DiTEST FAHRZEUGDIAGNOSE GMBH

Alte Poststrasse 152, A-8020 Graz-Austria

! (+43) (316) 787-0

Fax: (+43) (316) 787-1460

Ident number: Revision: Edition: Subject to alteration

AT0450E 06 08.2001

Operating Manual

Printed in Austria by DITEST

AVL DiSpeed 490

S/N ________________/_____

Copyright 2001 DITEST FAHRZEUGDIAGNOSE 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 DITEST. While every effort is made to ensure correctness, DITEST assumes no liability for errors and omissions.

Important Notice! - Important Notice!

This manual contains important warnings and safety instructions to be observed by the user. The product described is intended for only one certain area of application which is explained in the instructions. Furthermore, the manual explains the critical prerequisites for application and operation as well as the necessary safety measures to ensure smooth operation. No warranty is granted or liability accepted if the product is used in applications other 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 or approved by DITEST are to be used with the product. Due to the operating principle of this product, the accuracy of the measurement results it produces not only depend on its correct operation and function, but also on a variety of peripheral conditions beyond the control of the manufacturer. The results obtained from this product must therefore be subjected to careful examination by an expert (e.g. for plausibility) before any action is taken that is based on the results. Adjustments to and maintenance of instruments when open and under voltage are only to be carried out by a professional technician who is aware of the dangers involved. Repairs to the product are to be carried out by the manufacturer or qualified service personnel only. When the product is used, a technical expert must ensure that neither the test object nor the testing equipment is operated under conditions that may lead to damage or injury.

DITEST FAHRZEUGDIAGNOSE GMBH

Important Notice! - Important Notice!

Safety Instructions

Follow the manufacturers instructions when holding the cut-off speed of diesel engines!

The AVL Dual Sensor contains a powerful magnet. Bear in mind that strong magnetic fields can affect or ruin electronic or mechanical devices. Do not use the AVL Dual Sensor near anyone with a heart pacemaker.

When mounting the sensor, be careful to avoid injury from rotating or hot components (e.g. fan, exhaust manifold).

Any connected devices that use voltages greater than or equal to 50 V AC or 75 V DC must comply with the 73/23/EEC low voltage directive.

Only ever use power supplies that comply with the relevant standards to ensure that even in the event of an internal fault, the voltage is reliably restricted to 75 V DC at the output terminals.

DiSpeed 490

Contents

1. Application and Operating Principle 2. Scope of Supply and Accessories 3. Control and Display Elements, Connections 4. Startup - Connection to Exhaust Gas Tester 5. Operation 6. Maintenance, Care and Service Information 7. Technical Data Tips for Successful Measuring Operating Instructions in Brief

Operating Manual

DiSpeed 490

Contents

Contents

1. Application and Operating Principle ...........................................................................................1 2. Scope of Supply and Accessories ................................................................................................3
2.1 Basic Equipment ........................................................................................................................................3 2.2 Mounting of Exhaust Gas Tester .............................................................................................................4 2.3 Accessory ....................................................................................................................................................4

3. Control and Display Elements, Connections .........................................................................5 4. Startup - Connection to Exhaust Gas Tester ..........................................................................7
4.1 Connection to AVL Exhaust Gas Tester .................................................................................................7 4.2 Connection to Other Exhaust Gas Testers ..............................................................................................9 4.3 Connection to Other Exhaust Gas Testers ............................................................................................12

5. Measurements .........................................................................................................................................13
5.1 Operational Steps (Figs. A, B and C on last page)...............................................................................13 5.2 Suggested Mounting Positions for the AVL Dual Sensor ..................................................................14 5.3 Function Displays of Status LEDs in Detail .........................................................................................16

6. Maintenance, Care and Service Information ........................................................................17

6.1 General ......................................................................................................................................................17 6.2 Cleaning the AVL Dual Sensors ............................................................................................................17 6.3 Self-test Function .....................................................................................................................................17

7. Technical Data .........................................................................................................................................19 Tips for Successful Measuring ..........................................................................................................20 Operating Instructions in Brief ..........................................................................................................21

Operating Manual

Contents

AVL DiSpeed 490

II

Operating Manual

DiSpeed 490

Application and Operating Principle

1. Application and Operating Principle

The AVL DiSpeed 490 is a speed meter especially developed for exhaust gas testing. It can record the speed of any 4-stroke diesel or petrol engine. The AVL DiSpeed 490 can be connected to any exhaust gas tester with a speed input connection. The AVL DiSpeed 490 is suitable for both constant and dynamic speed curves. No need to select the number of cylinders. The heart of the system is the AVL Dual Sensor.

