MAN Diesel & Turbo

PMI Offline
Operation
User’s Reference Guide

This guide is part of a series of information guides which explains how to use the PMI Offline system and
software program:

Summary of Menus & Wizards

Operation
System Components Overview
Commissioning
2017.03.28

NOTICE

This edition of the manual applies to PMI 1703. Some screen shots are taken from earlier PMI versions.

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1 Contents
2 PMI Offline ................................................................................................................................................. 3
3 Getting Started ........................................................................................................................................... 3
3.1 System Overview ............................................................................................................................... 3
3.2 Quick Guide on Using PMI Offline ..................................................................................................... 4
4 Measuring and Viewing Cylinder Pressures ............................................................................................... 7
4.1 Perform a Manual Measurement ...................................................................................................... 7
4.2 Viewing Stored Measurements ....................................................................................................... 10
4.2.1 View a Saved Measurement ........................................................................................................ 10
4.3 Printing Stored Measurements ....................................................................................................... 12
4.3.1 Print View .................................................................................................................................... 12
4.3.2 Print Report ................................................................................................................................. 13
4.4 Backup and Restore ......................................................................................................................... 14
4.4.1 Back up Database ........................................................................................................................ 14
4.4.2 Restore Database......................................................................................................................... 15
4.5 Tuning of Engine Performance ........................................................................................................ 16
4.5.1 Introduction ................................................................................................................................. 16
4.5.2 General Adjustment Sequence .................................................................................................... 17
5 Appendixes ............................................................................................................................................... 19

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2 PMI Offline

PMI Offline is designed to provide engineers and service staff on test bed, onboard ship and at power
plants with a computerised tool for cylinder pressure measurements on MAN Diesel’s two-stroke diesel
engines. Its primary purpose is for:

 Engine performance tuning – based on observed changes in the combustion characteristic

parameters Pmax, Pcomp, and Pi
 Commissioning of ME / ME-B engines
 Fault finding and analysis of the combustion process

Serving a secondary purpose, PMI Offline provides an estimate of the engine shaft power.

3 Getting Started

3.1 System Overview

PMI Offline consists of a data acquisition unit (PMI-DAU), a pressure sensor, a PMI Calibration Box, a trigger
and TDC pulse generator (Tacho system), and the PMI system software (see Figure 1). The data acquisition
unit receives the measured combustion pressure cycles from the pressure sensor and forwards the
processed data to the PMI PC for storage, visualisation, and analysis.

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PMI Calibration Box Pressure sensor

Cylinder pressure measurements

Manual adjustment

CJB

TSA-A
CJB: Calibration Junction Box
TSA-A: Tacho System Amplifier
Tacho system

Two-stroke
diesel engine
Data Acquisition Unit
PMI-DAU

Data visualisation,
analysis & storage

PMI/CoCoS-EDS PC

Figure 1: PMI Offline System

3.2 Quick Guide on Using PMI Offline

From the PMI application you can:

 Record cylinder pressures and store them for later analysis (Figure 2)
 Commission the PMI System (Figure 3)

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Measurement views Make a new pressure

measurement
Measurements
stored in database

View saved
measurements

Figure 2: Viewing saved measurements in the Measurements menu

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Check an electrical Check trigger input

Perform a task
connection and configuration

View engine specifi-

cations used by PMI

Wizards and
Utilities

View set-up measurements and

configuration data used by PMI

Figure 3: The Tools sub-menu contains wizards and commands for performing various tasks

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4 Measuring and Viewing Cylinder Pressures

The PC program contains wizards to help the user perform various tasks. This section will provide a brief
description of the most common operations used in the PMI Offline program.

4.1 Perform a Manual Measurement

To measure the pressure in one or more cylinders, use the Perform a Manual Measurement wizard. The
wizard will guide you through each step required to make a cylinder pressure measurement.

Please refer to the appendix for a brief description of the PMI Calibration Box.

a. Start the wizard

To start the wizard, follow the steps shown in Figure 4:

2 Select

1 Select

Figure 4: Starting the Manual Measurement wizard from the Measurements menu

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Alternatively, the wizard may also be started from the Maintenance menu, using the steps shown
in Figure 5:

2 Select

3 Click

1 Select

Figure 5: Accessing the Manual Measurement wizard from the Maintenance menu

b. Follow the wizard

Read the welcome text and click “Next >” when the system has finished initialising. In the next
window, Figure 6 , the system is waiting to receive measurements. To make a pressure
measurement, follow the steps in the order given below.

