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LABORATORY FOR TESTING, RESEARCH AND CERTIFICATION OF

THE BIOFUEL INTERNAL COMBUSTION ENGINES


RENAR CERTIFIED LABORATORY
GENERAL PACKET OF TESTS THAT CAN BE MANAGED:
Testing of internal combustion engines with classic fuel, as a reference.
Testing the same engines with alternative fuels (biofuels) in order to study the following objectives:
Determination of impact wear, functional performance and engine reliability.
Determination of the testing irregularities with fuel who containing or not containing organic component.
Establishing the need to adapt in order to use alternative fuel engines.
Such tests require the application of the following methods of investigation:
continuous measurement of emissions (exhaust gases)
continuous measurement of particulate matter emission
continuous measurement of fuel mass flow;
combustion process analysis;
change the parameters of the electronic engine management system.
Test procedures
Steady performance tests;
Tests in phase;
Reproduction tests for approval;
Test cold start at -20C;
Closure p-V diagram (pressure - volume), p- (-Arial of 12) (space) (pressure-angle rotation);
Tests on the monocylinder engine.
Type of test

Test description

Procedure

Steady
performance test

Power curve, the curve of time, pollutant


emissions (HC, NOx, CO, CO2, SO2)
corresponding speed / load.
Opacity.

Heating cycle change throttle position,


rack fixed points on the entire speed
range (1000 - 6000) to change the
throttle position to maximum opening.

Transient test

Continuous measurement (5 Hz for


emissions, 10-100 Hz for other
measurements), Opacity, Inlet air flow,
CO/CO2, HC, NOx, SO2, Torque, speed,
power, Fuel mass flow.

Change the speed or change the time


constant load at constant speed.
Continuous measurement.

Reproduction
approval tests

Continuous measurement (5 Hz for


emissions, 10-100 Hz for other
measurements), Opacity, Mass air flow
intake CO/CO2, HC, NOx, SO2, Torque,
speed, power, Fuel mass flow

Change speed tests to specific time


curves approval.
Continuous measurement.

Test cold start at 20C

Continuous Measurement (5 Hz for


Emissions, 10-100 Hz for Other
Measurements), Opacity, CO/CO2, HC,
NOx, SO2,
Pressure in the chamber with a resolution
of 1 deg. RAC.

The engine is cooled to -20C.


It makes starting the engine and
measurements are made continuously.
Shortlisted Some of ECU parameters /
values is read (eg. Advance the
injection).

Closure chart p - V
p- (bold)

Figure p - V p- (-Arial 12)

As a test independently or
simultaneously with other tests as a tool
for system testing.

Test with
monocylinder
engine AVL 5403
GDI (gasoline direct
injection) and 5402
CR DI diesel (direct
injection common
rail)

Continuous measurement (5 Hz for


emissions, 10-100 Hz for other
measurements), Opacity, Mass air flow
intake CO/CO2, HC, NOx, SO2, Torque,
speed, power.
Flowrate of fuel mass.

Change the speed or change the time


constant load at constant speed.
Continuous measurement.

Activity Type

Combustion
process
analysis:

Technical Terms

Exemplification

Application on any gasoline


or diesel combustion engine
Engine operation without
restrictions
Optical
access
to
the
combustion chamber with
almost
no
combustion
interference
Visualization of temperature
distribution of diesel flames
(option)
Observation of flames and
illuminated phenomena in
engines
Digitized image transmission
from camera to PC without
quality loss
Automatic protocolling of all
relevant data and camera
adjustments
Automatic
animation
of
recorded images
Powerful picture processing
capabilities
Possibility of connecting high
sensitive cameras

The AVL VisioScope is a new generation of imaging


system for the development of combustion engines.

Note 1: Measured and calculated gas components:


Chemical
Formula
CO2
CO
NO
NO2
NOx
H2O
NH3

Gas component measured or calculated


Carbon dioxide
Carbon monoxide high
Carbon monoxide low
Nitrogen monoxide
Nitrogen dioxide
Total Nitrogen oxides
Water
Ammonia

Range in ppm
0 200 000
8 000 100 000
0 8 000
0 10 000
0 1 000
0 10 000
0 250 000
0 1 000

N2O
CH4
C2H2
C2H4
C2H6
C4H6
C2H5OH
IC5
NC8
AHC
NC5
HCHO
CH3CHO
COS
SO2
HNCO
HCN
HCOOH

Nitrous oxide
Methane
Acetylene
Ethylene
Ethane
1,3 Butadiene
Ethanol
Iso-Pentane
n-Octane
Aromatic hydrocarbons
n-Pentane
Formaldehyde
Acetaldehyde
Carbonyl sulfide
Sulfur dioxide
Isocyanic Acid
Hydrogen Cyanide
Formic Acid

0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 200
0 1 000
0 1 000
0 1 000
0 1 000

Note 2: Gas analysis at the MAC


th

The AVL 439 Opacimeter (G004) is the 4 generation of measurement instrument for recording exhaust gas
opacity in internal combustion engines using opacimetry, i.e. the measurement of the reduction of visible light
in a measuring chamber through which the sample gas is passed. The measurement value output will be
-1
indicated as well as in opacity N [%] or the absorption value k [m ].
Exhaust gas is passed through the measurement chamber where opacity is measured.
The AVL 439 Opacimeter is frequently used in development and certification areas. Because of its technical
design authorised testing laboratories like the RWTV in Germany or the UTAC in France have officially
accepted the 439 for statutory tryouts.
The operator interface of the 439 incorporates different algorithms for the electronics filtering of the
measured signal, which are defined and required in statutory test cycles.
By using the 439 tests i.e. the ELR test cycle (EURO 3, EURO 4) or the ECE R24 test cycle then results can
be easily achieved.
Note 3: For a more accurate analysis and a deeper understanding of all abilities laboratory can analyze this
data sheet in full.
Contact person:
Name: Dean Prof. Dr. Eng. Nicolae Burnete
Function: Project Manager
Email: Nicolae.Burnete@arma.utcluj.ro
Name: Lecturer Dr. Eng. Bogdan Ovidiu Varga
Function: Responsible for procurement and PR
Email: vbogdan@arma.utcluj.ro
Institution: Technical University of Cluj-Napoca
Phone: 0040-264415490,Fax: 0040-264415490
Web page:
www.testecocel.utcluj.ro

Technical Description

1.00.00

INFRASTRUCTURE, FACILITIES
AND SUPPLY SYSTEMS

GROUND FLOOR LAYOUT

1.01.00

CIVIL WORKS
TESIN2000.00

1.01.01

MODIFICATION OF EXISTING TEST CELL


TESIN1100.0101

The modification in the existing civil works will consist of:

Double wall for separation of the control room from the test room (15+5+10 cm)
Acoustic door from control room to test room 35dBA
Acoustic window (35dBA)
Mezzanine construction 3 m height (300 kg/m2) (side load, concrete floor).
Openings on existing roof for ducts (ventilation, gas extraction, water, electric)
Excavation of test room floor for pit construction (acc. drawing A02)
Baseplate foundation and pits (acc. drawing A02)
Covering metal plates for pit and trenches and floor painting.
External wall with acoustic door (1,2 x 2,1 m), replacing glasses with panels on ground floor
only.
Excavating 20 cm base for cold chamber 2,5x2,5 m
Finishing works (painting, etc.)
Suitable furniture for the entire test area / cell test.

The contracting authority will purchase in parallel with this tender services for preliminary
planning of the cell so that AVL will coordinate with the builder for the foundation, thickness of
walls and pits / recesses for technological equipment. The builder's obligation is to attain the
foundation pit, walls and floor of the test cell, the rest of facilities will be done by AVL according
to these specifications.

1.02.00

UTILITIES
TESIN3000.00

Consists of:

Test cell ventilation


Extraction system of the exhaust gas within the cell;
Fuel supply system to engine
Coolant supply and conditioning system;
Cold water supply and conditioning system;
Compressed air supply and conditioning system;
Safety system
Distribution box and electrical connectors;
12 V power supply system for combustion engine;
Power supply system for dynamometer;
Cabling between the existing system of electricity supply, dynamometer converter and
cabinet with electrical connectors.

Note:
Standard gas system for calibration is not necessary; we offer the gas analyzer SESAM
FTIR which does not require calibration gases

1.02.01

VENTILATION
TESIN3200.0101

System consisting of a inlet air unit, equipped with gravimetric filter, blower and impulsion grids,
and an extraction air unit consisting on a blower in box, grids and outlet ducts. System
3
capacity: 16.000m /h
Control

T
Air from ETC

1.02.02

EXHAUST EXTRACTION
TESIN3200.0102

System consisting of a blower for forced extraction, able to operate at high temperatures
(around 200C), ducting inside test cell, and chimney to the outside.

Engine Test Cell


FIRE
CENTRAL

Fire flap

ENGINE

DP
Alarm

1.02.03

FUEL SUPPLY
TESIN3300.0104

The fuel circuit consists in a standard diesel tank, with capacity 1.500 liters, and canisters for
special fuels (customer scope).
The system comprises a pneumatic pump for the fixed tank, and a mobile pneumatic pump for
the canisters. These pumps will fill a daily tank of 20 liters capacity, located at a height of 5m, to
supply by gravity the fuel measurement and conditioning equipment. Also includes the piping
and connectors to/from the engine.
Daily tank

Venting
line
Main tank
Engine
Test
Cell

Fuel
Measurement
Barrels

Fuel
conditioning

FIRE ALARM
CENTRAL

Engine

1.02.04

COOLING WATER 25C


TESIN3300.0101

The engine requires cooling water, to condition the internal engine coolant. The circuit must
provide water in adequate flow, pressure and temperatures, in order to supply the fluid to the
engine conditioner.
The proposed circuit consists of a air-cooled heat exchanger, located in the terrace, with cooling
capacity 150kW and operating temperatures 45-60C (outlet/inlet). The water will be supplied to
the test cell by means of a centrifugal pump, capacity 9m3/h and pressure 3bar, located in the
technical floor.
The circuit will include also all the piping to and inside the test cell, as well as the regulation and
monitoring devices.
Control

Engine test
cell

Air-cooled
Heat exchanger

1.02.05

COOLING WATER 7-12C


TESIN3300.0102

This circuit is necessary to supply water in the range 7-12C to the fuel conditioning unit.
The system comprises an air cooled chiller, with capacity 1,5kW, temperature range 7-12C,
including pumping with flow 300l/h @ 3bar.
The circuit will include also all the piping to and inside the test cell, as well as the regulation and
monitoring devices.
Control

Engine Test Cell


P
T
Air-cooled chiller
P

1.02.06

COMPRESSED AIR
TESIN3300.0103

A compressed air circuit with capacity 600l/min is necessary to supply the test cell devices
(baseplate, conditioners, etc.) as well as the preparation workshop for pneumatic tools.
The circuit consisting of a compressor 600l/min @ 9bar, the piping and filtering and regulation
elements.

1.02.07

FIRE AND GAS DETECTION AND


EXTINGUISHING
TESIN3200.0103

The system comprises a fire and gas central for alarming, and the related fire sensors (1xflame
and 2xsmoke) and CO and HC sensors, as well as the alarming (horn and flash) devices.
The extinguishing will be manual, by means of a foam extinguisher in a trolley, and manual
powder extinghishers.

1.02.08

ELECTRICITY
TESIN3100.0101

Consisting of a central electric cabinet, connected to the building distribution panel, with all the
protections and outlets to supply the test cell equipment, lights, sockets, etc. Also includes the
operation devices (relays, contactors, etc.) to switch on/off the test cell and utilities devices.
Also includes all the cable trays, cabling, lights and sockets for the test cell, control room and
climatic chamber.

1.03.00

SERVICES RELATED TO
INFRASTRUCTURE AND FACILITIES
TESIN3000.00

1.03.01

ENGINEERING AND PROJECT


MANAGEMENT
TESPPASTA.0101

Consisting of the calculations and design of the auxiliary circuits, the general layout, utilities
layout and diagrams, list of materials and documentation.
Project management consisting on overall PM and local support in installation and start up.

2.00.00
2.01.00

DYNAMOMETER
DYNAMOMETER
TP00ASTA.00

2.01.01

DYNOROAD 202/12 SL PACKAGE (EU)


TLA22/1SLP.01A1

Foot mounted AC drive, equipped with control and power cabinet, with torque and speed
controlled operation when used in combination with the test bed controller AVL BME or EMCON
Power section with IGBT converter for the direct connection to the mains supply (please see
installation instructions for details). Preselectable switching frequency provides nearly sinusoidal
currents to the mains and to the electric motor.
Equipped with a hybrid interface to the test bed controller, to allow the execution of torque or
speed control loops. The dynamometer can be upgraded to dynamic tests.

Your benefits at a glance:

Best AC motor efficiency with lowest mains distortion by latest state-of-the-art IGBT
technology.
Highest torque response by rotorflux-vector-control of the stator current.
High speed gradient by optimised inertia
Robust industrial design for operation under extreme ambient and environmental conditions.
Easy installation and commissioning.

Technical Insight:

ASYNCHRONOUS MACHINE
Foot mounted AC machine with squirrel cage rotor, prepared for mounting of T10FS 1kNm
torque flange.
AVL Type
Performances generator operation:
Nominal torque
Nominal power
Maximum speed

DynoRoad 202/12SL
525 Nm
220 kW
12.000 rpm

Performances motor operation:


Nominal torque
Nominal power
Maximum speed

473 Nm
198 kW
12.000 rpm

Overload capability (60s every 15 min)


Recovery load

25%
90%

Mass inertia:
AC-Motor alone
0,31 kgm
AC-Motor with standard connecting flange but
0,32 kgm
without torque meter
AC-Motor with standard connecting flange and
0,32 kgm
with torque meter
Forced air-cooling, air quantity
approx. 2.088 m/h
Upper part white aluminium RAL
9006

Coolant
Colour

10

Lower part ultramarine blue RAL


5002
Bearing and Winding
Included
Included
ROD 426 1024
963 kg
IP23
+5 to +40 C
Max. 95%, non-condensed

Temperature Monitoring
Connection Box
Blocking device
Speed Encoder
Weight
Degree of protection
Ambient temperature conditions
Ambient humidity conditions

TORQUE MEASURING UNIT


According to ordered HBM T10FS
CONTROL CABINET
For the supply and control of the AC drive and auxiliary devices, the control cabinet can be
connected directly to the mains supply.
It is equipped with IGBT mains converter and motor inverter with sinusoidal current band
control.
Every system is inclusive of net choke and line filters for electrical noise reduction and main
switch in the input field.
The Control cabinet is equipped with an hybrid interface to the test bed controller, to allow the
execution of torque or speed control loops.
Mains supply:
Voltage
Current nominal/peak
Frequency
Coolant

3 x 400 V +10%/-15%
315/394 A, with 400V supply
50 Hz 5 %
Forced air-cooling, air quantity
approx. 3.000 m/h
RAL 7032 pebble grey
820 kg
2226x1906x620mm
IP 23
+5 to +40 C
max. 95%, non-condensed

Colour
Weight
Dimensions (LxHxD)
Degree of protection
Ambient temperature conditions
Ambient humidity conditions

Technical Notes:
Dimensions Motor
Power diagram generator

PLP 103/003
PLP 525/220/12 gen

11

720

360

640

320

560

280

T
240

P
400

200

320

160

240

120

160

80

80

40

0
0

2000

Short Time Torque

4000

Torque

Installation instructions:

6000

Short Time Power

8000

Power

10000

Power [kW]

Torque [Nm]

480

0
12000

Speed [rpm]

PLP 170/002

Notes :
For service pupose via modem, a phone connection must be available at customer site close
to the power cabinet
In case of connection to a 380V mains voltage, the maximum power will be reduced by 5%

Note about packing : the indicated prices include packing, loading on trucks, weighing and
control. For transportation we recommend trucks with air suspension.
The system parts are covered with plastic sheets and packed in wooden crates.
Use: Covered transportation by rail and truck in western Europe except Great Britain. Storage in
open air is not allowed.

2.01.02

SIGNAL CABLES 25 FOR DYNOROAD SL


400
TLASLKITA.01

Set of cables between BME/EMCON series 400 - control cabinet (standard length 20 m) and
BME/EMCON series 400 motor (standard length 15 m).
Length up to 25m on request.

2.01.03

SHIELDED POWER CABLE MC2X070


(L=10M)
TLCA2X070A.01

Shielded Power Cables Type 2B

12

Flexible cables with special EMC performance


due to double shielded, low capacitive design.
Ideal for frequency converters for variable speed
of 3 phases AC motors, small, medium and large
sizes.