LED (red/yellow/green, monitors speed detection) Microphone (to record air-borne noise)

Magnet base with accelerometer (for recording structure-borne noise)

Tough plastic housing

Fig. 1-1 The sensors powerful permanent magnet makes the device easy to mount on the engine. The multicolour LED is responsible for the automatic function monitoring. It enables you to find quickly the most suitable site for speed measurements.

Operating Manual

Application and Operating Principle

AVL DiSpeed 490

The AVL DiSpeed 490 system is based on the evaluation of two signals: the structure-borne noise signal from the engine the air-borne noise signal The system records both signals simultaneously and the more suitable one is automatically used for the speed evaluation. That signal (Fig. 1-2) is then processed into speed pulses by an AVL evaluation algorithm (Fig. 1-3). Raw signal

Fig. 1-2 Conditioned speed signal

Fig. 1-3

Operating Manual

DiSpeed 490

Scope of Supply and Accessories

2. Scope of Supply and Accessories

2.1 Basic Equipment
AVL 490 DiSpeed (BO2340)

Fastening elements AVL Dual Sensor (BO2338)

Operating Manual (AT0450E)

Fig. 2-1 The AVL DiSpeed 490 is available as two different models:

AVL Package for AVL Exhaust Gas Testers

In addition to the basic equipment (Fig. 2-1), this packages also contains the connection cable for the AVL Exhaust Gas Tester (Fig. 2-2). No power supply unit is necessary.

Universal adapter package for other exhaust gas testers

In addition to the basic equipment (Fig. 2-1), this package also contains the universal connection adapter (Fig. 2-3). A power supply unit is necessary (not included in package). Recommended power supply unit: Order No. EN0342 (Fig. 2-4)

Operating Manual

Scope of Supply and Accessories

AVL DiSpeed 490

2.2 Mounting of Exhaust Gas Tester

Connection cable for AVL Exhaust Gas Tester Order No. BV2110 for AVL DiSmoke 435 and AVL DiGas 465 (1.2 m)

Fig. 2-2 Order No. BV2111 for AVL 4000 Exhaust Gas Tester family (1.2 m; not illustrated) Universal adapter
The AVL DiSpeed 490 delivers a simulated clamp-on transducer signal at this connection point. This connection point acts as a substitute for a clamp-on transducer. Any exhaust gas tester with its own special clamp-on transducer cable can be connected here for speed measurements.

External power supply for the AVL DiSpeed 490 (12 V, 350 mA, for details see Section 7 Technical Data) Order No. EN0342

Order No. EU1843

Fig. 2-3

Fig. 2-4

2.3 Accessory
Extension cable (5 m) for AVL Dual Sensor: Order No. BV2113 (not illustrated)

Operating Manual

DiSpeed 490

Control and Display Elements, Connections

3. Control and Display Elements, Connections

RS232

12V
+

Fig. 3-1 Status LEDs (red and green) Monitors the speed detection (at mounting site) Connection socket for AVL Dual Sensor Connection socket for AVL Exhaust Gas Tester or universal adapter (outputs a simulated clamp-on transducer signal, diesel engine speed measurement) Connection bar for inductive trigger clamp (outputs a simulated ignition voltage signal, petrol engine speed measurement)
RS232

Serial interface port (for service and test purposes) Power supply socket of the AVL DiSpeed 490

12V
+

When an AVL Exhaust Gas Tester is connected, no external power supply is needed - the AVL DiSpeed 490 is powered by the AVL Exhaust Gas Tester. 5

Operating Manual

Control and Display Elements, Connections

AVL DiSpeed 490

Operating Manual

DiSpeed 490

Startup - Connection to Exhaust Gas Tester

4. Startup - Connection to Exhaust Gas Tester

4.1 Connection to AVL Exhaust Gas Tester
(see Operating Instructions in Brief, Fig. A-1 and Fig. A-2) Mount the AVL DiSpeed 490 on the equipment trolley Use the Velcro strip provided to secure it to the trolley. Choose a mounting site on your equipment trolley that you can see from the vehicle while you are carrying out the measurement (i.e. you can see the status LEDs). Clean the mounting site on the trolley. Separate the two halves of the Velcro strip. Cut the strip so that you have four pairs (approx. 2.5 2.5 cm). Glue the four Velcro squares to the cleaned underside of the AVL DiSpeed 490 at the four corners. Apply glue to the outer side of the Velcro squares and press the whole unit onto the cleaned equipment trolley. Fig. 4-1 and Fig. 4-3 show examples of mounting positions.