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1 Attach

Indicator valve

2 Open

3 Verify green

5 Wait for Results

4 Press ’OK’

PMI Calibration Box

Figure 6: Operations involved in performing a manual measurement

Steps (Figure 6)

1) Attach pressure sensor to cylinder.

2) Open indicator valve.

Note: If this is the first cylinder being measured, make sure the sensor has reached working
temperature by keeping the indicator valve open for one minute before proceeding to the next
step.

3) Verify that ‘Ready’ green lamp is on – not flashing. A steady light indicates ready for
measurement.
4) Press “OK” button to start a measurement. The flashing ‘Ready’ lamp indicates the system is
measuring.

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5) Wait to receive pressure curve.

Note: If a measurement is not successful, the red Error indicator lamp on the PMI Calibration
Box will turn on. Check the Event Log on the PC screen for additional information and
instructions.

Close the indicator valve when the measurement appears on the screen. Then move to the next
cylinder to be measured and repeat the previous steps.

When all measurements have been completed, click “Next >” and follow the wizard to completion.

4.2 Viewing Stored Measurements

4.2.1 View a Saved Measurement
All saved measurements are stored in the database. To view any previously saved measurement, follow the
steps in Figure 7.

2 Select measurement

Select view 3

1 Select

Figure 7: Viewing key pressure values from a stored measurement

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Viewing Modes (Step 3, Figure 7)

Menu Items Description

Key pressure values from each cylinder and power output are listed in tabular
form.

Adjustment recommendations for balancing cylinder pressures requiring the

least number of steps to bring within specifications. Available only for MC
engines.
Key pressure value deviations from the ‘mean’ values are shown for each
cylinder.

Cylinder pressures are plotted relative to each cylinder’s TDC angle.

Cylinder pressures are plotted against the crankshaft angle.

Cylinder pressures are plotted against the relative cylinder volume.

A series of cylinder pressure curves are plotted through 10 crankshaft

revolutions. Each curve represents the actual signal measured at the sensor.

To reduce the effects of noise, a series of 10 consecutive pressure curves (raw data) received from the
sensor are averaged, and the resulting curve is rendered in the PV, P-CA, and PT diagrams. The averaged
curve also forms the basis for calculating all the key parameters shown in the Key Values table and the
Balance plot. Each of the 10 consecutive curves that form the average is rendered in the “PT (Raw Data)”
menu.

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4.3 Printing Stored Measurements

Graphs, tables, and engine set-up information from stored measurements can be printed in two ways:

 Print View
 Print Report

4.3.1 Print View

A selected graph or table from a stored measurement is printed on a single page together with engine
performance information.

Follow the steps in Figure 8 to print a specific graph or table.

Select measurement 2 4 Click

Select a view 3

1 Select

Figure 8: Printing a selected graph or table from a stored measurement

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4.3.2 Print Report

All graphs and tables of the selected measurement are printed in a multi-page report format.

Follow the steps in Figure 9 to print a report for a selected measurement.

3 Click

2 Select measurement

4 Select items

1 Select

5 Click

Figure 9: Printing a report from a selected measurement

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4.4 Backup and Restore

All measurements and engine configuration data are stored in the PMI database. The database can be
backed-up locally to another folder location on the PC hard disk or to an external drive to prevent loss of
data in case of a system failure. A previously backed-up database can be restored or loaded into the PMI
Offline program.

4.4.1 Back up Database

To back-up the database, follow the steps in Figure 10.

2 Select

4 Click

Click 3

1 Select

Figure 10: Storing a backup copy of the database to a selected location

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4.4.2 Restore Database

To restore a previously backed-up database, follow the steps in Figure 11:

2 Select
4 Select database

5 Click

3 Click

1 Select

Figure 11: Replacing the current database with another

Warning: Restoring a database will cause the currently active database to be overwritten. All data
and measurements in the current database will be lost.

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4.5 Tuning of Engine Performance

4.5.1 Introduction
Tuning the combustion process for best performance consists of two operations:

 Balancing cylinder pressures to minimise deviation from mean

Cylinder pressure

Mean

Balancing

Non-optimized engine Balanced engine

 Adjusting cylinder mean pressures to ensure engine operation at the “ordered” (design) level.