L2
PE

PE

L1

L3
PE

Technical Insight
Shielded power cables (multicore copper cable) to be installed between AC motor and
control cabinet.
Type:
Outer diameter
Minimum bending radius
fixed mounting
movable mounting
Length (quantity x1)

2.01.04

(2YSLCYK-JB 3X70+3X16) x 2
40,6 mm (+/- 0,5mm)
163 mm
609 mm
10 m

TORQUE FLANGE HBM T12 G L 1KNM


TLBT1KNMF.01

Torque flange with frequency output


signal
Calibration of the torque flange by means
of shunt-calibration (defined detuning of
the strain gauges Wheatstone bridge)

Your Benefits at a Glance

Low rotor weights


Low mass moments of inertia
Small outside diameter
No bearings, no slip-rings
High torque measurement accuracy
Technical Insight

Class of accuracy
0,03
Nominal torque
1 kNm
Nominal speed
12.000 rpm
Nominal
sensitivity (range between
30 kHz
torque=zero and nominal torque)
Characterisitc tolerance, relative to the
< 0,05 %
actual value of the signal span :
Linearity deviation incl. hysteresis, related
< 0,01 %
to the nominal sensitivity:
Temperature effect per 10K on the output
signal, relative to the actual value of the < 0,03 %
signal span :

13

Temperature effect per 10K on the zero


signal, relative to the nominal (rated) < 0,01 %
sensitivity:
Rel.
standard
deviation
of
the
reproducibility, by reference to variation of < 0,01 %
the output signal acc. to DIN 1319:
Mass moment of inertia
0,0059 kg.m
Protection class (EN 60529)
IP 54
Technical description
PLP 421/006-e

2.01.05

CALIBRATION LEVER 1K FOR


DYNOROAD
TLBCAL1KA.01

Calibration lever with weight


trays prepared for mounting
on an HBM torque flange
T10FS 500 N.m or T10FS 1
kN.m.

Only intended for calibration check. Additional measurement error to be considered when using
the calibration lever due to radial force applied on the torque flange.

Your Benefits at a Glance

Reduced error due to bending effects during calibration thanks to a special AVL design
Easy to handle

2.01.06

Dimensions

CALIBRATION WEIGHTS 525NM (52,5KG)


TLCW0525A.01

Calibration Weights set for AVL dynamometers with a nominal torque of 525Nm

14

Technical Insight
Set of weights to calibrate the torque measurement unit of AVL Dynamometers with a nominal
torque of 525Nm.
Intended to be used in combination with the optional AVL calibration system (arm lever and
weight trays) with a standard calibration ratio of 1kg = 10Nm
The delivered weights have the following tolerances:
Weight (kg)
0,5
1
2
Tolerance (g)
0,075
0,15
0,3

2.01.07

5
0,75

10
1,5

20
3

BLOCKING DEVICE DYNOROAD 2XX SL


TLABLOCKAB.01

Blocking Device for DynoRoad SL Drives type 220kW

3.00.00
3.01.00

TEST BED MECHANICS


ISOLATED BASE PLATES
TP34AE.00

3.01.01

ISOLATED BASE PLATE


3500x1500x300/7
TP34AF000A.01A1

AVL Isolated Base Plates, made of a dense, steel alloyed special cast iron, allow an easy setup
of the test bed components. By using air springs with automatic level control, spring movements
caused by different load distribution or torque alteration are compensated, i. e. the air springs
provide a constant, load independent vertical position of the isolated base plate at low natural
frequency.

AVL- BASE- PLATES: underside view of an air- spring suspensioned


AVL- Isolated Base Plate
Example

Your Benefits at a Glance

High level control accuracy of 0,1 mm (load independent)


Easy fixing of all test bed equipment thanks to standardised T-slots 28H12
High grade of vibration isolation between base plate and building
Easy to integrate in test cell floor thanks to low height

15

Technical Insight

Dimensions (L x W x H):
Mass:
max. Load:
Material:
Low natural vertical frequency:
Distance between T-Slots:

approx. 3.500 x 1.500 x 300 mm


Pit- depth = 350 mm compulsory!
approx. 4900kg
7.800 kg at 5 bar air supply
special cast iron
approx. 3 Hz
200 mm

For layout and dimensions, see drawing:


For specs for substructure, see drawing:
Technical facility requirements

3.01.02

5602M02Z/D00E0
5602M02Z/D01E0
air quality class 2 DIN ISO 8573-1

DRAINING GUTTER FOR ENGINE ONLY


TP34AE003A.01

Draining- Gutter f. Engine Only base plates that runs around the base plate with two drainage
outlets at the front end for "Engine-Only" and "Power Pack" base plates up to max. size of 5000
x 1900 mm

3.01.03

SURFACE ZINC COATED PER M


TP34AE001A.01

Galvanised surface for corrosion protection for Engine-Only & Power Pack base plates.

Your Benefits at a Glance

smooth surface
corrosion protection against high humidity (e.g. for use in climatic chambers)

3.02.00

ENGINE MOUNTING SYSTEM


TP34B.00

3.02.01

ENGINE MOUNTING SYSTEM PS 800-960


TP34CH000A.01

The Engine Mounting System PS 800-960 for passenger car and light commercial vehicle
engines serves for mounting the unit under test onto the pallet system. The adjustable length,
width and height allow precise positioning of the supports to the engine's original mounting
points.

AVL Engine Mounting System PS

16

Example

Your Benefits at a Glance

Simple width adjustment thanks to sliding support legs


Accurate and quick height adjustment via trapezoidal threaded spindles of supports
Suitable for all AVL standard pallet systems
Corrosion protection provided by use of aluminium and galvanized and oiled spindles and
nuts

Technical Insight

The engine mounting system represents the link between the pallet system and the test engine.
It consists of one crossbeam whose position can be adjusted by sliding along the base plate,
with two mounted on supports.

Note

The customer is responsible for the assembly of the engine onto the engine mounting system by
using the original motor rubber bearings. As interface a M12 or M16 female thread is available
on each support.

Technical Data

Weight
Maximum load
Width adjustment
Height adjustment
Connection thread
Material
Surface
Interface with pallet system

approx. 50 kg
200 kg
170 to 800 mm
800 to 960 mm
M12 or M16 female thread
aluminium, steel
anodized, galvanized
4 T-slot nuts DIN 508 M14x50 for each crossbeam

Design and dimensions similar to drawing no. 12126

3.02.02

ENGINE MOUNTING FRAME 579


TF0579A.01

For installation of AVL research engines series 540, 580 and LEF 530 on the test bed.

17

AVL 579 engine mounting frame


The mounting frame is provided with damping blocks to absorb engine vibrations.
For different engine weights rubber dampers with different shore-hardness are available.

3.03.00

STANDS & SUPPORTS


TP34B.00

3.03.01

INTERMEDIATE FRAME TYPE 400


TP34BC000A.01

The welded intermediate frame serves for adjusting the test bed shaft height and for mounting
the dynamometer onto an AVL base plate

AVL Stands and Supports: Intermediate Frame


Example

Your Benefits at a Glance

Torsionally stiff design


Quick mounting of the intermediate frame onto AVL base plates
Quick alignment of the dynamometer
Quick mounting of the dynamometer and shaft guard due to standardized drilling templates
Technical Insight

18

Each frame is custom-built for the specified dynamometer and shaft height. The supporting
surfaces on top, bottom and front of the frame for mounting the frame to the base plate as well
as for the mounting of the dynamometer and the shaft guard are machined and bright.

Technical Data

Material
Surface
Colour
As supplied

steel
sandblasted, primed, painted
RAL 5008 (grayblue)
machined, unpainted areas preserved

Attention:
Exact test bed shaft height must be indicated at purchase order!

3.04.00

ENGINE TROLLEY SYSTEM


TESPPAS.00

3.04.01

ENGINE TROLLEY- MANUAL DOCKING


TESPLASTA.0201

The Engine Trolley Manual Docking with spring loaded wheels is suitable for manual transport.
Technical Insight:
track width:

approx. 720 mm

Design and dimension similar to drawing 5628M00H/D01I0 and 5628M00H/D02I0.


Scope of Supply
each consisting of:

1 welded base frame with T-slots, alignment and fixing elements,


reference support- surface for the centering gauge
1 oil pan (2- part design, approx. 20 litre)
4 spring loaded wheels (2 of them swivelling and lockable)
1 pre- mounting of the components

steel parts galvanised zinced


Remark:
The requested engine brackets are to be supplied by the customer. The track with of approx.
720 mm fits to the AVL standard base plates.

3.04.02

ENGINE TROLLEY RECEIVER - MANUAL


DOCKING
TESPLASTA.0202

The Engine Trolley Receiver MD is suitable for the manual engine trolley system for the
installation at AVL standard isolated base plates.
Technical Insight:

19

Design and dimension similar to drawing 5628M00H/D01I0 and 5628M00H/D02I0.

3.05.00

DRIVE SHAFT SYSTEMS


TP34D.00

3.05.01

DRIVE SHAFT SCRE 540


TFSCTB540.01

Drive-shaft for connecting Single Cylinder Engine Series 540 to dyno of the Single Cylinder
Compact Test Bed. For meeting the Single Cylinder Engine axis height to the dyno an additional
support is included.

Specifications of the drive-shaft:


Speed range
Engine inertia
Stiffness C T dyn

3.05.02

800 7.000 rpm


2
0.4 kgm
43.300 Nm/rad

COUPLING SHAFT 900/4200


TP34DG000A.01

The Coupling Shaft serves for the connection between the unit under test and the
dynamometer. These shafts are suitable for all engine test beds and are used, when higher
degrees of cyclic irregularity or high slightly changing oscillating torque are given.

AVL Drive shafts: Coupling Shafts


Example

Your Benefits at a Glance

Suitable for all test run types


Optimized for high specific loads
Wide length adjustment

Technical Insight:

The Coupling Shaft 900/4200 consists of a torsionally soft coupling and a cardan shaft.
Nominal torque
Torsional stiffness
Max. speed
Operating length
Length adjustment

900 Nm
4200 Nm/rad
7300 rpm
540 mm
-11 / +43 mm

Design and dimensions similar to drawing 00025883


Attention:

20

The offered shaft can change during project realization for technical reasons!
Note:
The Coupling Shaft is mounted to the flywheel via an adapter flange. As this flange is UUT
dependent, is has to be supplied by the customer.
Note:
The calculation base for AVL drive shaft systems is the main exciter, the combustion process of
the engine in the dominating order.
Possibly appearing auxiliary exciters (e.g. ECU and actuator frequencies respectively, high idle
control) can only be taken into consideration if they are notified by the customer before the shaft
layout.
The appearance of such non declared auxiliary exciters might cause component failure.
AVL can not be held responsible for such occurring causes of damage and reserves a
disclaimer for direct costs and consequential damages in case of drive shaft failure.

3.05.03

SAFETY COVER TYPE 2


TP34AA004A.01

The Safety Cover prevents test cell staff and measuring equipment from unintentional contact
with the rotating drive shaft system and is meant to reduce potential consequences of shaft
ruptures.
AVL Safety Cover Type 2 is meant to be used together with standard AVL shafts with torque
measuring flange or with large auxiliary couplings.

AVL Stands and Supports: Safety Cover


Example
Your Benefits at a Glance

protects personnel and measuring instruments thanks to solid steel pipe


safety contact switch prevents test run starting with open shaft guard
quick and easy to open with mechanical quick- release lock
easy to fix to the AVL- intermediate frame of the load unit or AVL- base plate
Technical Insight

The Safety Cover consists of two hinged half- tubes closed by quick- release lock. A
momentary- contact switch checks whether the Safety Cover is open or closed. The automation
system then only permits test operations to start if the guard is closed.
Technical Data
Dimensions (l x w)
Mass
Suitable for shaft heights

3.05.04

approx. 650 x 450 (without support)


approx. 55 kg (without support)
700, 750, 800, 850, 900, 950, 1000 mm

ADAPTATION FLANGE
TP34DA001A.01

The AVL adapter flange is used to fit the drive shaft flange to the existing dynamometer
interface for AVL standard drive shafts.

21

4.00.00
4.01.00

THROTTLE ACTUATOR
THROTTLE ACTUATOR
TP00ASTA.00

4.01.01

THROTTLE ACTUATOR THA 100


TP07AJ000A.01

For the adjustment of the throttle or injection pump on internal combustion engines.
Suitable for the execution of legal driving cycles according to ECE, FTP, EPA and Japan
guidelines.

Your benefits at a glance

Automatic adjustment of zero and end position

Technical Insight

Power and Control Unit


Suitable for wall mounting in the test room
IGBT-converter for the servomotor
Hybrid interface
Supply: 3 x 380 V +/- 10%/50/60 Hz; 2 kVA
3 x 400 V +/- 10%/50/60 HZ; 2 kVA
3 x 415 V +/- 10%/50/60 Hz; 2 kVA
3 x 440 V +/- 10%/50/60 Hz; 2 kVA
3 x 480 V +/- 10%/50/60 Hz; 2 kVA
other power supply range on request
Ambient temperature: 5 to 50 deg. C
Air humidity: max. 85% without condensation
Height x width x depth: 500 mm x 500 x 300 mm
Colour:
Door: ultramarin (RAL 5002)
Body: greyblue (RAL 5008)
Weight: 20 kg
Protection: IP54,

Actuator
Linear positioning unit with integrated brushless, convection cooled servomotor with resolver
Shifting travel: 110 mm
Shifting force: 120 N (up to 40 deg. C)
Shifting force: 110 N (up to 50 deg. C)
Shifting speed: 0,5 m/sec
Positional repetitive accuracy: < 0.05 mm
Ambient temperature: -30 to 50 deg. C
Air humidity: max. 85% without condensation
Height x width x depth: 170 x 350 x 315 mm
Colour:
Motor: ultramarin (RAL 5002)

22

Frame: greyblue (RAL 5008)


Weight: 11 kg
Protection: IP54, inclusive plug

4.01.02

MINITERMINAL THA 100


TP07AJ001A.01

Serves as a menue-oriented control unit for the adjustment of the final position of the throttle
acutator THA 100.

Technical Insight

Error code display via LC-display


Manual and automatic adjustment of final position via softkeys
Push or pull operation
Selectable language module in English and German
10 m CAN-Bus connection to the control unit

5.00.00
5.01.00

AUTOMATION SYSTEM
TEST SYSTEM CABINET
TP01A.00

The new highly flexible operating room concept of AVL considers the constantly changing
requirements and work situations when executing engine and powertrain tests.
Because of the process orientated design of the system components a flowing transition
between test stand operation, data post processing and office area is now no problem.
The modular and variable system can simply be adapted at any time also to new workflows or
spatial requirements.
Beyond that, compact and intelligent solutions are available particularly for cramped space
conditions (e.g. container test beds).
An optimal product design, honoured with the highest Austrian Design price Staatspreis
Design, secures a harmonious attractive appearance and the fulfilment of ergonomical as well
as functional requirements.

23

5.01.01

TEST SYSTEM OPERATING & CONTROL


DESK
TP01BB000C.01A1

For mounting of PUMA system units as well as of control, monitoring and measuring
insturments.
Modular design, offering many possibilities for system extension.
The industrial and easily accessible construction offers optimum conditions for installation,
commissioning and service.

Your benefits at a glance

Cabinet
hinged frame
detachable side panels
detachable hinged frame plate, serves for mounting of system specific units such as
switches, etc.
EMC suitable mounting panel, passivated, yellow
EMC suitable 19" hinged frame profiles, passivated, yellow
cable feeding via ceiling and floor
Desk
hinged table plate

Technical Insight

Cabinet
19" mounting area for electronics 41 HU
Desk
19" operating area (2 x 3 HU)

24

writing surface: plastic-laminated wood fiber board "lightgrey RAL 7035"


Colour: Cabinet and desk RAL 5002 (ultranavyblue), RAL 5008 (greyblue)
other colour on request)
Place of installation:

operator's room

Temperature range:
Relative humidity:

5 ... 35C
20 ... 80 %

Supply voltage:
Frequency:
Power consumption:

3~400/230VAC +/-10 % (L1, L2, L3, N, PE)


50/60 Hz 2 %
approx. 3000 VA (excl. Power for engine and dyno control)

Design according to drawing P01BB000C.01

5.01.02

ELECTR. ENG. F. TEST SYSTEM /


STATION
TP80FF000A.01

Planning for the production of an Engine Only test system (1 x Dyno,1 x Combustion Engine),
typical for R&D or endurance run .

5.01.03

CABLE BOOM 2.5 M


TP25AH000A.01

The modular built cable boom 2.5 m for wall mounting, with integrated separated cable and air
ducts, serves for mounting the Boom Box(es) FEM and other additional parts. To enable an
ideal positioning of the measurement transducers in the UUT area, the cable boom is executed
tiltable.

