinder to be measured is unfired and the others are fired). The 428 TDC sensor can be installed in most engines in existing indicating, injection or spark plug bores. The 428 TDC sensor evaluates the variation in capacitance between the piston and the sensor probe head. Using SMD technology, a specially developed electronic circuit delivers an analogue signal corresponding to the piston lift when it is near TDC. The difference between TDC and trigger mark is calculated by determining the symmetry angle of the compression lift signal. 1.3 Design The TDC-Sensor 428 complete consists of the standard 260 mm sensor probe, the sensor electronics which is directly mounted to the sensor probe with a 10 m connection cable and a clamping set. For extra long sensor probe and mounting adaptors see Chapter Optional Accessories, Page 6. The sensor probe comprises a sensor element of the appropriate length and a sensor probe head. The sensor probe can be adjusted easily by means of the clamping mechanism. The sensor probe is installed in existing engine bores with a suitable adaptor. The sensor electronic circuit is the same for all applications irrespective of sensor probe length and installation position. For analysing the TDC signal, the AVL Indicating Equipment Indimeter 619, Indiset 620, Indiset Advanced 631, Indimaster 670, can be used in conjunction with a suitable Angle Encoder (resolution 0.1 deg. crank angle, i.e. AVL 364/365 Angle Encoder). [...]... TDC-Sensor Set 428 =TI0428SETA.01= As a supplement to the indicating equipment there is a TDC-Sensor Set which contains the recommended minimum parts required, namely • TDC-Sensor 428 complete =TI0428A.01= • Extra Sensor Probe, 260 mm long 428. 10 =BO 0586= • Adaptor M14x1.25 428. 51 =YF 0486= • Adaptor M10x1 428. 52 =YF0482= • Adaptor sleeve 428. 53 =YF0483= Operating Instructions 5 Application Area TDC-Sensor. .. Sensor Probe, 260 mm long 428. 10 =BO 0586= Distributor 428 =EU 1726= Clamping Set complete, comprising: • Adjustement Piece 428. 30 =YF 0456= Knurled Nut 428. 31 =YF 0457= • Clamping Cone 428. 20 =YF 0454= Hexagonal Nut 428. 21 =YF 0455= • Fixing Nut 428. 40 =YF 0453= • Operating Manual 428 =AT0327E= See Figure 9-1: Sensor Electronics 4028Z03, Figure 9-2: Sensor Probe 428. 10 or 428. 12, 428. 14, Figure 9-3: Clamping... installation position are given in Chapter Selection of Measurement Bore, Page 13 Operating Instructions 3 Application Area 4 TDC-Sensor Operating Instructions TDC-Sensor System Components 3 System Components 3.1 Scope of Supply TDC-Sensor 428 =TI0428A.01= The TDC Sensor 428 complete consists of the components listed below These are supplied as a complete order, but can, also be ordered separately... hqÃurhthyà 6qh Ãvhy !vÃTpxr Figure 4-1: TDC-Sensor 428 - Assembly 10 Operating Instructions TDC-Sensor Operation Principle 5 Operation Principle 5.1 TDC-Sensor 428 The sensor probe is fixed in the adaptor by the clamping cone The adjustment piece is then to define the gap between piston and sensor probe head (see Figure 5-1: TDCSensor 428 Page 11) The sensor probe head and the piston are... the balancing unit, piston at BDC) • Carry out the measurement 2 Operating Instructions TDC-Sensor General Description 2 Application Area The AVL TDC-Sensor 428 is used to determine the precise position of TDC in dynamic operation It can also be applied for approximate static determination of TDC The TDC-Sensor 428 standard model with 260 mm sensor probe is designed to fit most IC engines up to truck... Application Area TDC-Sensor 3.2 Optional Accessories 3.2.1 Sensor Probes Standard Probe 428. 10 L = 260 mm Probe for cylinder heads with deeper installations bores 428. 12 L = 360 mm Probe for cylinder heads with deeper installations bores 428. 14 L = 5000 mm / Figure 3-1: Probe 3.2.2 Adaptor for Standard-Probe 428. 10 The following adaptors are available for standard sensor probes L=260 mm) tobe... pv pvÃryrr 9rsvrq qvhpr 8 8" 8! 8# 8hhvvr ÃÃÃi vqtr Tr à ir Thqh q hpvt Qv Figure 5-1: TDC-Sensor 428 Operating Instructions 9vssr rvhy ÃÃ6yvsvr PÃÃÃÃÃÃÃÃÃÃÃÃPà Figure 5-2: Principal circuit diagram 11 Operation Principle 12 TDC-Sensor Operating Instructions TDC-Sensor Preparations for Measurement 6 Preparing the Measurement 6.1 Selection of Measurement Bore To install... Transducer bores $ ! + ' C@Yà [ 0 [ 0 Figure 3-2: Adaptor 428. 51 for spark plug bores with M14x1.25 thread and indicating bores for pressure transducer with M14x1.25 thread 6 Operating Instructions & TDC-Sensor Systemkomponenten $ $ ' C@Yà # à ' C % à & ' % à # H H Figure 3-3: Adaptor 428. 52 for spark plug bores M10x1 thread and indicating bores for pessure transducer... Figure 6-4: Adaptor for indicating- or spark plug bores with M14x1.25 thread For standard length of sensor probe (260 mm) AVL offers the Adaptor 428. 51 (see Chapter Adaptor for Standard-Probe 428. 10, Page 6) Operating Instructions 17 Preparations for Measurement • TDC-Sensor Adapter for Indicating Bores with M10x1 Thread Insert the adaptor directly into the indicating bore and use the same gasket as for... The analogue signal corresponding to the piston lift is applied to the BNC connector of the 428 TDC-Sensor and should be connected to the input of the evaluation equipment via a connection cable of 10 m length (i.e E124-10) Operating Instructions 23 Preparations for Measurement 6.4 Electrical Balancing 6.4.1 TDC-Sensor Purpose of Balancing Balancing of quiescent capacitances The sensor probe and the . ....................................................................................................................................5 3.1.1 TDC-Sensor 428 =TI0428A.01= 5 3.1.2 TDC-Sensor Set 428 =TI0428SETA.01= 5 3.2 Optional Accessories............................................................................................................................6. 4028Z03, Figure 9-2: Sensor Probe 428. 10 or 428. 12, 428. 14, Figure 9-3: Clamping Set complete. 3.1.2 TDC-Sensor Set 428 =TI0428SETA.01= As a supplement to