Velcro strip

Fig. 4-1 Operating Manual 7

Startup - Connection to Exhaust Gas Tester

AVL DiSpeed 490

Plug the AVL Dual Sensor into the AVL DiSpeed 490 and tighten the screws.

Fig. 4-2 Connect the AVL Exhaust Gas Tester Connect the AVL cable (BV2110) to the AVL DiSpeed 490.

Fig. 4-3 Connect the AVL cable (BV2110) to the AVL DiSmoke 435 or AVL DiGas 465.

Fig. 4-4 8 Operating Manual

DiSpeed 490

Startup - Connection to Exhaust Gas Tester

Settings on the AVL Exhaust Gas Tester Select one of the following settings in the appropriate speed sensor selection menu for the AVL Exhaust Gas Tester: "AVL DiSpeed" "TDC sensor digital (1 pulse/cycle)" "Automatic" "Diagnostic plug (1 pulse/cycle)" "Optical pick-up (1 pulse/cycle)"

Always follow the instructions in your exhaust gas tester manual!

4.2 Connection to Other Exhaust Gas Testers (with Universal Adapter; cf. Operating Instructions in Brief, Fig. A-3)
Mount the AVL DiSpeed 490 on the equipment trolley (see Section 4.1) Plug the AVL Dual Sensor into the AVL DiSpeed 490 and tighten the screws (see Section 4.1) Plug the universal adapter into the AVL DiSpeed 490. Connect the cable from the 12 V plug-in power supply unit to the AVL DiSpeed 490.

Universal adapter

Connection of plug-in mains supply unit

Fig. 4-5 Operating Manual 9

Startup - Connection to Exhaust Gas Tester

AVL DiSpeed 490

Connect the clamp-on transducer cable The clamp-on transducer cable is mounted on the AVL DiSpeed 490 in two stages: First clamp the ground tongs onto the metal sleeve of the universal adapter

Fig. 4-6 Then attach the clamp-on transducer cable to the flat plug of the universal adapter.

Fig. 4-7

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Operating Manual

DiSpeed 490

Startup - Connection to Exhaust Gas Tester

In a some cases, testers may need an extra ground connection between the AVL DiSpeed 490 (universal adapter) and the tester (e.g. testers ground clamp).

Exhaust gas tester settings Select the clamp-on transducer signal input on your exhaust gas tester.

Always follow the instructions in your exhaust gas tester manual!

Operating Manual

11

Startup - Connection to Exhaust Gas Tester

AVL DiSpeed 490

4.3 Connection to Other Exhaust Gas Testers (via trigger clamp; cf. Operating Instructions in Brief, Fig. A-4)
Mount the AVL DiSpeed 490 on the equipment trolley (see Section 4.1). Plug the AVL Dual Sensor into the AVL DiSpeed 490 and tighten the screws (see Section 4.1). Connect the cable from the 12 V plug-in power supply unit to the AVL DiSpeed 490. Attach the trigger clamp of your exhaust gas tester to the trigger bar of the AVL DiSpeed 490. Exhaust gas tester settings Select speed measurement with trigger clamp (1 ignition pulse per engine cycle).

Always follow the instructions in your exhaust gas tester manual!

Some testers need a higher trigger current. A special trigger signal amplifier kit, ID no. BH0180, is available for these testers.

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Operating Manual

DiSpeed 490

Measurements

5. Measurements
5.1 Operational Steps (Figs. A, B and C on last page)
Carry out the following steps to calibrate the measurement ranges of your AVL DiSpeed 490. The current status of the calibration phase is displayed both on the AVL DiSpeed 490 and on the AVL Dual Sensor by the status LEDs. There are two status LEDs on the AVL DiSpeed 490 (red and green) while a multi-colour LED (red/yellow/green) is integrated in the AVL Dual Sensor.

Initial status
Make sure that the red status LED is lit before attaching the dual sensor. In measurement mode, assuming that the AVL DiSpeed 490 is being powered by electrical current and is correctly connected to the exhaust gas tester - the red status LED is lit.

Select the mounting position / engine at idle

Attach the AVL Dual Sensor at a suitable site (see Section 5.2). Let the warm engine run at constant idle revs. After approx. 3 to 10 seconds, the green status LED will light up on the AVL DiSpeed 490 at the same time as the red one. The multi-coloured status LED on the dual sensor is now yellow. This means that the idle speed is currently being measured and the mounting position is a suitable site for measuring speed values when the engine is running at a constant speed. If the status LEDs do not light up as described, try another mounting position.