AVL- Cable Boom with Boom Box for wall mounting


Example

Your Benefits at a Glance

Easy positioning of the measurement transducers above the unit under test via swivel arm
1 or 2 Boom Box(es) FEM mountable
Integrated separated cable and air ducts
Separated cable ducts (measurement and control lines)

Technical Insight

Boom length
Displacement
Max. permissible load

2.5 m
approx.: 85
240 kg

25

Air flow
Colour boom
Material boom

approx. Q= 160 m/h at H= 250 Pa with option


TP25BG000A.01
aluminium anodized and RAL 5008 (grey- blue)
AlMgSi 0,5 F22

Note:
The boom has to be mounted on a vertical wall with max. 2 inclination.
In case of low room ceiling contact with GPM or HCP is required.

5.01.04

BOOM BOX FEM


TP25BF000A.01

The BOOM BOX FEM accommodates AVL Front End Modules, 19" racks and top hat rail
modules. The BOOM BOX FEM consists of two halfes of identical design, which can also be
mounted separately on the AVL swivel arm in the test cell.
The sensors of the test unit are connected to the FEM modules accommodated in the Boom
Box via short connection lines. The sensor lines and pressure hoses are sealed using sealing
lips.
The purpose of this arrangement is to ensure the fast digitalization of the analog signals and to
reduce the electric wiring in the test cell.

Symbolpicture

Your Benefits at a Glance:


Fully hinged housing cover, thus ensuring excellent accessibility for engine set-up,
installation, service and maintenance.
A second Boom Box can be added on at any time.

Technical Insight:
A Boom Box FEM consists of two equally designed halves.
In addition to the rails for 19-rack mounting, a DIN TS35 standard profile for the integration of
non-19-FEM modules is provided.
One Boom Box half can accommodate the following units:
5 pcs. 19-F-FEMs and 2 pcs. non-19-F-FEMs, or, alternatively:
9 pcs. non-19-F-FEMs.
FEM_Ps are accommodated in the second Boom Box half, separately from the other F-FEMs
(separation of media).
Further technical features:
Sponge rubber seal at the line entrance into the housing.

26

Colours:
Housing cover: Naturally anodized aluminium, ultramarine (RAL5002)
Frame: Gray-blue (RAL5008)
Design according to drawing no.: P25BF000A

5.02.00

AUTOMATION SYSTEM HARDWARE


TP03A.00

5.02.01

PUMA OPEN ENGINE TESTING HW


TP08B0TA.01

This package includes the system hardware for operating an automation system that uses SW
package PUMA Open Engine Testing
Basic System Hardware
The components included are the basic hardware of the automation system.
The basic hardware provides processing capacity for parts of the automation software as well
as serial interfaces (RS232) for measuring devices, operating panel and maintenance. It also
includes the interface hardware for the AVL I/O- and control systems.

Data Acquisition with FEM


FEMs (Front End Modules) designate a modular I/O system for high-precision measurement,
demand value output and control, designed for application in a test bed environment.
Installing the measurement modules near to the engine keeps the measurement lines short and
reduces the probability of disturbances to a minimum. Signal conditioning by software
configuration allows all measurement channels to be used for all sensor types.
Measurement of temperatures (thermocouple and PT100), voltages, currents, resistances
and measuring bridges. A measurement module that is configurable by software and suitable
for all signal types
Modular design: additional modules can be connected easily at any time
High precision and high resistance to interference through front-end technology

27

Test Bed Computer


Powerful test bed computer which is compatible with the PUMA Open hardware and software.
The detailed specification for the test bed computer is always updated as new components are
available and can be obtained upon request.

5.02.02

CAN INTERFACE BOARD / HP (2 LINES)


TP08BC004B.01

Via the CAN Interface Board the PUMA Open system can exchange data with control units and
other nodes via CAN (Controller Area Network).
Possible applications include
recording of data from control units (ECU)
control of automatic test runs using data from the ECU
simulation of CAN nodes
acquisition of data from AVL CAN Open pressure transducers
integration of CAN based devices or I/O
I/O and communication is handled in the real-time system of PUMA Open.

Your benefits at a glance

CAN communication up to 1000 Hz per line


Suitable for Raw CAN (via ASAP 2 description files, disclosure of protocol not required) and
for AVL CAN Open pressure transducers
Supports the CAN standard ISO 11898 (5Volt)
Increased performance due to DMA architecture and optimised real time driver
Two CAN lines per board

Notes

The use of the PUMA Open Software V 1.2 or higher is the precondition for the function of the
High-Performance CAN-Interface Board with 2 Lines.

5.02.03

TEMPERATURE SENSOR PT100/F-FEM-AI


TP09AA000D.01

Temperature sensor PT100 for the measurement of temperatures up to 300 deg.C.

Technical Insight

type A according to EN 60751


length: 100 mm
diameter: 3 mm
connecting cable 3 m
connector (bayonet) for F-FEM-AI*
M8 x 1, shiftable

28

5.02.04

CABLE EXTENSION PT100-15/F-FEM-AI


TP09AA001D.01

Extension cable for the Pt100 sensor. The connectors for the connection to a Front End Module
Analog in (F-FEM-AI*) are included.

Technical Insight

Length: 15m

5.02.05

TEMPERATURE SENSOR NiCrNi(KTYPE)FFEM-AI


TP09AD000B.01

Thermocouple sensor NiCrNi (K-type) for the measurement of temperatures up to 1000 deg.C.

Technical Insight

type IEC 584 Kl. 1


length: 100 mm
diameter: 3 mm
connecting cable 3 m
connector for (bayonet) F-FEM-AI*

5.02.06

CABLE EXTENSION NiCrNi-15/F-FEM-AI


TP09AD001B.01

Extension of the compensation line cable of the thermocouple NiCrNi (K-type). The connectors
for connection to a Front End Module Analog in
(F-FEM-AI*) are included.

Technical Insight

Length: 15m

5.02.07

CONNECTORS FOR B-/F-FEM-AI* (16)


TP08BB017A.01

Set of connectors (Bajonet-type) for connection of analog signals to the Front End Module
Analog In B-FEM-AIN or F-FEM-AI*.

5.02.08

TFT DISPLAY 17"


TP33BL000A.01

17" TFT-LCD Flat panel display (equals 19" CRT-Monitor)


Resolution 1280 x 1024

29

5.02.09

UPS PACKAGE 1500 VA / 19"


TP33DD000A.01

For the protection of the PC in case of variations or breakdown of the power supply (also
functions as a filter). In case of a breakdown, all active PC-applications will be terminated, open
files closed and the PC shut down in a controlled manner.
Technical Insight
Double Conversion On-line UPS with 1500 VA / 1350 W
230 VAC +/- 10%, 50/60 Hz +/- 3 Hz (120 V on request)
H x W x D: 2 HU x 19 inch x 450 mm (rackmount)
Capacity at load with one PC, two TFT Monitor, one Interfacebox / PCI and one Power Supply
24 VDC / 20 A: approx. 8 min
Environment temperature: 0-40 Deg. C
Relative humidity: 0-95% (non-condensing)
Note
When using the UPS together with PUMA Open the PUMA Open SW option "Power Fail
Handling" is additionally required.

5.03.00

CONTROL AND SIMULATION


TP06E.00

5.03.01

TEST RIG CONTROL EMCON 400


TP06EA000B.01

Hardware and software for the control and manual operation of the combustion engine and
dynamometer on an engine test bed.
The basic configuration of the EMCON 400 is a complete digital test bed control and monitoring
system. The system uses proven algorithms to control hydraulic and eddy current
dynamometers as well as DC and AC machines from AVL and other suppliers. The
dynamometer conditions are fully monitored with definable responses. Up to 16 additional
system conditions can be monitored with definable delay time and response type.
The EMCON 400 has an ergonomically designed operating panel. Incremental encoders permit
the exact setting of demand values and ensure bumpless transfer of control modes. The LCD
shows both demand and actual values as well as parameter settings and operating menus.
Alarm and warning messages are also displayed. Function buttons with LED status are
available for selecting operating modes and control functions.
The EMCON 400 is completely integrated in the AVL PUMA automation system.

30

Your benefits at a glance

Precise operation through excellent torque and speed control stability over the whole
performance range
User-friendly handling through ergonomic design of operating elements and flexible
parameter adjustment via display

5.03.02

ENGINE CONNECTION BOX


TP9000ASTA.0101

Each consisting of:


12 V Engine supply
1u. Rack of 600x600x250 mm. with door and mounting board.
1u. Breaker C60N Pcc. 6kA of 16A type II
1u. Manual switch with the control on the side of the cabinet of 25A.
2u. Breaker C60N D Pcc. 6kA of 4A type II
2u. Fuse holder board 40A
2u. Fuse holder board 20A
3u. Fuse holder board 10A
1u. Fuse holder board 4A
2u. Fuse holder board 1A
1u. VU meter indicator of 12V
14u. Plug of different colours.
1u. Mobile frame for cabinet with wheels.
Engine signals connection
6 connexion plugs
3 Amphenol connector
1 DB9 connector

5.04.00

AUTOMATION SYSTEM SOFTWARE


TP03A.00

5.04.01

PUMA OPEN ENGINE TESTING SW


TP03C0TC.01

The application package PUMA Open Engine Testing allows the customer to perform typical
tasks e.g. the development of state-of-the-art engines based on new technologies (e.g.
gasoline direct injection or HCCI, Common Rail, VVT and TCI diesel based technologies) on a
flexible test bed system with an open integration platform.

The application package PUMA Open Engine Testing is used to carry out typical testing tasks
for basic engine development. It is also the basis for engine application (ECU data loading, lookup table tuning.
Intelligent measuring device management especially for emission measurement systems is the
basis for unmanned development test operation also during weekends.

31

Powerful interfaces to the engine electronic system and optimization tools allow the user to
make time-saving variations of ECU look-up table values.
The deep integration of indicating measurement systems into the automation system provides
higher data transmission rates, fast limit monitoring and direct control of engine electronics
quantities.
The scope of functions of this package has been tailored to the requirements of the application
and can be extended at any time by additional functions and software modules.
Additional support and know-how in the form of consulting options can be obtained from AVL, if
required.
Your benefits at a glance

Test library concept to standardize in-house test procedures


Intelligent measuring device management unmanned operation
Powerful interfaces, full support of ASAM ODS, MCD and ACI
Deep integration of indicating measurement systems safe monitoring and control
Availability of extension modules

Technical information
Application-specific Functions:
Device Interfaces
In its function as test bed integration platform, PUMA controls and coordinates a large number
of devices. For details about the scope of supply, please refer to the fact sheet "PUMA Open
Engine Testing".
ASAM Standard Interfaces
PUMA supports state-of-the-art and powerful standard interfaces which comply with the ASAM
standard (Association for Standardization of Automation and Measuring Systems).
The ASAP3 interface is used to link an ECU application system (APS) with the AVL PUMA
system in accordance with the protocol standard V2.1. Via the ASAP3 interface, the PUMA
system can access up to 400 values.
The SANTORIN ASAM-ODS server provided with additional tools (SPACE) ensures the quick
and convenient administration of parameters and results.
Media Control
Reproducible ambient conditions on the test bed (coolant, oil, intake air, air humidity, fuel)
drastically reduce the measured result scatter. It is also possible and recommended to control
media conditioning systems for coolant (AVL 553), oil (AVL 554), combustion air (AVL ACS) and
fuel (AVL 753) directly from the PUMA system by using 12 PID and/or 12 2/3-point-controllers.
Comparable to a PLC, the Test Cell Controller / 1 TCC function is used for the startup,
shutdown, control and monitoring of peripheral test bed equipment. The included function
Scripting Basis / 1 Context provides the possibility to create application or customer specific
VBScripts.
Basic Functions:
PUMA Operating System
The PUMA operating system is the core of the test bed software, the powerful platform for all
automation tasks.
Simultaneously Usable Normnames
Within a testrun 1000 Normnames in total can be used simultaneously.
Local Test Bed Administration
With the editors included the user can change parameters directly from the test bed computer.
Local Parameter & Result Administration

32

The database management toolbox SPACE (local license) is used for the easy administration of
parameters and result data in the local test bed database.
Local Test Order Preparation
This package includes the editors and functions for the definition or adaptation of the testing
tasks. In addition, using Temporary Norm Names, predefined reserved quantities of the PUMA
system can be assigned temporarily and test bed specifically to measured quantities, without
having to change the central normname directory.
Control and Automation Functions
The functions included allow the user to operate the automation system in manual and
automatic mode.
Graphical User Interface
Test order, automation functions, process values, user dialogs and system messages are
displayed well-structured and clearly using the PUMA Operator Interface (POI).
Measurement Data Acquisition & Storage
All quantities in the PUMA system can be acquired in measurement requests and the results
can be stored permanently.
Steady-state measurements with 200 channels and continuous recording by means of 3
recorders with 96 tracks each are supported.
Result Presentation
PUMA supports local, automatic printouts of measured results and system messages.
Multi Level Safety Monitoring
PUMA provides multi-level safety monitoring tools to ensure the optimal safety of operator, unit
under test and test bed in all operating states. Up to 128 channels can be monitored by the
PUMA - System.
Formula Calculation
Formula calculations can be performed cyclically or on demand using the formula compiler
included (suitable for 256 calculated values and up to 16 groups of formulas).
Look-up Table Handling
With this function, the user can create and post-process arbitrary look-up tables in the PUMA
system. These look-up tables are then available for operating point dependent limit monitoring.

5.04.02

POWER FAIL HANDLING SOFTWARE


TP03CV000A.01

In case of a power failure the power fail software ensures a defined stop and new start of an
automatic PUMA test run.
In case of power failure of the test bed during an automatic test run, the power fail software
ensures a defined finishing of the test run and the storage of all data which is relevant for
continuing the test run on the test bed computer. As soon as the power is back the test run will
be continued at the point of interruption or at a freely defined point.

Notes

For this function in addition an uninterruptible power supply (UPS) with suitable power for the
supply of the test bed computer is required.

5.04.03

CONCERTO-PREMIUM HARDLOCK
LICENCE
TI0CONPREA.02

CONCERTO Premium is a graphic evaluation software for detailed post processing,


presentation and documentation of various data that is evaluated at the test bed, in the vehicle
or at simulation systems e.g. for creation of graphs, tables and protocols; also for data export
and archiving.

33

CONCERTO Premium offers extensive possibilities and comprehensive functions for selection,
processing, presentation and correlation of various automation, measuring and simulation data
as well as for report generation and batch processing.
The nearly unlimited direct access to combustion data, recorder data, log point data and data
from ASAM ODS database systems makes data conversion tools obsolete and allows easy
comparison of different data sets.
CONCERTO Premium includes the full functionality of CONCERTO Advanced for Indicating,
CONCERTO Advanced for Test Bed as well as additional functions.
CONCERTO is available as single licence running on a PC, licensed by an USB hardlock.
Your Benefits at a Glance
Intuitive user interface, Drag and Drop, Wizards for easy, menu guided creation of diagrams,
tables and reports, context sensitive help
Data Explorer: comprehensive overview and convenient access to various data sources
(local or network drive, data bank)
Calculator: simple formula creation via predefined function and macro instructions
Formula / Script Editor: full programming environment incl. extensive library with predefined
functions for various applications
CalcGraf graphical formula editor for comprehensive creation and display of algorithm for
combustion analysis
Automated data processing via macro, script and batch commands
Open interfaces: integration into customer specific software or applications via open COMand Active-X architecture
Adaptability of user interface: complete adaptability of menu structures, integration of scripts
into existing menus, integration of object categories in the object assistant and adaptability of
CALCULATOR interface enable optimal adaptability to customer specific field of application.
Technical Insight
Access to various data : AVL PUMA files, AVL I-files (indicating data) , ASAM-ODS data
bank systems, ATF files, generic ASCII, Matlab, AVL CAMEO result files, etc.
Evaluation and comparison of test bed data: steady state, dynamic and endurance test data,
emission data, combustion data, etc.
Interactive analyzing possibilities by means of extensive cursor functions
Wide selection of visualization possibilities: line, bar, step chart, scatter plot, x-y diagram,
envelope, ISO line and 3D-diagram, 4D-objects, listings, tables, videos, statistic boxes,
waterfall diagrams etc.
Data and graphic export via ASCII, HTML or meta file
Extended data search: possibility of selected data search and navigation, based on channel
content (e.g. based on limit criteria)
Encryption functionality for customer specific formulas and scripts for increased data security
Notes

PC operating system: Windows XP or Windows Vista


Hardware requirement: Pentium 4 PC with 512 MB RAM or higher and a free USB port (on
request a hardlock for parallel port can be delivered instead of the USB hardlock)

34

6.00.00
6.01.00

MEASURING SYSTEMS
CONT. FUEL MEASUR. UP TO 600KW
FLEXFUEL
TMCONT50M.00

The system combination of AVL Fuel Mass Flow Meter FlexFuel and AVL Fuel Temperature
Control FlexFuel is used for continuous measurement of fuel consumption on engine and
chassis dyno test beds in research, development and production.
With highest accuracy at shortest measuring times the mass flow is determined directly and
continuously providing permanent measuring readiness.
The measuring system with an integrated statistic evaluation method is used mainly on steadystate test beds for reduction of test times and for cycle measurement on transient, dynamic,
chassis or oil test beds with long test times.

Complete system: AVL Fuel Mass Flow Meter with AVL Fuel Temperature Control

6.01.01

FUEL METER/TEMP.CONT.
FLEXFUEL/HEATING
TMCONT50M.02

The combination of Fuel Mass Flow Meter FlexFuel and AVL Fuel Temperature Control
FlexFuel with integrated heating is a high precise and continuous fuel consumption
measurement system, which is used worldwide at almost all engine test beds where engines of
a maximum consumption of 125 kg/h are tested. The system stands out for high accuracy and
excellent temperature stability.
The fuel measurement system AVL Fuel Mass Flow Meter FlexFuel together with AVL Fuel
Temperature Control FlexFuel with integrated heating enables a high precise fuel consumption
measurement also at low flow rates and short measurement times.

35

The following data and functions are available:


Indication of fuel consumption in kg/h, l/h, l/h (API)
Indication of fuel density in kg/m
Measurement and indication of the actual fuel consumption at a measurement frequency of
20 Hz
Average consumption for pre-selected measuring time or pre-selected measuring weight
Total/interval consumption for determined measuring time
Running average calculation with additional indication of standard deviation and
measurement uncertainty
Selection of nominal fuel temperature analogue or via RS232
Indication of actual fuel temperature analogue or via RS232
Continuous evaluation of the temperature gradient in the measuring circle
Output of warnings to avoid wrong measurements
Gas bubble separation and monitoring
Fully automatic built-in accuracy check and calibration
Fast and efficient fuel change
Indication of error and status report
Service interval display
Monitoring of cooling water supply

Your Benefits at a Glance

Measurement accuracy of 0.12% through direct mass flow measurement and highest
temperature stability of the fuel conditioning system
Rapid measurements even at lowest levels of consumption
The highest level of reliability and universal suitability to the requirements of modern
measurement methods and injection systems
From a single cylinder through to a 600 kW large engine with one sensor and measurement
system
Built-in accuracy check and calibration according to ISO 9001

Technical Information

The complete FlexFuel system consists of an AVL Fuel Mass Flow Meter and an AVL Fuel
Temperature Control with integrated heating.

36

Schematic diagram: Fuel Mass Flow Meter FlexFuel with Fuel Temperature Control FlexFuel
with integrated heating
With a high accuracy mass flow sensor the fuel consumption is determined continuously and via
direct mass flow measurement in kg/h.
The density does not have to be determined in addition to the direct determination of the
gravimetric or specific fuel consumption like in volumetric measurement methods. The fuel
consumption can thus be determined to an accuracy of 0.12 % for the whole system under real
test bed conditions.
The measurement system stands out for simple installation at all gasoline or diesel injection
systems and is therefore universally applicable. This is achieved through the use of a specially
developed pressure control system that makes vehicle-like conditions possible on the test bed.
The additional measurement of the fuel density can be used for quality control or checks for the
correct fuel used. The volumetric consumption information is also available.
The measurement range from 0 to 125 kg/h covers all engine types from a single cylinder
through to a 600 kW large engine with one sensor and measurement system.
The high dynamic AVL Fuel Mass Flow Meter FlexFuel has a calibration interval of at least three
years and is therefore designed to provide a permanent availability for the test bed. In addition it
features a built-in accuracy check and calibration (see option calibration unit) according to ISO
9001 which can be performed at any time during running engine and with the original fuel (fuel
specific restrictions for gasoline fuels).
The AVL Fuel Temperature Control FlexFuel with integrated heating with its high accurate and
stable temperature regulation is an unchallenged market leader in the field of fuel conditioning
systems.
The fuel temperature can be pre-selected within the range of 10...80C. The achievable fuel
temperature, however, depends on the cooling water temperature or the amount of heat
retained in the engine return fuel.
The high precise temperature control provides a constant pre-set fuel temperature at the engine
and guarantees the high measurement accuracy of the whole test system.

37

Continuous gas bubble separation ensures that the fuel supply to the engine is free of bubbles.
The integrated monitor outputs a warning when gas bubbles occur in the measurement system.
The engine feed pressure can be controlled up to 6 bar (rel.) (pressure control on request).
Built-in service interval displays enable preventive maintenance which helps to reduce and plan
downtimes.

Technical Data

Recommended measuring range:


0...125 kg/h, 0...165 l/h (at 0.75 g/cm)
Systematic measurement uncertainity: Us 0.12 %
Density measurement uncertainty:
0.0005 g/cm3
Step response according to ISO 16183: T10...T90 < 125 ms
Maximum measurement frequency:
20 Hz (analogue output)
No. of measurements (running average): 1...99
Ambient temperature:
5...50 C
Fuel supply pressure:
0.1...0.8 bar
Fuel supply flow:
max. consumption + 20 kg/h
Fuel supply temperature:
- 10...+ 40 C
Fuel supply temperature:
- 10...+ 40 C
Fuels:
Gasoline also up to 100% alcohol (M100 or E100)
Diesel also incl. 100% Biodiesel
Cooling power:
1.6 kW at 10C spread and 0,5 bar cooling water
differential pressure
Heating power:
1.6 kW
Fuel circulation capacity at 50Hz:
Standard 240 l/h, optional 450 l/h
Pressure control (option):
feed pressure: ~ 0...4 bar (rel.)
return pressure: ~0...0.5 bar (rel.)
special ranges available on request
Temperature control range:
adjustable from appr.10C*...80 C**
* depending on cooling water temperature
** depending on heat return flow of the engine
Solution with heating available
Temperature stability:
+ / - 0.02 K
Option special temperature ranges:
-8 C...70 C
-30 C...80 C
Interfaces:
2x RS232 (AK compliant)
analogue 0...10V
digital I/0
Power supply:
230V, 50 Hz
220V, 60 Hz (option)
100V, 50-60 Hz (option)
115V, 60 Hz (option)
Power consumption:
2.25 kW
Dimensions:
770 x 1630 x 345 mm ( W x H x D )
Weight (dry):
165 kg

Compatibility

The FlexFuel system of AVL Fuel Mass Flow Meter and AVL Fuel Temperature Control with
integrated heating can be combined with the following systems:
Filling pump and pressure control available on request

38

6.01.02

FUEL FILTER FINE 733.F1M METHANOL


PROOF
TM0733F1MA.01

Fuel filter fineness 25.


To be arranged in the supply line to the Fuel Meter.

Technical Insight

Hydraulic connections:
cylindrical inside thread R 1/2" to DIN 2999
Resistant to all commercially available petrol and diesel fuel types with a methanol or ethanol
content of up to 100% of vol. (M100, E100).

6.01.03

FUEL FILTER COARSE 733.F2M


METHANOLPROOF
TM0733F2MA.01

Fuel filter fineness 60.


To be arranged in the supply line to the Fuel Meter and in engine return line.

Technical Insight

Hydraulic connections:
cylindrical inside thread R 1/2" to DIN 2999
Resistant to all commercially available petrol and diesel fuel types with a methanol or ethanol
content of up to 100% of vol. (M100, E100).

6.01.04

FLAME FILTER FF1


TM0730FF1A.01

To be arranged in the venting line, prevents flaming of the fuel-air-mixture inside the venting
line.

Technical Insight

Hydraulic connections:
inside thread R 1/2", cylindrical to DIN 2999
Resistant to all commercially available petrol and diesel fuel types and alcohol fuels (e.g. M100,
E100).

39

6.01.05

SHUT-OFF VALVE FOR FUEL METER


FLEXFUEL
TM0735AVM.01

Saftey shut-off valve


If a malfunction occurs in the Fuel Mass Flow Meter, the 735 or 735S actuates this valve which
then shuts off the fuel supply to the measuring system.
Resistant to all commercially available petrol and diesel fuel types with a methanol or ethanol
content of up to 100% of vol. (M100, E100).

6.02.00

OPACIMETER 439
TM0439A.00

6.02.01

OPACIMETER 439 G004, 230V


TM0439G04A.01

The AVL 439 Opacimeter (G004) is the 4th generation of measurement instrument for recording
exhaust gas opacity in internal combustion engines using opacimetry, i.e. the measurement of
the reduction of visible light in a measuring chamber through which the sample gas is passed.
The measurement value output will be indicated as well as in opacity N [%] or the absorption
-1
value k [m ].

Exhaust gas is passed through the measurement chamber where opacity is measured.
The AVL 439 Opacimeter is frequently used in development and certification areas. Because of
its technical design authorised testing laboratories like the RWTV in Germany or the UTAC in
France have officially accepted the 439 for statutory tryouts.
The operator interface of the 439 incorporates different algorithms for the electronics filtering of
the measured signal, which are defined and required in statutory test cycles.

40

By using the 439 tests i.e. the ELR test cycle (EURO 3, EURO 4) or the ECE R24 test cycle
then results can be easily achieved.

Your Benefits at a Glance

Flexibility:
Application on engine- as well as chassis dynamometers and also for mobile driving tests
Large application area in the fields of development and certification
Suitable for applications where purge-air into the exhaust gas duct is not permitted (e.g. in
front of exhaust gas after-treatment systems)
Simple operation:
Controlling as a stand-alone instrument via AVL cable-remote control IC4210 or PC439
SW, but also in test bed automation system using the AK generic communication interface
and PUMA operating interface (439 PUMA device driver)
Reliable zero stability
Fast signal rise time
High signal sensitivity
Extensive software functions for R&D
Less efforts on maintenance
Conforms to ISO 11614 design instructions

Technical Insight

The optical path length is 430 mm and the measurement gas temperature in the measuring
chamber will be kept constant in the range of approx. 100C by using a heater.
A constant flow of exhaust gas is drawn from the exhaust pipe through the sample line (welded
sample probe) and conditioned sampling hose by means of a diaphragm-type pump pack. The
recirculation of the sampled gas via a return line to the exhaust pipe of the test engine ensures
constant sample flow also at varying pressure conditions. Due to this feature the 439 can be
used for many different applications on the exhaust gas duct whilst still operating within the
instruments limits.
In the conditioned sampling line, the sampled gas is fed to the inlet of the measuring chamber at
a temperature of approximately 100C, i.e. for higher exhaust gas temperatures, (up to 600C
maximum), the sample is cooled and for cold exhaust gas it is heated.
An important benefit of this temperature conditioning is the reliable signal stability and high
signal sensitivity.
The standard configuration consists of a flexible 1 metre sampling line, with integrated probe
and a flexible 1.5 metre conditioning hose (optionally. a 3 metre conditioning hose is available,
i.e. total length 4 m). The sample return line is the same length.
The 439 G004 uses for the first time two zero-air-valves (one of it is included in the articles for
the 4 different sample hoses), which provides economical and safety advantages.
The air pressure consumption will be reduced and the operating safety regarding possible
damage and simplification in operation of the 439 will be increased.
Further the purge-air will not be back flushed into the exhaust gas duct, but leaded via a bypass
of the external zero-air-valve into the ambient.
The second zero-air-valve is located in the area of the exhaust gas recirculation inside the 439.
Output of Measurement Values:
The measurement results for opacity N [0 to 100%] and for the absorption coefficient k [0 to
10m-1] are available at both the serial interface and at the analogue outputs.
The measurement value can be displayed either as an unfiltered raw value or (according to the
required regulations) a filtered signal (Bessel filter, low pass, sliding average, etc.)

41

The measurement value corresponds to the measuring chamber temperature of 100C and
relates to a measurement gas pressure of 1bar, made possible by the pressure and
temperature sensors in the measuring chamber and consideration in the sequence control.
For stand alone operation where no test bed automation system is present the AVL 439 can be
operated by an optional remote control unit (IC4210). The instrument can also be operated from
a stand-alone computer or notebook using terminal emulation or optional PC439-software.
Both alternatives can be chosen as an option for the 439.
Calibration:
Automatic zero point calibration
Built in automatic calibration of the linearity of the photocell (Lin Check)
Calibration is possible with certified reference filters (different transmission filters available as
an option)
Types of Measurement:
Continuous measurement (standard measurement)
Sliding average
Bessel filtering, adjustable parameters
Peak value measurement "raw value"
Peak value measurement of free acceleration as per ECE R 24
Peak value measurement of sudden load set ups as per ELR Test to EURO III (with Bessel
filtering)
Zero gas measurement

Technical Data

Output of measurement values

Opacity N [%] 0 ... 100 %


-1
-1
Absorption coefficient k-value [m ] 0 ... 10 m

Measurement value resolution

0,1 % Opacity or 0,0025 m (10 s mean value)

Zero stability

{0,1 % or 0,0025 m } / 30 min (Drift with zero


gas)

Signal rise time

0,1 s (at flow rate 40 l/min)

Sampling rate for opacity signal

50 Hz

Output rates

Serial interface: up to 2 Hz by using the AKgeneric communication interface (required by


protocol)
Analog output: 50 Hz

Exhaust gas temperature

Max. 600C

Exhaust gas pressure

-100 ... +400 mbar (incl. pulsation peaks)

Ambient temperature

5 ... 50C

Power supply

230 V (100/115 V optional) +/- 10 %, 50 ... 60 Hz

Power consumption

1 kVA (max.)

-1

-1

Compressed air supply/consumption Max. 100 l/min, 4 bar (non-oiled, dried and
filtered)
Mechanical dimensions

Approx. 650 420 450 mm (W x H x D)

Weight

Approx. 47 kg (basic unit without options and


equipment)

42

Notes

The sample hose is not part of the 439 basic unit and according to the demands it can now be
selected from 4 different types. Whereby the main difference is the kind of material (Silicon or
Viton) and the two different lengths (2,5m or 4m).
The standard configuration of the sample hose consists always of a flexible sample line with
integrated sample probe (total length 1m) as well as the flexible conditioning tube with the
length 1.5m (total length 2.5m) or with the length 3m (total length 4m) and the zero-air-valve
with the control hose. The lengths of 2.5m or 4m are also used for the return sample lines,
which are already part of the sample hose articles.
Basically it should always be considered to keep the sample hoses as short as possible, in
order to avoid deposits on the tube inner walls and thus to eliminate unwanted variations on the
measured values.
It is a must to select one of these 4 types of sample hoses (must have option), otherwise the
439 is not operative !

6.02.02

SAMPLE HOSE W. ZAV. COMPL. SI, 2.5M


TM0439NV25.01

Complete sample hose with zero-air-valve and return sampling line with a total length of 2.5
meter for exhaust gas sampling with the AVL 439 Opacimeter.
Will be needed for the operation of the AVL 439 Opacimeter generation 4 (G004).
A constant flow of exhaust gas is drawn from the exhaust pipe through the sample line (welded
sample probe) and conditioned sampling hose by means of a diaphragm-type pump pack. The
recirculation of the sampled gas via a return line to the exhaust pipe of the test engine ensures
constant sample flow also at varying pressure conditions. Due to this feature the 439 can be
used for many different applications on the exhaust gas duct while still operating within the
instruments normal limits.
In the conditioned sampling line, the sampled gas is fed to the inlet of the measuring chamber at
a temperature of approximately 100C, i.e. for higher exhaust gas temperatures, (up to 600C
maximum), the sample is cooled and for cold exhaust gas it is heated.
An important benefit of this temperature conditioning is the reliable signal stability and high
signal sensitivity.
The 439 G004 uses for the first time a zero-air-valve which provides advantages in economy
and safety.
The air pressure consumption will be dramatically reduced and the operating safety regarding
damaging and simplification in operation the 439 will be increased.
The sample hose is not part of the 439 basic unit and according to the demands it can now be
selected from 4 different types. Whereby the main difference is the kind of material (Silicon or
Viton) and the two different lengths (2.5m or 4m).
The standard configuration of the sample hose consists always of a flexible sample line with
integrated sample probe (total length 1m) as well as the flexible conditioning tube with the
length 1.5m (total length 2.5m) or with the length 3m (total length 4m) and the zero-air-valve
with the control hose. Those mentioned lengths 2.5m or 4m are also used for the return sample
lines, which are already part of the sample hose articles.
Basically it should be always considered to keep the sample hoses as short as possible, in
order to avoid deposits on the tube inner walls and thus to eliminate unwanted variations on the
measured values.