Rev the engine to a high speed

On diesel engines, rev the engine up to high speed (upper calibration point, approx. 7090 % of cut-off speed) and hold it there until the red status LED goes out on the AVL DiSpeed 490 (after 5 seconds at the latest). Now rev the engine to cut-off speed.

When first revving up to cut-off speed, check that the engine cuts off correctly!

Operating Manual

13

Measurements

AVL DiSpeed 490

On petrol engines, rev quickly to a high speed (approximately the highest that you want to measure, any speed between 2000 and 6000 rpm). Hold this speed until the red status LED on the AVL DiSpeed 490 goes out (after 5 seconds at the latest). The status LEDs on the AVL DiSpeed 490 and AVL Dual Sensor are now green. This means that the highest speed has been detected and the AVL DiSpeed 490 is also able to measure dynamic speed curves that typically occur during emissions testing when the sensor is mounted in this position. If the status LEDs do not light up as described, try another mounting position.

5.2 Suggested Mounting Positions for the AVL Dual Sensor

The AVL Dual Sensor has a magnetic base and must therefore be attached to a metallic part of the engine. The speed recording is best guaranteed when the engine vibrations are not cushioned by parts on rubber bearings between the engine and the mounting position (e.g. engine suspension). You can mount the AVL Dual Sensor when the engine is at standstill or when it is idling. You will discover from the LEDs whether the selected mounting position is suitable as soon as the engine is running at idle. If the AVL Dual Sensor is mounted on the engine while idling, Observe the safety instructions at the beginning of this manual. The LED on the AVL Dual Sensor shows after 3 to 10 seconds whether the AVL DiSpeed 490 has measured the speed (see Section 5.3).

The AVL Dual Sensor can be attached to the following engine parts: Screw heads

Fig. 5-1

Fig. 5-2

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Operating Manual

DiSpeed 490

Measurements

Flat metal parts

Fig. 5-3 Mounting brackets (lifting ring for engine mounting)

Fig. 5-4 Oil drain plug

Fig. 5-5 Generator bracket e.g. on MB-Actros (not illustrated)

Operating Manual

15

Measurements

AVL DiSpeed 490

5.3 Function Displays of Status LEDs in Detail

The functions of the AVL DiSpeed 490 are displayed by means of LEDs: two LEDs (red, green) on the AVL DiSpeed 490, one LED (red/yellow/green) on the AVL Dual Sensor. Red LED illuminated Power supply to AVL DiSpeed 490 is OK Self-test OK No speed signal detected Red and green LEDs Idle speed detected (lower calibration point). illuminated Detection of idle speed is usually within 3 to a maximum of (red/yellow/green LED 10 seconds after mounting the sensor. on dual sensor lights up If no speed signal is detected in this time, attach the AVL yellow) Dual Sensor somewhere else. Now the steady-state speed values are measured. Green LED illuminated The AVL DiSpeed 490 has detected the engines high speed (upper calibration point). With this status, the AVL DiSpeed 490 is also calibrated for dynamic speed measurements. Both steady-state and dynamic measurements can be carried out.

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DiSpeed 490

Maintenance, Care and Service Information

6. Maintenance, Care and Service Information

6.1 General
The AVL DiSpeed 490 does not need any special maintenance. The AVL Dual Sensor should be cleaned from time to time to ensure that it always functions properly.

6.2 Cleaning the AVL Dual Sensors

To be able to pick up the structure-borne noise signal properly, the magnet base must be free from metal dust or chips and dirt. Similarly, the microphone holes on the top of the AVL Dual Sensor for recording air-borne sound must not be blocked. Use a mild cleaning agent to clean the sensor. Alternatively you can apply a blast of compressed air horizontally across the upper sensor face to draw any dirt out of the microphone holes. Do not clean the microphone holes with a sharp implement the microphone could be damaged. Never direct the compressed air at right-angles to the sensor surface because that would destroy the sealing membrane and the microphone!