Your Benefits at a Glance

Flexibility:

43

Application on engine- as well as chassis dynamometers and also for mobile driving tests
One sample probe for different engine sizes (from the small single cylinder engine up to big
ship engines)
Less application efforts:
Welding pieces for sample probe and return sampling line
Flexible sample probe (corrugated tube) works as a cooling line
Zero-air-valve to reduce the compressed air consumption and increases the operation safety
Conditioned sample line (conditioning hose) to increase the signal stability and signal
sensitivity

Techncal Data

Sample line with probe (corrugated


tube)

Length: 1m
Material: Stainless steel

Zero-air-valve

Mechanical activation via compressed air


Electrical activation via pilot valve takes place in
the 439 basis unit

Control hose for zero-air-valve

Length: 1.5m
Material: Teflon

Conditioning hose

Length: 1.5m
Material: Stainless steel with silicon covering

Welding piece and clamping units

Material: Stainless steel

Return sampling line with back


sampling probe

Length (total): 2.5m


Material: Silicon hose and corrugated stainless
steel tube 0.5m for back sampling

Max. Exhaust gas temperature at


sample and back sample point

Max. 600C

Notes

The above have to be ordered in addition to the basic article, in order to achieve an operative
and ready for measurement AVL 439 Opacimeter.

6.02.03

CONDENSATE TRAP
TM0439KOFA.01

A condensate trap in the return sampling line could avoid heavy losses on the AVL 439
Opacimeter.
Such a condensate trap will be offered by AVL.

Your Benefits at a Glance

Operation of the 439 also possible at descending Sample Hoses


Application Instructions for using the Condensate Trap
Extension of the 439 Life Time

Technical Insight

The exhaust gas return sampling line is usually laid parallel to the sampling line. If it is laid in an
ascending direction to the exhaust pipe, it is possible for collected residual moisture to flow back

44

into the exhaust pipe. To prevent this happening, we recommend fitting a condensate trap at the
lowest point in the return sampling line. To fit it, cut through the hose, connect up the
condensate trap and fix it in position.
The application instructions describe very extensivly the measures which are possible and
should be taken during the installation of the sample hoses.

6.02.04

SET FILTER INSERT


TM0439FILT.01

To protect the sensible components of the diaphragm pumps of the AVL 439 Opacimeter
against soiling a soot filter insert is installed in front of it.
The filter insert should be replaced in certain intervals by a new one.
This set includes 6 pieces of filter inserts wherewith a longer and proper working of the 439 will
be ensured already.
Maintenance can be performed due the fast and easy exchange of the filter insert.
For each AVL 439 Opacimeter one piece of filter insert is required.
The average life time of one filter insert is approx. 2 to 4 weeks, but of course depends very
strongly on the kind of application, usage and composition of the exhaust gas (sampled gas).

6.03.00

ENGINE AIR FLOWMETER


TP16A.00

6.03.01

AIR MASS FLOW METER 0-1200 kg/h


TP16AD000A.01

Mass flow meter for gases according to the principle of the hot film anemometer.
The rapid response to flow changes enables the measurement of the air mass flow in stationary
and dynamic operating states.

Technical Insight

Accuracy:
Reproducibility:
Temperature influence:
Pressure influence:
Operating temperature:
Response time:
Large measurement range:
Operating pressure max:
Pressure losses at Qmax:

< 1 % of measured value


reduced accuracy with 0 5 % of the range
0,25 % of measured value
< 0,03% / K from measured value
< 0,2% / 1 bar from measured value
-25 ... +80 C Medium and environment of the
measuring tube (short time operation down to
-40C was already executed)
T63 = 12 ms
(1:40)
2,5 bar abs.
40 mbar

The stated specifications are only valid if the offered up- and downstream tubes are used.

45

6.03.02

ACCESSORIES MASS FLOW METER 01200KG/H


TP16AD001A.01

Required accessories with open air filter for Air Mass Flow Meter 0 1200 kg/h to achieve the
specified accuracy.

6.03.03

DIGITAL EVALUATION UNIT


TP16AF000A.01

The digital evaluation unit provides the auxiliary power for the sensing element.
Furthermore it converts the flow rate dependent signal into a mass flow linear standard signal.
Technical Insight
Power Supply:
Version A (standard):

input voltage 195 264 VAC


frequency 47 63 Hz
power consumption 38 W

Version B (on request):

input voltage 97 132 VAC


frequency 47 63 Hz
power consumption 38 W

Caution:

Version A will be delivered if not specified !


Version B has to be specified at least at purchase order !

Ambient temperature:
Air humidity:

-25 ...+50 C
max. 85 %, not condensing

Digital display of the actual mass flow.


Analogue output (The analogue measuring value is available as a voltage signal 0 - 10 V on the
output of the evaluation unit. Thus the recording of rapid processes and execution of control
functions is enabled.)

6.04.00

HUMIDITY MEASUREMENT
TP17A.00

6.04.01

HUMIDITY MEASURING EQUIPMENT IS


TP17AD000B.01

For the measurement of relative humidity and air temperature in the test cell.
Technical Insight
Supply:
Ambient temp.:
Velocity of air:

20 ... 28 V DC
-40 ... +60 C
< 30 m / sec.

Relative humidity:
Measuring range:
Accuracy:

0 ... 100 % rF
2 % RH (0 .... 90 % RH)

46

3 % RH (90 ... 100 % RH)


+20 C
4 ... 20 mA

Nominal temp.:
Output signal:
Temperature:
Measuring range:
Accuracy:
Output signal:

6.05.00

-40 ... +60 C


0.2 C
4 ... 20 mA

BAROMETRIC PRESSURE
MEASUREMENT
TP18A.00

6.05.01

BAROMETRIC PRESSURE TRANSDUCER


CANOPEN
TP18AD000A.01

Digital transmitter for acquisition of the barometric pressure in the testcell.


The signals acquired by the pressure transducer are transferred in physical units to the PUMA
Open system by means of a CANopen interface.
The temperature compensation, linearisation and digital filtering is integrated in the processor of
the sensor.

Your Benefits at a Glance

Data realtime synchronized with PUMA Open


Automatic sensor detection ( measuring range, serial number, type )
Position referred address assignment of the transmitter is done automatically by means of
Daisy Chain Technology

Technical Insight

The pressure proportional analog signal, generated by a thin film cell made of steel is digitized
by a 16 BIT A/D converter. The digital signal is acquired and processed by PUMA Open via a
CANopen interface.
PUMA Open synchronizes the CANopen barometric pressure transducer with the defined
acquisition frequency ( synchronized transmission of the pressure value to PUMA Open ).
The calibration of the CANopen barometric pressure transducer is done in the PUMA Open
system by means of the semiautomatic calibration ( SAC ) with 16 calibration points. The values
between the calibration points are determined by means of linear interpolation.

47

Technical Data

Pressure Range:
Total Error:

800 to 1200 mbar abs.


+/- 0,1% F.S. / -20C...+85C , typ.
+/- 0,3% F.S. / -20C...+85C, max.
+/- 0,05% F.S. , typ.
+/- 0,2% F.S. (1year/20C)
-25 to +85 C
CANopen DS404
Automatic position referred
addressing by means of Daisy Chain
during Power Up

IP 65
15g (20....2000Hz)
24 VDC via CAN-Bus connector

Repeatability:
Longterm drift:
Operating Temperature:
Data Interface:
Addressing:

Temperature compensation:
Linearisation:
Digital Low Pass Filter:
IP Protection:
Vibration:
Power Supply:

Notes

System Requirements: Software PUMAopen 1.2 or higher


Interface Requirements:
PUMA CANopen Interface board
PUMA CANopen driver software for pressure transducers

6.06.00

PRESSURE MEASUREMENT
TP10A.00

6.06.01

PRESSURE TRANSDUCER CANOPEN


FOR C-FEM-P
TP10CB000A.01

Digital transmitter for pressure acquisition in the field of engine and powertrain testing in the
automotive industry.
The signals acquired by the pressure transducer are transferred in physical units to the PUMA
Open system by means of a CANopen interface.
The temperature compensation, linearisation and digital filtering is integrated in the processor of
the sensor.

48

Standard Ranges Gauge (relative) Max. Over


Pressure

Typical Application

-150 to 50 mbar rel.


-300 to 300 mbar rel.
-1 to 0 bar rel.
-1 to 1 bar rel.
-1 to 2,5 bar rel.
0 to 600 mbar rel.
0 to 1 bar rel.
0 to 2,5 bar rel.
0 to 4 bar rel.
0 to 6 bar rel.
0 to 10 bar rel.
0 to 16 bar rel.

Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum
Intakemanifold vacuum/Turbo
Exhaust back pressure
Exhaust back pressure
Turbo pressure
Turbo pressure
Fuel pressure
Oil pressure
Oil pressure

1 bar
1 bar
3 bar
4 bar
6 bar
1 bar
3 bar
6 bar
8 bar
15 bar
20 bar
32 bar

Further pressure ranges on request.


The minimum range is 200mbar.

Your Benefits at a Glance

Accurate recording of highly dynamic pressure curves due to high speed data acquisition of
up to 1000 Hz ,
Data realtime synchronized with PUMA Open
Highest comfort due to automatic sensor detection (measuring range, serial number, type)
Zero Offset adjustment directly in the pressure transducer controlled by PUMA Open
Position referred address assignment of the transmitter is done automatically by means of
Daisy Chain Technology

Technical Insight

With the CANopen pressure transducer you can acquire pressures of liquid and gaseous media.
The pressure proportional analog signal, generated by a thin film cell made of steel is digitized
by a 16 BIT A/D converter. The digital signal is acquired and processed by PUMA Open via a
CANopen interface.
This allows dynamic pressure monitoring and recording (up to 1000 Hz per transducer) by
means of Real-time synchronised high speed data acquisition with PUMA Open.
The Zero Offset adjustment is done directly in the pressure transducer, initiated by a command
in the PUMA Open System.
In addition to the internal calibration, PUMA Open offers for CANopen pressure transducers the
semiautomatic calibration ( SAC ) with 16 calibration points. The values between the calibration
points are determined by means of linear interpolation.

Technical Data

Total Error

+/- 0,1% F.S. / -20C...+85C , typ.


+/- 0,3% F.S. / -20C...+85C, max.
+/- 0,05% F.S. , typ.
+/- 0,2% F.S. (1year/20C)
-25 to +85 C
-25 to +100 C
5 Hz to 1000 Hz in Steps
5000 values/sec. max.
CANopen DS404
Automatic position referred
addressing by means of Daisy Chain
during Power Up
50 Nodes max.

Repeatability
Longterm drift
Operating Temperature
Media Temperature
Sampling Rate
Total Through-put-rate per CAN-Line
Data Interface
Addressing
Number of Transmitters per CAN Line

49

IP 65
Outside thread M14x1,5
15g (20....2000Hz)
24 VDC via CAN-Bus connector

Temperature compensation
Linearisation
Digital Low Pass Filter
IP Protection
Pressure connection
Vibration
Power Supply

Notes

System Requirements :
Software PUMAopen 1.2 or higher
Interface Requirements :
PUMA CANopen Interface board
PUMA CANopen driver software for pressure transducers
The pressure tubing from pressure transducer to the measuring point is part of the customer.
The PUMA System covers the CPU-performance demand of a typical set up with 16
CANopen pressure transducers of 100Hz a piece in one CAN-line. Extended configurations
can be realized after a performance check of the complete system has been carried out.

6.06.02

QUICK RELEASE COUPLING


TP10DB001A.01

Is used to connect and disconnect the engine pressure channels quickly at the transducers.
The Quick Release Coupling includes a non-shutoff connector on the transducer and a shut-off
coupling on the Teflon hose. After opening the Quick Release Coupling, the shut-off coupling on
the Teflon hose prevents the media from flowing out. The non-shutoff connector on the
transducer connects the pressure transducer with the ambient pressure, thus creating the basis
for PUMA supported offset compensation.

6.06.03

C-FEM-P 19" HOUSING


TP10CA000A.01

19-housing with internal wiring for up to 8 CANopen pressure transducers.

50

6.06.04

TEFLON HOSE 5M
TP10DB002A.01

Connects the transducer to the measuring point on the unit under test.

Technical Insight

Possible pressure load for the Teflon hose 4x1 mm:


Temperature range:

7.00.00
7.01.00

22 bar at 20C, 9 bar at 150C.


200 to +260C

EMISSIONS ANALYZER
FTIR SESAM APPLICATION PACKAGE
TEFFP.00

AVL SESAM-FTIR Application Packages provides an optimized, robust, and user-friendly


emission measurement system for typical emission measurement applications. Such application
packages are prepared, with all the required additional features necessary to make the standard
FTIR work for such applications. Only the heated sample gas line, the heated pre-filter and
commissioning must be ordered separately, accordingly to the customer specifications.

7.01.01

FTIR APPL. PACKAGE - GENERAL - 5HZ


240V
TEFFP0009A.01

AVL SESAM-FTIR Application Package - General 5Hz 240V provides an optimized, robust, and
user-friendly emission measurement system for most typical emission measurement application.
It contains all the required hardware and software components and exhaust gas evaluation
methods.
Furthermore, its extensive factory calibration makes the system ready to be used without any
further calibrations. In conjunction with the background recording, re-calibration of the FTIR is
not needed for several years.
An intuitive operator interface makes the system easy to use and frees the operator to focus on
his development work and not the operation of the measurement system.
The AVL SESAM-FTIR has proved outstanding performance for such application already in
many installations worldwide.
Application task: Gasoline, CNG and LPG
This application package tailored for the emission measurement requirements of Positive
Ignition (PI) engines.
Application task: Diesel
This application package tailored for the emission measurement requirements of Compression
Ignition (CI) engines.
Application task: Diesel SCR

51

Extremely low emission limits for diesel powered Light Duty (passenger cars) and Heavy Duty
(trucks and buses), like EURO-IV, US2007 and 2010, require the development and calibration
of advanced exhaust gas after-treatment systems to reduce NOx and particulate matter. For
these reasons several technologies exists for the NOx reduction, like Hydrocarbon Selective
Catalytic Reduction (HC-SCR), NOx Storage and Reduction (NSR), Plasma Techniques, and
Selective Catalytic Reduction (SCR).
The Urea-SCR technology will be mainly used in for Heavy Duty and Light Duty Diesel
applications. The NSR is already now the preferred solution for lean burning direct injection
gasoline passenger cars and to some extent also with diesel powered vehicles.
The Urea-SCR technology uses urea from a tank as a reducing agent. The reduction of NOx is
accomplished through a controlled injection of the urea solution into the hot exhaust gas. This is
combined with one or more catalytic converters. The urea breaks down into NH3, HNCO and
CO2. NOx is reduced when it reacts with NH3, on the surface of the catalyst, to produce nitrogen
and water vapor. The Selective Catalytic Reduction (SCR) is a complex chemical process,
which consists of several reactions, running simultaneously in the exhaust gas after-treatment
system. The primary reaction when using NH3 is the removal of NO and NO2. This process
forms nitrogen and water. Additional secondary reactions take place, like an increase of NO2
content (from enhancing the removal of NO), the generation of ammonia from injected urea, the
removal of remaining NH3, and the formation of nitrous oxide (N2O, laughing gas).
Development and calibration of such vehicles with SCR technology are focused on managing
exhaust gas temperature, urea dosing strategies, and being sensitive to certain undesired gas
components. This makes it almost mandatory to measure several gaseous components such as
NO, NO2, NOx, N2O, NH3, HNCO, HCOOH, H2O, CO, CO2 and others. All these gas
components must be measured and managed at different sampling locations, like pre-cat, mid
bed, post- cat. Due to the chemical interaction of all these gas components, it is crucial to
measured all components simultaneously, perfectly time aligned, and at a fast response time.
This necessitates the need to measure all the gas components in the same measuring cell with
the same measurement technology. Only the FTIR analytical measurement technology is able
to meet these demands. The FTIR is capable of measuring simultaneously, all the relevant
gases, in one measuring cell with one analytical technology.
Application task: Bio Fuel
Modern fuels very often contain a certain fraction of Bio-fuel, like Ethanol. This application
package also measures gaseous components for such applications.
Measured and calculated gas components
All exhaust gas evaluation methods are installed and configured. All gas components are
factory calibrated accordingly to this application. The calibration is valid for several years.
Chemical
Formula
CO2
CO
NO
NO2
NOx
H2O
NH3
N2O
CH4
C2H2
C2H4
C2H6

Gas component measured or calculated


Carbon dioxide
Carbon monoxide high
Carbon monoxide low
Nitrogen monoxide
Nitrogen dioxide
Total Nitrogen oxides
Water
Ammonia
Nitrous oxide
Methane
Acetylene
Ethylene
Ethane

Range in ppm
0 200 000
8 000 100 000
0 8 000
0 10 000
0 1 000
0 10 000
0 250 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000

52

C4H6
C2H5OH
IC5
NC8
AHC
NC5
HCHO
CH3CHO
COS
SO2
HNCO
HCN
HCOOH

1,3 Butadiene
Ethanol
Iso-Pentane
n-Octane
Aromatic hydrocarbons
n-Pentane
Formaldehyde
Acetaldehyde
Carbonyl sulfide
Sulfur dioxide
Isocyanic Acid
Hydrogen Cyanide
Formic Acid

0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 1 000
0 200
0 1 000
0 1 000
0 1 000
0 1 000

AVL SESAM-FTIR Version 4


The AVL SESAM-FTIR Version 4 is a dynamic multi gas component measuring system,
optimized for exhaust gas of internal combustion engines. Now available in its fourth generation
it provides proven reliability and outstanding new features.
It belongs to the AVL SESAM-FTIR (System for Emission Sampling and Measurement) product
portfolio. It consists of hardware and software components required for the measurement of
various constituents in raw exhaust. FTIR measures undiluted exhaust at 185C.
Successful online modal exhaust evaluation is addressed with the fast dynamic response time
of 1 sec (rise time t10 t90), and the perfectly time aligned signals for all measured components.
This is accomplished by having all measurements made at the same time, and in the same
measuring cell.
Comparative results obtained from tests using both FTIR and conventional exhaust gas
measurement techniques have proven excellent correlation.
It fulfills all response time requirements for all emission standards and emission legislation
which define raw modal analysis and undiluted transient measurement, like ISO16183,
ISO8178-11, EN2005/78/EC (Euro-IV Heavy Duty).
The measuring results are displayed and stored in the concentration of the various gas
components. The AVL SESAM-FTIR in combination with input signals from an exhaust flow
measurement unit, or a fuel flow meter or an air intake meter, can also deliver mass emission
based results in g/sec or g/km (g/mile). With the optional available software extension
packages, the mass based result evaluation can also be done within the FTIR system.
Your benefits at a glance
AVL SESAM-FTIR is an ideal tool to support all types of development work involved with the
measurement of exhaust gas emissions from various sized engines and vehicles. This
instrument also enhances the development of exhaust gas after-treatment systems and the
evaluation of various types of fuels.
Besides its outstanding measurement performance, its flexibility allows for stand alone
operation as well as full integration into test bed automation. With the available options, it can
be tailored to any application need and any operation mode.
Advanced data recording and data evaluation calculations are available as optional software
packages.