6.3 Self-test Function

The AVL DiSpeed 490 has a power-on self-test function. Every time the operating voltage is applied, the hardware components of the evaluation unit are checked to see that they are functioning correctly. The test takes 2 seconds. If the red LED stays illuminated, that means that the power supply is OK and the power-on self-test is completed with no component found faulty. If a component is defective, the red LED will flash periodically. Number of flashes 1 2 8 9 10 11 Error RAM I7 defective RAM I8 defective MIC channel input not functioning MIC filter stage defective VIB channel input not functioning VIB filter stage defective

Operating Manual

17

Maintenance, Care and Service Information

AVL DiSpeed 490

18

Operating Manual

DiSpeed 490

Technical Data

7. Technical Data
Engine Speed 4-stroke diesel and petrol engines Diesel engines: Petrol engines: Speed detection range Idle speed: High speed: Signal input 4006000 rpm 4008000 rpm 4001200 rpm 17006000 rpm

AVL Dual Sensor for air-borne and structure-borne noise

Signal output

Charge signal (clamp-on transducer ): simulation of a clamp-on transducer signal (1100 pC) Digital pulse: 5 V TTL compatible Inductive pulse: simulation of an ignition signal for inductive trigger tongs, approx. 150 mA amplitude

Power supply

12 V DC, 350 mA If an AVL Exhaust Gas Tester is connected, it also powers the AVL DiSpeed 490.
12V
+

If other testers are used, a plug-in power supply unit is used (linear voltage controller, no clocked power supply unit). 0+50 C, not in direct sunlight +0+65 C (magnet base: -20125 C)

Operating temperatures Evaluation unit: Sensor cable: Storage temperature Atmospheric humidity Protection class -20+60 C

< 90 %, non-condensing AVL DiSpeed 490: AVL Dual Sensor: IP31 IP54

Dimensions Weight

227 184 48 mm (length width height) AVL DiSpeed 490: AVL Dual Sensor: 0.8 kg 0.38 kg

Conformity

89/336/ EEC Directive on Electromagnetic Compatibility Met with the following standards complied: EN 50081-1 Generic Emission Standard 1992 EN 50082-1 Generic Immunity Standard 1992 19

Operating Manual

Technical Data

AVL DiSpeed 490

Tips for Successful Measuring

Remember that the measurement results depend on the quality of the mounting position. There are a number of screw heads and flat metallic parts in the engine area that are suitable for mounting the AVL Dual Sensor (see Section 5.2). If the status LED is still red after 10 seconds in one mounting position (with the engine idling), try another mounting position. The following problems can occur in borderline situations:

Recovery time at idle after run-out

Fact: No combustion occurs in the engine during run-out. The AVL DiSpeed 490 therefore loses the speed information and needs a few seconds at idle to find the correct speed again. After the engine has run-out, observe whether the speed finds the idle value again within a maximum of 5 seconds (it is here that the AVL DiSpeed 490 has the most difficulty evaluating the speed due to the low combustion noise at idle). If it does, you can use this mounting position for the emissions test. Higher speeds are then clearly detected. If idle speed is not indicated within 5 seconds of run-out, choose another mounting position.

Remedy:

Speed jumps by a certain factor (4-cylinder diesel engines)

Fact: Remedy: In a few rare cases, the output speed can jump by a factor of 1.33 or 2. Choose a mounting position that is at different distances from the individual cylinders (see Section 5.2).

Speed displayed even though AVL Dual Sensor is not mounted on the engine
Fact: Remedy: This situation can occur for various reasons. One possible cause is the tightly coiled cable unrolling the first time it is unpacked. Carry out a reset (= reset to initial status with status-LED red). Tap the AVL Dual Sensor very lightly on a mounting surface to trigger a reset.

20

Operating Manual

DiSpeed 490

Operating Instructions in Brief

Instruments that can be connected (see Section 4)

Fig. A-1: AVL

DiSmoke 435 / AVL DiGas 465

A B K L U V W X M N Y Z C D O P E F Q R LF G H S T I J

DiSpeed
RS232 12V
+

F1

F2

F3

F4

F5

F6

1 4 7

2 5 8

3 6 9 0

(BO2338) (BV2110)

DiSmoke

Fig. A-2: Exhaust

Gas Tester Family AVL 4000

DiSpeed
RS232 12V
+

F1

F2

F3

F4

F5

F6 LF

(BO2338) (BV2111)

CLASS

DiGas

Fig. A-3: Other

Exhaust Gas Testers (universal adapter)

DiSpeed
RS232 12V
+

(BO2338) (EN0342) (BO2338)

Fig. A-4: Other

Exhaust Gas Testers (trigger clamp bar)

DiSpeed
RS232 12V
+

(BO2338) (EN0342)

Operating Manual

21

Operating Instructions in Brief

AVL DiSpeed 490

Operating Steps

Function check

red

Idle speed captured

800 yellow

High speed captured

green 5000

22

Operating Manual