53

AVL SESAM-FTIR has been designed and developed to be operated by technicians who have
no previous experience with FTIR based systems. No knowledge of software programming or
FTIR spectroscopy is required. It is easier to operate than a conventional emission bench!
With the longtime stable factory calibration it does not require regular calibration, check and
linearity processes. Without the need for calibration gases, it is the most cost effective emission
analysis system on the market. Combined with the minimal maintenance effort and its
robustness it delivers the lowest total cost of ownership.

Multi-component analyzer system with the ability to detect regulated and non-regulated
emission components
Optimized signal to noise ratio
Excellent dynamic behavior rise time t10 - t90 within 1 sec
Perfectly time aligned signals
Complete software automation with easy to use intuitive operation
Full integration into test bed automation systems standard AK protocol to host
Low total cost of ownership (TCO)
Factory calibration stable over years
No calibration gases required
Minimal service and maintenance requirements
Works much more reliably than conventional analyzers
19 closed cabinet
Industrial-type FTIR spectrometer, installed within the cabinet
Optional expanded software packages available for advanced stand alone operation
Technical Insight
The Fourier-Transform Infrared (FTIR) spectroscopy enables time-resolved (modal) on-line
measurements. This method is highly suitable for in depth investigation of transient processes in
combustion engines. It is capable to determine up to 25 gaseous exhaust components
simultaneously.
The AVL SESAM-FTIR has been designed to be operated by technicians who have no previous
experience with FTIR based systems. No knowledge of software programming or FTIR
spectroscopy is required. Actually it is easier to operate than a conventional emission bench, or
any other analytical system. All operation is done via the advanced software package.
Within the cabinet all components for required to perform the measurement are located,
including the FTIR analyzer module itself. The cabinet is mounted on castors and can easily
move around.

FTIR spectroscopy
Unlike conventional infrared (NDIR) analyzers, which use a single wavelength of infrared light to
measure a single gas component, FTIR spectrometers use a wide range of infrared wave
lengths to detect simultaneously all spectral information available from the gas sample.

54

The AVL SESAM-FTIR uses a Michelson interferometer with two mirrors, one fixed and one
moving. A wide band infrared radiation from the light source is split into two beams by a beam
splitter. One of the beams passes through the beam divider onto the moving mirror and the
other is reflected onto the fixed mirror. Both beams are then recombined to one beam again
along with an interference effect depending on the optical path length difference (retardation)
caused by the actual position of the moving mirror relative to the fixed one. If the retardation is
zero, the two beams are perfectly in phase and all light from the source will be transmitted into
the measuring cell. If the retardation is unlike zero, the beams will be out of phase and less light
(up to zero) will be transmitted into the measuring cell. Consequently, at every mirror movement
(scan) between its turning points the detector will record an "interferogram" (intensity vs. time)
as result of the varying interference of the beams.
When the sample gas cell is filled with exhaust gas, each single exhaust gas component will
absorb infrared light at different wave length and depending on its concentration. This spectral
absorption will change the interferograms, which then comprise the total information of the
complete spectral absorption of all gas components contained in the exhaust sample.
By the Fourier Transform (FT) method interferograms are converted back via mathematical
procedures into an infrared spectrum (intensity vs. wavelength), which is the absorption
spectrum of the relevant exhaust sample. This enables the determination of the concentration of
all infrared-active components of the exhaust gas sample.
Just like standard evaluation methods, as used for general purpose laboratory FTIR analyzers,
the AVL SESAM-FTIR uses specially developed evaluation methods. These methods have
been developed over the last 15 years and are continuously being optimized and improved.
These methods combine the specific requirements for exhaust gas measurement of internal
combustion engines and specific mathematical functions to minimize cross interferences.
The factory calibration of all measured gas components on each single AVL SESAM-FTIR
system ensures the highest possible analytical performance combined with the long time
stability of the calibration.
Optionally, conventional analyzers as well as all necessary sampling compounds can be
integrated. The analyzers just as all other functions are controlled via the software.
The following analyzers can be integrated, the integration of conventional analyzers require to
use the Basic Unit Large Cabinet:
Heated FID (THC) module
NDIR (CO2-EGR) module
PMD (O2) module
The conventional analyzers are operated in the usual way like any conventional emission
bench. A supply with the typical operation gas and calibration gas is required. See the analyzer
data sheet for the detail specifications.
Technical Features
The gas cell is easy to remove and clean and does not require special optical alignment after
cleaning.
All optical parts of the FTIR are mechanically auto-aligned, this means they can easily be
exchanged or repaired. The final optical adjustment is performed by the automated optical
alignment function.
Sample purging time of 1 second due to the optimized gas cell.
No loss of concentration in the sample, because condensation is prevented (important
especially for hydrocarbons and all other components, that resolve in water). Sample lines
and gas cell are heated to 190 C (gas cell 185 C).

55

Synchronous measurement for all components (no individual delay times). This makes time
synchronization easier, especially for pre / post catalyst measurements.
Excellent long term stability, FTIR comes with factory calibration for all measured gases. The
calibration remains stable during life time of the FTIR.
No regular calibration necessary, only daily background sampling using zero gas is needed.
SESAM-FTIR Air Conditioning Features
SESAM-FTIR Air Conditioning unit allows the SESAM-FTIR cabinet to be installed inside an
engine test cell.
Conditions for the Basic SESAM-FTIR cabinet with Air Conditioning Package are 15C to
55C (59F to 131F)
Software features
The AVL SESAM-FTIR has been designed to be operated by technicians who have no previous
experience with FTIR based systems. No knowledge of software programming or FTIR
spectroscopy is required. Actually it is easier to operate than a conventional emission bench, or
any other analytical system. All operation is done via the advanced software package.

The software is installed on a PC, with a Microsoft Windows operating system. It uses the
Windows operation conventions as well as the AVL look and feel of the other products. In this
manner each test bed operator is quickly familiar with the basic functions.
The normal measurement operation is reduced to simple and easy to understand
instrumentation operation. All results displayed are already the final result as needed by the
operator.
All the controls for the system, like sample preparation (solenoid valves, temperatures, etc.), the
data evaluation of the Fourier Transform calculations, conversion into quantitative units and
spectra management (FTIR Control Computer), Interferometer control (lasers, light source,
detector, etc.) and monitoring is done by the FTIR specific software in the background.
System diagnostics and maintenance screens are available for system maintenance or for a
possible need to take a deeper look into. In addition the operator is supported with easy to
understand and operate screens showing the actual flow diagrams and online graphics. If
needed the data source for the analytical data evaluation, like the absorption spectra, is
available.
The integration into any test bed automation system is done via the standard emission
measurement protocol, as defined by the AK standard. If needed, optional analog output signals
can be delivered, for simple analog based interfacing to test bed automation systems or data
recorders.
Optional software package can be installed on the system PC to advance operation, especially
for stand alone operation. Such options starts with simple data recorder and can expand up to
test run automation systems, with full data evaluation routines.

56

Technical Data
Data Sampling
Scanning Rate
Number of simultaneous measured or calculated gas
components
Spectral Region for Analysis
Wavenumber Resolution
Measurement Cell

Detector cooling
Liquid Nitrogen consumption
Time between refills
Material in Contact with Sample

Sample Gas Flow


Response Rise Time (t10 t90-time)
per ISO16183 definition
Purge gas
Purge gas consumption
Compressed Air
Compressed Air consumption
Dimensions (W x H x D)

5 Hz at 25 measured
components
1 scan per second
up to 25

gas

650 to 4000 cm-1


0.5 cm-1
Multi-path 2 m gas cell (folded
optical path)
volume 200 ml
heated to 185 C
Liquid Nitrogen
50 ml/h
16 h
Stainless Steel
Teflon
ZnSe (cell windows)
Gold plated Aluminum (mirrors)
10 l/min
1 second
Synthetic Air or N2
0.5 1.0 l/min - continuous
5-6 bar rel
40l/min, only during sample
24 HU
600 x 1300 x 1150 mm
23.6 x 51.2 x 45.3 inches
150 kg
330 lbs
3- single phases 240 VAC 50/60 HZ
10 to 55 C
20% to 80% humidity, non
condensing
30 min

Weight
Power supply
Operating Environment
Warm Up Time (95% heated)
Notes

AVL SESAM-FTIR Application Packages are optimized for certain common and popular
measurement applications. In this manner we can standardize the manufacturing and calibration
processes as well as to automate it. Therefore, we can offer such application oriented solutions
at an optimized price, too. With this article not all options are available. All FTIR articles, which
can be used with such packages, have an indication. This indication can be found in the article
information (see Notes).
AVL SESAM-FTIR Basic Units are used to realize customer specific configured systems. The
AVL SESAM-FTIR Basic unit can be combined with any other FTIR article. There are three
Basic Units, one with a small cabinet, one with a large cabinet and one with a X-large cabinet.
Not all hardware options can be integrated in the small cabinet, like additional conventional
analyzers. In that case the Basic Unit Large Cabinet or the Basic Unit X-Large Cabinet must
be ordered.

57

7.02.00

FTIR - SESAM ACCESSORIES


TE95A.00

consisting of:

7.02.01

FTIR ANALOGUE OUTPUTS 16


CHANNELS
TEFFO0202A.01

FTIR Analog Output Option provides freely configurable analog output.

Your benefits at a glance

Freely configurable which variables are made available on the output


Easy integration to analog data recorders or automation systems

Technical Insight

16 outputs
0 - 10 V or 0 - 20 mA, configurable

7.02.02

FTIR PRE-FILTER, HEATED WITH BACK


FLUSH
TEFFO0001A.01

The heated Pre-filter is used to remove particulates from the exhaust sample to avoid
contamination in the sample stream as well as contaminations in the measurement cell of the
FTIR system, and any integrated analyzer module. It supplies a back flush functionality.
This pre-filter is especially design and made to prevent measurement artifacts. Such artifacts
can be chemical or physical reactions of the gases with the surface of the filter module or the
filter material itself, or time delays and hang-ups for certain gases. Especially NH3, which is a
limited emission component in the European emission legislation, can be strongly affected,
when not done properly.
Especially the measurements of critical gas components, which are not measured in
conventional emission systems, like NH3, are taken care by this special pre-filter. In addition it
has been designed to avoid long delay times and smoothening effects of the gases, which
would reduce the dynamic of transient measurements.

Your benefits at a glance

Unit prevents particulates from getting into measuring system


Increased reliability
Higher measuring quality

58

Technical Data

Filter holder

Stainless steel

Temperature controlled

190C

Start up time

15 min

Notes

This article works within the context of the product FTIR.


The usage of a pre-filter is mandatory for the FTIR operation.
This article can be used all FTIR Basic Units and with FTIR Application Packages.

7.02.03

FTIR HEATED SAMPLE LINE - 4M


TEFFO0002A.01

FTIR heated line provides heated routing of exhaust gas from the sample probe to the FTIR
sample inlet.

Technical Data

Length

4m

Temperature controlled

190C

Notes

This article works within the context of the product FTIR.


The usage of a heated sample line is mandatory for the FTIR operation.
This article can be used all FTIR Basic Units and with FTIR Application Packages.

7.02.04

DRIVER BENCH LAN AK AVL SESAM-FTIR


TA52JB004A.01

7.03.00

INSTALLATION &
COMMISSIONING/TRAINING
TE86A.00

7.03.01

FTIR - SESAM COMMISSIONING


TE85PA000A.01A1

The FTIR SESAM COMMISSIONING consists of 3 days commissioning/training on site.


The following services will be provided:
Visual check of the scope of supply
Mounting the system

59

Ground connection check


Main power supply check
Check of calibration and operation
Check of main functions
Check of heated lines operation and control
Check of optional system features due to order specification

Putting into operation is based on the following conditions:


All the building and installation work has to be completed. The test stand cell as well as the
operators room have to be in well-swept condition.
All supply media must be completely installed and ready for operation:
Electrical supply, shop air
Exhaus equipment, ventilation of test cell
Availability of a dry, lockable room for storage of the material rquired for putting into
operation
Working regulations for commissioning:
The seller will send an experienced and qualified specialist to the buyers plant for
commissioning.
The commissioning specialist(s) will not prove engine test results (apart from correct
calibration work of the delivered systems).
Scope of supply

7.04.00

PACKAGING EXHAUST GAS


MEASURINGTECHNOLGY
TE87A.00

7.04.01

PACKAGING PER 19'' CABINET


TE87AA000A.01

Proper packaging for worldwide transport of a 19-cabinet.

The packaging has been designed to ensure the immaculate operation of the shipped exhaust
gas analysis instruments at its final destination.

Notes

The packaging is adequate for the following products:

Exhaust gas analysis system AMA 1800


Exhaust gas analysis system AMA 4000 Advanced
Exhaust gas analysis system CEB II Advanced
Constant volume sampling system CVS 4000 Light Duty
Full flow particulate sampler FFP 4000

Further details are available on request.

60

8.00.00

8.01.00

COMBUSTION DATA ACQUISITION


SYSTEM
INDIMODUL 621
TI0621A.00

The AVL Indi-Advanced series is the new generation of high performance AVL Indicating
Systems.
The IndiModul 621 is a modular high speed indicating equipment for research and development
of engines and components. It is designed for use at test beds and in vehicles.
Highest flexibility in functionality and application is guaranteed due to modularity and powerful
options.

The included software for PUMA connection and the optional software Communication Interface
allow remote operation from test beds and direct communication with other equipment. The area
of application of the basic system can be extended by various software packages (see options
CalcGraf, FlowGraf, "Recorder Function", "Real-time knock analysis, Driver software for NIPC cards, etc.").
The IndiModul 621 is controlled by the PC operating software package AVL IndiCom. This
software package assists the user in the parameterisation of the measurement and data
evaluation, in the fast and direct data access, all this with minimum training efforts.
For detailed and convenient analysis of all combustion related data the post processing
software IndiCom-Offline is recommended. IndiCom-Offline has been optimised for fast data
access, versatile calculation, flexible display and report generation with a single tool. It allows
also to configure the IndiModul 621 in the office (in off-line mode while not connected) and to
test the set-up with already measured or with predefined data.
The data format is also compatible for the AVL data post processing software CONCERTO-I or
Top-CONCERTO.

8.01.01

BASIC EQUIPMENT 621 FIREWIRE/NOTEBOOK


TI0621NB.01

The IndiModul 621 is a high speed 8-channel indicating system, for crank angle related
measurements on internal combustion engines, injection systems etc.
The innovative graphical user software AVL IndiCom supports the user during parameterization,
measurement and data processing.
The described IndiModul 621 also provides a firewire connection (IEEE 1394) to the notebook
(FireWire PCMCIA-Card included in scope of supply).

61

Real time data acquisition system with extensive on-line combustion analysis:
Crank angle based data acquisition with simultaneous real-time evaluation of indicating and
knock results (option: real time knock monitoring)
Oscilloscope mode and single measurement in real-time, multi-channel digital voltmeter
Continuous or single measurement on time base (recorder function)
Event monitoring
Event triggered measurement with pre and post history
Channel individual measurement windows and measurement resolutions
PUMA connection: remote control from an AVL PUMA automation system via serial link (RS
232) or TCPIP (need PUMA Open 1.1 or higher)

Your Benefits at a Glance


Easy handling due to intuitive user interface
IndiPar: graphical parameterization for the clear and easy access to the hardware settings
Numerous real-time result calculations available during measurement
Built-in plausibility checks for a safe operation
Big variety of different display objects (x/y-diagram, waterfall diagram, etc.) for display of
measured and calculated data and for detailed reporting
Export of data or graphics

Technical Insight
8 analogue differential inputs with individual 14Bit / 800 kHz ADC per channel:
- Input voltage +/-10V
- On-board data memory 8Mbyte
(extendible to 20 MByte by means of memory extension)
Angle- and measurement resolution : 0.025 to 1.0 deg. c.a.
Time-based measurement resolution: 0.00125ms 5000ms
8 digital outputs: TTL level (alternatively to be configured as 4 open collector and 2 relay
outputs)
Sockets for connecting AVL Angle Encoder 364 or 365
Integrated CDM-multiplier incl. 60-2 logic (TTL level required) for a measurement resolution
up to 1.0 deg. c.a.
PC-connection via IEEE 1394 interface (firewire)
Extension by cascading further IndiModul (8 channels each), up to maximum 4 IndiModul
can be cascaded.
Technical Data
Power supply
Power consumption
Ambient temperature
Relative humidity
Dimensions (width x height x
depth)
Design
Complying with legal regulations

10.5...36 VDC
45 VA
0 50 C
10...75 % (not condensing)
19 x 1 HU x 280 mm (320 mm including cable
connectors)
Table or rack version
CE

Notes

62

Hardware requirements: Pentium 4 Notebook with 1.8 GHz and minimum 512 MB RAM, CDROM drive and free PCMCIA slot (an IEEE1394/FireWire PCMCIA-card is included in the
scope of supply)
PC Operating System: Windows XP
For connection with a notebook the use of the integrated firewire (IEEE1394) plug of the
notebook is recommended. If the notebook is not supplied by AVL, a list of positively tested
notebooks can be supplied by AVL.

8.01.02

MEMORY EXTENSION FROM 8MB TO


128MB
TI0621MMA.01

Memory Upgrade from 8MB to 128MB for one IndiModul 621 with FireWire.
If the memory upgrade is ordered for an existing system, the installation has to be carried out by
a qualified AVL service technician.

Your Benefits at a Glance

Allows the acquisition and storage of indicating raw data over a very long measurement
duration with high crank angle resolution
Application example: recording of 4 cylinder pressure signals on one data acquisition module
over 15.000 cycles (typical FTP cycle) with a resolution of 0,2CA from 10...70 CA and a
resolution of 1CA from 360...360 CA

Technical Insight

Hardware extension auf 128MB dynamic memory for the installation in an IndiModul 621 with
FireWire.

Notes

The option is valid for one IndiModul 621 with FireWire and necessitates IndiCom 1.3.
The IndiModul including all cascaded units require minimum a Pentium 4 PC with a RAM size
larger 256MB plus the sum of memory size of all the acquisition modules.
Currently a maximum acquisition memory of 768MB per IndiModul system is supported.
Because of the memory extension the memory for the oscilloscope is limited to 8MB.

8.01.03

COLD START MEASUREMENT FOR 621


TI0621CSMA.01

The software option Cold Start Measurement enables the combustion analysis starting from the
first movement of the angle marks, as well as the acquisition of engine start measurement on
time base with following conversion to crank angle base.

In mode Cold Start the data are recorded from the very first movement of the engine without
waiting for synchronisation by the trigger pulse. The TDC correction is performed automatically
after stopping the measurement. Therefore, convenient check of all signals will be possible
immediately after measurement.
In the time based engine start measurement, an analog CDM trace (i.e. 60-2) is recorded in
addition to the measurement signals. After the measurement, the time based signals are
converted into CA-base and can consequently be used for calculation of CA or cycle based

63

results. A benefit of the time based start measurement is the recording of values before the
actual engine start.

Your Benefits at a Glance


CA-based start measurement:
Combustion analysis right from the very first angle mark
2 visualisation possibilities:- as strip chart- TDC compensated as overlapping cycles
No complicated re-cabling due to automatic internal re-routing of trigger and crank angle
signals
Time based start measurement:
Recording of signals before actual engine start
Precise conversion from time base to CA-base through interpolation of CDM
Notes
This software option is available for the IndiModul 621 with IndiCom only.
The time based start measurement requires IndiCom 2.0 or higher

8.01.04

NOTEBOOK WITH SW-INSTALLATION


TI0620PCB.01

The Notebook consists of a DELL Latitude notebook D600 (or similar type with equivalent or
better specification) and includes also the installation of the operating software IndiCom.

Technical Data

Microprocessor

Intel Pentium M, 1.6 GHz

RAM

512 MB

Hard Disk Drive

40 GB EIDE hard disk

Floppy Drive

3 1/2

CD/DVD Drive

DVD/CD-RW Combo Drive

Ethernet Adapter

10/100/1000 Ethernet LAN

Ports

1*Ser 16550, 1*ECP, 2*USB 2.0

Operating System

Windows XP preinstalled

Housing

Notebook

Accessories

Logitech Pilot Mouse (or similar)

Support

3 years DELL Gold Technical Support

Notes

Suitable for Indiset Advanced 631, IndiModul 621 with Link, Indiset 620 and Indimeter 619
For use with IndiModul 621 with FireWire, Indiset Advanced Plus 641 or Indimaster
Advanced 671 a PCMCIA-Firewire card is mandatory, we recommend Margi 1394-to-Go or
Unibrain FireCard400

64

8.01.05

ANGLE ENCODER 365C-SET FOR INDI


ADVANCED
TI0365CC.08

Angle Encoder Unit with integrated marker disk, mounted optical cable and opto-electronic
converter but without Pulse Converter Box (Angle Encoder 365C), suitable for mounting to a
free shaft end or belt pulley.
The AVL Angle Encoder 365C (flange mounting unit GG0736 and electronics BO4293, plug-in
type) will be delivered without Pulse Converter Box (3064Z05 or 365Z01) Therefore, it is to be
connected directly from elecctronics BO4293 to an indicating system of the AVL Indi Advanced
series or to an existing Pulse Converter or to the IFEM Signal Conditioning Rack 6FA1 with
CDM Interface.
For this connection of the Angle Encoder 365C the Connecting Cable BV2026 is included.
The plug connectors allow more flexible mounting of AVL Angle Encoders in combination with
Indi Advanced systems or IFEM-Rack with CDM-Interface since there is no more need to find a
proper mounting place for the bulky Pulse Converter.

Your Benefits at a Glance

Cost saving version in combination with AVL Indi Advanced system or with the AVL IFEM
Signal Conditioning Rack
Precise measurement up to n = 20,000 rpm, even in dynamic operation
Compact size with low-mass and therefore low inertia
High tensile strength materials (titanium shaft, high tensile strength housing)

Technical Insight

The angle information is transmitted by light pulses from an encoder through an optical cable,
length 2 m, to an emitter-receiver-electronics. The digital signal is generated in the plug type
electronics unit.
The necessary power supply is provided by an AVL Indi Advanced system or by CDM-Interface
or by pulse converter.
For further technical data, mounting dimensions and available accessories see leaflet or manual
for Angle Encoder 365C.

8.01.06

MICROIFEM PIEZO 4CH SDC


TI04PIEZA.03

4-channel microIFEM 4P3G indicating amplifier for acquirement of combustion pressure signals
or other piezo electrical signals at the test bed or in the vehicle. With a switchable ground
potential also the application of mass isolated sensors is possible.
The robust mechanical design allows mounting close to the sensors, e.g. in a cable boom box.
This allows short cable distance between sensors and amplifiers and therefore allows lowest
impact of electromagnetic interference. The direct connection of piezo sensors reduces signal
drift and possible problems with polluted connectors. The wide range of temperature and the
small dimensions allow universal application.
Automatic sensor identification when using piezo-electric sensors with sensor identification
(SID). The amplifier is equipped with an additional SID board (with HF-technology), which
automatically detects the connected sensor. The allocation of all relevant sensor data is done
via sensor database. Additionally the operating time of the sensor will be registered. The

65

integrated operation time monitor updates the operation time information on the sensor data
connector in certain intervals to be set by the customer and thus enables the monitoring of the
calibration interval or a rough estimation of the sensor condition.
Alternatively the sensor identification or parameterization of sensors can be accomplished
selectively with an integrated Fischer connector using an applicable TEDS.
Your Benefits at a Glance
Remote controlled parameterization via PC-menu (sensor type and sensitivity, signal range,
amplification, offset, sensor type, etc.)
Automatic sensor identification for sensors with SID-technology
AVL Sensor Data Connector (TEDS)
Monitoring of the connected sensor only in combination with the AVL SID
On-board storage for amplifier settings and sensor parameters
Ground-loop suppression by full galvanic isolation between signal input and output
Switchable ground potential for mass isolated sensors
Robust mechanical design for use on test beds and in vehicle
Technical Insight
Dimensions W x H x D
Power supply
Sensitivity
Linearity error
Upper cut off frequency of low pass
Resolution for gain factor
Output voltage
Temperature range

8.01.07

220 mm x 40 mm x 230 mm
9.5 V ... 36 V DC
8 ... 800pC/V
< +/- 0.01% FS
12, 50 or 100 kHz; remote controlled setting
16 Bit
-10V ... +10V
-40C+60C (-40F..+140F)

MICROIFEM 1HU/19'' RACK TRAY INCL.


CABLE
TI04FRMT1B.01

The microIFEM (micro Indicating Front End Module) rack mount offers space for 2 microIFEM
modules for mounting in a 19 rack and includes microIFEM cascading cable set.
If mounting in a 19-rack or cable boom is required this rack mount allows convenient fixation of
one or two microIFEMs on a tray with 1 HU.

Your Benefits at a Glance

Space to house up to 2 microIFEM amplifier modules


Convenient 19 rack mounting

Technical Insight

Size: width x height x depth = 448 mm x 44 mm x 195 mm


depth ~ 250 mm with connectors and cables
Cable 24V rack to rack

66

Cable RS232 rack to rack:


Length 0.3 m
appropriate connectors

Notes

If just one microIFEM is mounted the use of the MICROIFEM BLIND COVER 9,5
TI04FRCOVA.01 is recommended.
microIFEM cascading cable set serves as connection to the microIFEM. Ensure that the
maximum continuous current of the supply connector doesnt exceed 8A, (e.g. 24 V DC power
supply: 16W / 24V = 0.67A, i.e. 9 Racks can be cascaded.)

8.01.08

EXTERNAL POWER SUPPLY 24VDC, 70W


TI04FPOSUA.02

External 24V-power supply unit for max. 4 microIFEM amplifier modules (depending on ambient
temperature).

Technical Insight

Input voltage range


output power

100 - 240VAC (50 - 60Hz)


3A at 24VDC (70 Watt)

Compatibility

In case several microIFEM second generation (.02) are used simultaneously following max.
ambient temperatures are allowed:
4 devices: Tmax = 45C
3 devices: Tmax = 50C
2 devices: Tmax = 55C
1 device: Tmax = 60C

8.01.09

GLOW PLUG ADAPTOR DESIGN COST


TIAGDESA.01

Design cost for manufacturing drawings and clarification of the neccessary dimensions for Glow
Plug Adaptors AG03 and AG04 and Glow Plug Sensor GU13G.
Please advise with order the precise dimensions of the installation bore. Use the Table of
Dimensions sheet in the sensor folder or in www.avl.com/sensors Adapter for this purpose.

8.01.10

HIGH PRESSURE INDICATING SET


GH12P/AG03
TI0600HME.02

Transducer, adaptor, cables etc. for measurement of combustion chamber pressure in diesel
engines by means of Pressure Measuring Probe GH12P in conjunction with glow plug adaptor
AG03 without machining the cylinder head.

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The transducer is mounted to the engine via a glow plug adaptor included in the set. For signal
processing a free input channel with charge amplifier must be available per indicating system.
The outer shape of the AG03 is performed according to the dimensions original glow plug and
its installation bore. When ordering a glow plug adaptor, AVL would need the precise
dimensions of the glow plug and installation bore. Please use the Table of Dimensions sheet
in the sensor folder or in www.avl.com/sensors. After check of these dimensions the drawing for
manufacturing is created.
Your Benefits at a Glance

No machining of the cylinder head necessary


High signal quality due to virtually flush mounted sensor
Lowest pipe oscillations
High accuracy due to GaPO4 measuring element
High sensitivity due to GaPO4 measuring element

Technical Data
Pressure Measuring Probe GH12P
Measuring Range (FSO)
Sensitivity (nominal)
Linearity
Operating Temperature Range
Mounting Thread
Glow Plug Adaptor AG03
Mounting Thread

8.01.11

0...250 bar / 2900 psi / 20 MPa


15 pC/bar / 1.03 pC/psi / 150 pC/MPa
</= +/- 0.3 % FSO
up to 400C (750F)
M5 x 0.5
>= M10

THERMO PROTECTION PH01


TIYF0592A.01

Thermo Protection for use with Transducers GM12D, GH12D, GU12P, GU12S and GU13X.
The Thermo Protection PH01 is to be used in case of extreme thermal load (knock analysis at
petrol engines; highly supercharged engines) or in cases where transducer accuracy is of
utmost importance.
The Thermo Protection reduces the combustion-gas quantitiy which is pulsing in the area of the
sensor membrane and withdraws its heat, so that the thermal load of the membrane is reduced.
Thus the membrane is protected and the cyclic drift of the transducer is reduced by approx.
50%.
In sooting engines (Diesel, GDI) the catch of the small bores of the Thermo protection or the
filling of the space between the membrane and the thermal protection has to be taken into
account and can be avoided by carrying out proper cleaning intervals.

Your Benefits at a Glance

Transducer protection against thermal overload


Reduction of the cyclic drift by approx. 50%

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8.01.12

SET OF MOUNTING TOOLS TS01


TIWG0121A.01

Set of mounting tools TS01 for proper installation of Miniature Pressure Transducers
GM12D/GH12D, Pressure Measuring Probes GU12P/GU12S and Dummy DG01.

8.01.13

BOX SPANNER TA16


TIWG0200A.01

Box spanner TA16 for proper installation of Pressure Transducers SL31D2000, SL31D200 and
Glow Plug Adaptor AG03.

8.01.14

COMMISSIONING INDIMODUL 621


TI0621IBNA.01A1

Commissioning of an IndiModul 621 light (AVL scope of supply) and a subsequent 2 days
onsite training.
Introduction in functions and operation, on the basis of a single visit not later than 5 months
after delivery.

Notes

Travel and accommodation expenses for the AVL employee(s) are included
Interpretation/translation is to be provided by the customer (exception: German, English).

Pre-conditions

The system will be available without interruption from the time of arrival of our staff during
the entire service intervention.
The engine will be operational before arrival of our staff and correctly fitted with all the
necessary pressure and displacement transducers as well as the angle encoder.
For demonstration of the data transfer the appropriate computer system will be available and
operational.
Any additionally required extra time due to non respect of the above mentioned requirements
will be invoiced separately.

9.00.00
9.01.00

CONDITIONNING UNITS
COOLANT CONDITIONING SYSTEM
CONSYSCOOL
TP24A.00

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Coolant Conditioning System ConsysCool


The Coolant Conditioning Systems AVL ConsysCool with primary or secondary circuit control
are used for engine test beds for conditioning the engine coolant temperature to a predefined
value and maintaining it within tight tolerance limits.
The PID controller function is executed either by the test bed host (e.g. AVL PUMA System), the
internal PLC (ConsysCool 200) or an external controller rack with PID controller (available on
request).
Particular advantages are the control accuracy, fast response and modular design.
The AVL ConsysCool Coolant Conditioning System is integrated into the engines coolant circuit
instead of the normal radiator.

9.01.01

CONSYSCOOL S 200
TP24BB000A.01

The coolant conditioning system AVL ConsysCool S 200 with secondary circuit control is used
for cooling the engine coolant to a free definable temperature within tight limits, independent
from the operating state. The control is done by the PUMA System.
The AVL ConsysCool S 200 is suitable for engine test beds with engine ratings up to approx.
230kW.

AVL Coolant Conditioning System ConsysCool S 200


Symbol

Your benefits at a glance:

High control accuracy and control dynamic


Underfloor usage without unit change possible
High quality and quality rating through stainless steel piping
Favorable price through reduction upon controlled cooling
Optional connection of the system to a test bed automation system
(e.g. AVL-PUMA) or an external PID- controller

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Technical data:
Main data:
Dimensions (L x W x H): approx. 750x600x450 mm
Dimensions with attachments (L x W x H): approx. 960x620x450 mm
Weight: approx. 90 kg
Ambient conditions:
Ambient temperature: 0 to 40 C
Air humidity (rel.): 20 to 80 %, not condensing
Primary circuit:
Nominal cooling capacity (QC): 200 kW
Operating temperature (TB): 10 to 140 C
T- control range nominal (TR): 70 to 125 C
T- control range advanced (TR): 20 to 125 C
Control accuracy (engine inlet): 0,7 C or higher *)
Control accuracy (engine outlet): 2 C or higher *)
Pressure loss at v(Nom) = 12 m/h (p): approx. 0,2 bar (excl. feeding)
Max. system pressure: 6 bar
Max. mixture ration water/glycol: 50/50
Coolant capacity in unit: 8 l
Secondary circuit (cooling water requirements):
Temperature at unit inlet: 0 to 30 C
Pressure: min. 2,5 bar, max. 6 bar
Pressure loss max. 1,5 bar
Max. glycol content: max. 5 %
Recommended water hardness: 7 8 dH
Connections engine side (primary circuit):
Nominal width (DN): 1"
Nominal pressure (PN): 6 bar
Connections cooling water side (secondary circuit):
Nominal width (DN): 1"
Nominal pressure: 6 bar
Pneumatic connections:
Nominal width hose (DN): (int.) 4 mm; (ext.) 6 mm
Minimum pressure (pmin): 4 bar
Maximum pressure (pmax): 6 bar
Electricity:
Voltage (U): ~ 2 x 400 VAC 10 %
Frequency (f): 50 / 60 Hz 1 % (permanent)
2 % (short term)
Connection power (P): appr. 0,1 kW
Protection class: IP 54
*) The coolant temperature stability might exceed the given values. Higher fluctuations might
occur due to too small engine coolant flow, typically at engine idle or with small engines.
Additional requirements:
Additional requirements for unit operation:
1 channel FEM A
1 channel FEM DAC

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1 PID software controller in PUMA system


The unit is suitable for the use with all PUMA 5.x and PUMA Open versions.
Alternatively the external controller rack can be used.

9.02.00

SUPPLY SYSTEM FOR RESEARCH


ENGINES
TF0576A.00

The AVL 576 oil and water conditioning unit is specially designed the AVL Single Cylinder
Engines series 530.

The system comprises of

Cooling water supply system: for the automatic control of the cooling water temperature
Lubricating oil supply system for the automatic control of the lube oil temperature. Supplies
oil to the power train, valve train, gear train and balancer shafts of the research engine.

9.02.01

SUPPLY AND CONDITIONING UNIT 577


TF0577A.01

For coolant and lube oil supply of the AVL Single Cylinder Engines series 540 and 580 or Single
Cylinder Research Engines up to approx. 1 litre swept volume.

The AVL 577 oil and water conditioning unit is specially designed for Single Cylinder Engines
and allows control of the cooling water temperature and the oil temperature independently while
heating or cooling. The temperature control via set values is realised by the integrated PID
controller in the switch box. The oil and coolant connections as well as the electrical signal
connections and mains are equipped with quick All components and the switch box are
mounted on a common frame.

AVL 577 oil and water conditioning unit

72

Your Benefits at a Glance

Maximum operating comfort allows temperature control of both oil and coolant
independently while heating or cooling
Quick connectors for lube oil, coolant and electrical cables and mains
Small, compact cubic design
Integrated PID controller on switch box
Technical Insight
Operating range of the unit:
Oil circuit:
Temperature control range
Cooling capacity (nominal)
Heating capacity (preheating)

40* - 120 C (+/- 1 C) Pmax. 5 bar


6 kW
4 kW (not to exceed max. control temperature)

Coolant circuit:
Temperature control range
Cooling capacity (nominal)
Heating capacity (preheating)

50* - 110 C (+/- 1 C) Pmax. 1.4 bar


40 kW
3.5 kW (not to exceed max. control temperature)

* under the assumption that the temperature of the supplied external cooling water on
customers test bed is below 30 C

Supply voltage
Connecting power
Protection class
Dimensions W x H x D
Weight
Cooling water quantity
Cooling water pressure

AC 3 x 400 V N/PE +6%/-10% PE 50/60 Hz


9.5 kW
IP54
approx. 600 x 750 x 1100 mm
approx. 150 kg
3

min. 3m /h
min. 2 bar (at inlet when using an open water circuit)
max. 6bar
Cooling water hardness
< 5 dH
Maximum permitted content of suspended solid matter < 20 mg/litre

Notes

The conditioning unit with internal oil tank is designed for connecting to combustion engines
with dry sump oil circuits only. No oil return suction pump is used engine oil return line only by
natural height difference.

9.03.00

EXHAUST BACK-PRESSURE
ADJUSTMENT
TP35D.00

Kit for the remote control of the exhaust back pressure of combustion engines, suitable for use
at an engine test stand.
The remote control function will be provided by the test stand computer (e.g. AVL-PUMA
system.) Alternatively an adequate potentiometer can be used (available on request).

73

9.03.01

EXHAUST BACK-PRESSURE
ADJUSTMENT 80
TP35AR000A.01

Kit for the remote control of the exhaust back pressure of combustion engines with a power of
up to 250kW, suitable for use at an engine test stand.
The control of the exhaust gas back pressure will be done manually (remote controlled) by a
control flap which is integrated into the engine test bed exhaust system. The exhaust gas
pressure is adjusted during engine full load operation typically.
The remote control function is provided by the test stand computer (e.g. AVL-PUMA system).
Alternatively an adequate potentiometer can be used (available on request).

Your benefits at a glance

Easy adjustment of the exhaust gas pressure at engine full load operation for different
engine sizes to be operated on the test bed

Technical Insight

The kit consists of an adjustment flap NW 80, housing GGG40, flap and
shaft 1.4301, operating temperature max. 650C, with connection flanges for the installation in a
customer supplied exhaust system.
The flap adjustment is done by an electrical actuator. A stainless steel mounting console is
provided to fix the flap onto the engine test bed base plate or the test cell floor.
Interfaces:
Input:
Adjustment signal (0-10V)
Electrical connections: 230 VAC / 15 W - 50Hz
Design and dimension similar to drawing no 5490M00A/D00V0

10.00.00

SINGLE CYLINDE ENGINE


CONVERSION GASOLINE TO
DIESEL

This offer describes the conversion of an AVL SCRE 5403 GDI to a standard AVL SCRE 5402
CR Diesel DI engine.
For this purpose the existing SCRE 5403 GDI which is at TU-Cluj has to be sent free of
charge to AVL Graz for conversion to Diesel Direct Injection and CommonRail Fuel injection
topworks with functional test run.

10.01.00

AVL SINGLE CYLINDER RESEARCH


ENGINE 5402
TF5402A.00

74

The AVL 540 passenger car size single cylinder engine is an excellent tool for research and
development of combustion concepts, hardware parts, injection systems, EMS etc by highest
flexibility for realising various engine versions - standard or customised.
The Basic Unit 5400 can be used for completion with different topworks within a certain
bore/stroke range. The typical sizes are:
Bore
Stroke
Swept volume
Max. speed
Max. combustion pressure

65 100 mm
60 95 mm
0.20 0.75 litre
8000 rpm
150 bar (at bore 95 mm)

The basic unit could be offered as a standard version (AVL 5401 gasoline port injection, AVL
5402 diesel with CR or AVL 5403 gasoline direct injection) or can be completed to a single
cylinder engine with customer specific hardware parts.

AVL Single Cylinder Research Engine 5402


Recommended Options / Extensions:
st

Balancer system: mass balancer 1 order


Starting system: starter with starter ring gear
Conversion kit for optical topworks 514

10.01.01

COMPONENTS CONVERSION
RESEARCH ENGINE 5403 GDI TO 5402
DIESEL DI CR
TF540ASTA.0101

Description of the AVL 5402 CR Diesel DI engine:

DOHC 4-valve single cylinder research engine for Diesel 4-stroke operation with Common-Rail
injection and control unit comprising the AVL Basic Unit 5400.

Your Benefits at a Glance

75

Engines can be equipped with state-of-the-art or even future engine technology


Exact replication of customer specific multi cylinder engines ensure excellent correlation to
the production engine
Conversion to well proven optical topworks possible to allow the application of modern laser
supported measuring techniques

Technical Insight

Crankcase:
Rigid structure in cast iron with 2 underslung main bearings. Separate aluminum housings
contain the front and rear oil seals.
Crankshaft:
Manufactured from a steel billet and nitride hardened. Flywheel flange mounted and bolted to
the crankshaft.
Cylinder block/-liner:
Cast iron cylinder block contains the replaceable cylinder liner and supports the cylinder head
assembly.
Cylinder liner:
Cast iron, design uses a top flange location and double O-ring coolant sealing at the base.
Cylinder head:
Special unit casting in aluminum. 4-valve design with a unique swirl port concept and double
overhead camshaft acc. to the AVL-LEADER engine. The valves are inclined by 3.5 degrees.
Advantages:
more space for a Unit Injector installation (if required)
less dead volume at the seat rings
bigger seat diameter possible
Two different intake ports, a helical and tangential, are used. This combination enables optimum
positioning of the ports. The cylinder head is prepared for the installation of a cooled pressure
transducer type AVL QC3XC dia 10mm or equal uncooled version.
Camshaft drive:
Special camshaft drive pulleys with internal adjustment possibility for easy changing of valve
timing, adjustable tensioner.
OPTION: Common-Rail Injection equipment (BOSCH CP1 1600 bar)
NOTE: The visualisation software INCA and a measuring and control unit ES690 for access to
the ECU are not included in this offer.
Bore
Stroke
Swept volume
Max speed
Max. BMEP
Max. output

85 mm
90 mm
510 cm3
4200 rpm
~ 14 bar at 2300 rpm / supercharged operation
~ 19 kW at 4200 rpm / supercharged operation

Rotation inertia approx. 0.4 kgm

Note

76

The engine series 540 requires external supply systems for coolant and lube oil with electrically
driven pumps for example the AVL577 oil and water conditioning unit which can be offered
separately.

Scope of Supply for upgrade of SCRE

Each consisting of:

1 Crankshaft assembly, stroke 90 mm


1 Assembly for Diesel CR DI Topworks
1 Cylinderblock / liner assembly, bore 85 mm
1 Cylinder head assembly incl. inlet and exhaust camshaft
1 Camshaft drive
1 Set mass balancer weights
Following components of the existing AVL 5403 GDI SCRE will be reused for upgrading the
engine to Diesel DI CR topworks:
crankcase, upper and lower part with mass balancing system (except mass balancer
weights)
flywheel with flywheel cover

10.01.02

AVL CR FUEL INJECTION EQUIPMENT


FOR SCRE 5402
TF540ASTA.0102

Common-Rail Injection equipment (BOSCH CP1 1600 bar) und 3 injections per cycle (pre, main
and post). Open ECU system (AVL) with full access to injection parameters like SOI (start), DOI
(duration), PRAIL (railpressure) with maps.
NOTE: The visualisation software INCA and a measuring and control unit ES690 for access to
the ECU are not included in this offer.

Scope of Supply for upgrade of SCRE

Each consisting of:

1 CR injection equipment: incl. solenoid injector / rail /high-pressure pump /control unit / sensors
/ wiring loom / fuel lines / safety mechanical overpressure valve, etc
TM
1 AVL RPEMS : open ECU based on BOSCH MES-5 with AVL Software

77

10.01.03

ENGINE CONVERSION 5403 TO 5402 AND


FUNCTION TESTING
TF540ASTA.0103

Engine conversion from AVL 5403 GDI to 5402 CR DI version with components from items
above.
The 5403 engine hast to be sent to Graz FOC for this conversion. After disassembly the Diesel
components will be assembled on the crankcase housing.
The engine will be functional tested on an AVL test bed before delivery.
The testing will be reported with measurement values as:
Power
Torque
Speed
Indicating: max. in cylinder pressure, IMEP
Injection timing parameters
Several Temperatures and Pressures

10.01.04

ETAS ES690 AND INKA


TF540ASTA.0104

for access to injection parameters on BOSCH ECU for adjustment.

11.00.00

OPTICAL ACCESS SYSTEM FOR


COMBUSTION RESEARCH

Technical University of Cluj is planning to use a single cylinder diesel engine for the
investigation of fuel injection, mixture formation and combustion events. For this purpose, AVL
has provided a quotation to upgrade an existing gasoline single cylinder engine with a diesel
cylinder head.
For the purpose of optical in-cylinder spray and combustion analysis Cluj and AVL have
identified the AVL VisioScope system as most suitable. This is offered in a separate standard
quotation.

78

As an alternative to the standard VisioScope quotation, AVL can offer an economized


VisioScope package( AVL VisioScope Economy ) which fulfills following tasks:

Illumination and View into the combustion chamber by means of 1 bore and the all in
one endoscope.
Straight view endoscope
Pixelfly color camera
Electronics
PC and VisioScope software
Thermovision advanced flame evaluation SW

All components are part of the standard VisioScope system. Therefore, any future expansion of
the system can be accomplished on basis of this economy system.
Adaptation of endoscope bore to cylinder head: is part of the deliverables in the quotation for
the diesel engine cylinder head.

11.01.00

AVL VISIOSCOPE
TFIMAGERA.00

The AVL VisioScope is a new generation of imaging system for the development of combustion
engines. The system incorporates the latest camera technology with an extended image
processing software for enhanced optical diagnosis of combustion and injection phenomena.
The high dynamic range of the camera allows observation of phenomena with low light
radiation. The system goes far beyond the pure observation of engine phenomena by providing
extensive post processing functions, thus opening up new methods of visual analysis.

AVL VisioScope

79

11.01.01

VISIOSCOPE SYSTEMHARDWARE
TKSASTA.0101

The AVL VisioScope is a fully digitized triggerable imaging system for combustion research and
development. The system components are based on latest technology available for camera and
PC.

The system visualizes and records images of injection and combustion processes, in addition
mechanical motion of components can be investigated in both diesel and gasoline engines.
Proven endoscope technology provides a high degree of flexibility for adaptation and enables
optical access to almost all parts of the engine, without effecting engine operation.
Your Benefits at a Glance

Application on any gasoline or diesel combustion engine


Engine operation without restrictions
Optical access to the combustion chamber with almost no combustion interference
Visualization of temperature distribution of diesel flames (option)
Observation of flames and illuminated phenomena in engines
Digitized image transmission from camera to PC without quality loss
Automatic protocolling of all relevant data and camera adjustments
Automatic animation of recorded images
Powerful picture processing capabilities
Possibility of connecting high sensitive cameras

Technical Insight
Picture resolution: 640 x 480 pixel, color
Dynamic resolution: 12 bit (4095 steps)
Max. shutter speed: 10 micro to 10 milliseconds

11.01.02

THERMOVISION ADVANCED DIESEL


APPLICATION
TF0513DTVA.03

Software package for the calculation and display of spatial temperature distribution of a sooting
diesel flame. In addition large data sets can be evaluated automatically.
The software package Thermovision Advanced processes a number of measurements
automatically. The concise presentation of the flame temperature or the soot density versus
crank angle permits easy comparison of engine operation conditions.
The temperature is calculated offline from images of the diesel flame taken with the calibrated,
digital RGB camera of the VisioScope. The temperature and soot density calculation is based
on the 2-colour method with the model of a local homogeneous distribution of soot density.

80

Technical Insight
The diesel flame temperature or soot density images created by Thermovision Advanced
Software are split into zones which correspond to different combustion regimes (spray torch,
end gas) or other regions of interest. Within these zones an integral value of the flame
temperature respectively soot density is evaluated for every detail screen. These results are
saved in a spread sheet.
Results evaluated by Software ThermoVision (ThermoVision Statistics) can be exported as IFile for evaluated by CONCERTO. So temperature and soot density distributions can be
presented versus time (CA). Individual engine operating points therefore can be compared to
each other easily
The calculation of the temperature is carried out in two stages:
calibration of the image record
thermographic analysis
During the first processing stage, an optical correction factor can be defined either automatically
or manually. The correction factor allows the local layer thickness to be unambiguously
identified in the subsequent temperature analysis.

12.00.00

12.01.00

TESTBED 2: COLD TEST


CHAMBER
COLD CHAMBER
TESIN3000.00

12.01.01

COLD CHAMBER
TESIN6500.0101

Consisting of an isolated chamber with thermal panels, and access door for engine trolley, and
the cooling equipment to keep the temperature inside the room at -30C, and able to cool down
the engine from the initial temperature (estimated 25C) to the start temperature (-30C) in a
period of 30 hours. After the engine start, the inside temperature is not controlled.
Evaporator will be installed inside the chamber, hanging from the roof. Compressor and
condenser in the building terrace.

81