Cylinder pressure

Ordered mean
Current mean

Mean adjustment

Non-optimized engine Mean pressure tuning

To perform the above operations, two adjustment methods are available depending on the type of engine:

1. ME & ME-B engines

Cylinder pressures are adjusted in the Process Adjustment menu of the Main Operating Panel.

2. MC engines

Cylinder pressures are adjusted directly on the fuel pump via the fuel index and VIT controls. On
small bore engines, shims are inserted or removed from the fuel pump.

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4.5.2 General Adjustment Sequence

4.5.2.1 ME & ME-B Engines

Check Pi
STEP 1
Low Load Balance Pi
Low Load

MOP
PMI PC

Check Mean Check Pi

STEP 6 Adjust Mean
Pmax STEP 2 High Load
Pmax Balance Pi
High Load
Measure
MOP
MOP
PMI PC PMI PC

Me
as ure
ure as
Me

Me
ure as
as ure
Me
Measure

Check Pmax Check Pcomp

STEP 5 STEP 3 balance Balance
balance
Balance Pcomp
Pmax

MOP
MOP PMI PC
PMI PC

Check Mean
STEP 4 Pcomp
Adjust Mean
Pcomp

PMI PC MOP

Figure 12: ME engines - general tuning adjustment sequence

On ME and ME-B engines without the PMI Auto-tuning option, cylinder pressures are manually adjusted
using the ECS MOP. The recommended adjustment sequence is illustrated in Figure 12. First, balance the
cylinder load. Then, balance the cylinder pressures Pcomp and Pmax followed by an adjustment of the mean
pressure level by raising or lowering the mean level to within the running specifications at the given load.
Each step in the figure involves taking a complete set of manual cylinder pressure measurements, analyzing
the results in the PMI PC, making the necessary adjustments in the ECS MOP panel, and verifying the
results. See Appendix B for further information.

Important: Always consult the specific adjustment procedure in the engine operation manual before
proceeding.

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4.5.2.2 MC Engines

Figure 13: MC engines - general tuning adjustment sequence

On MC engines, the cylinder pressures are adjusted depending on the type of fuel pump. This will involve
one or more of the following manual adjustments to the fuel pump: index, shim or VIT. Figure 13 illustrates
the general adjustment procedure. The procedure may vary depending on your particular engine.

Important: Always consult the specific adjustment procedure in the engine operation manual before
proceeding.

In Figure 13, Pmax is adjusted first to prevent bearing overload followed by adjusting Pi. Each step in the
figure involves taking a complete set of cylinder pressure measurements, analyzing the results, making the
necessary adjustments, and verifying the results. See Appendix C for further information.

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5 Appendixes

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Appendix A: Elements of the ECS MOP Pressure Adjustment Screens

A.1 Cylinder Load Tab

Cylinder adjustment button Horizontal tabs

0 0 0 0

Adjustment panel

Adjustment range (% SMCR)

Offset adjustment value

Figure 14: Cylinder load offset adjustment window

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A.2 Cylinder Pressure Tab

Mean adjustment button Cylinder adjustment button Horizontal tabs

0 0 0 0

Adjustment panel

Adjustment range (bar)

Offset adjustment value

Figure 15: Cylinder pressure offset adjustment window

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Appendix B: ME & ME-B Engine Tuning and Adjustments

B.1 General Adjustment Sequence

Check Pi
STEP 1
Low Load Balance Pi
Low Load

MOP
PMI PC

Check Mean Check Pi

STEP 6 Adjust Mean
Pmax STEP 2 High Load
Pmax Balance Pi
High Load
Measure

MOP
MOP
PMI PC PMI PC

Me
as ure
ure as
Me

Me
ure as
as ure
Me
Measure

Check Pmax Check Pcomp

STEP 5 STEP 3 balance Balance
balance
Balance Pcomp
Pmax

MOP
MOP PMI PC
PMI PC

Check Mean
STEP 4 Pcomp
Adjust Mean
Pcomp

PMI PC MOP

Figure 16: ME engines - general tuning adjustment sequence

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On ME and ME-B engines without the PMI Auto-tuning option, the cylinder pressures can be manually
adjusted using the ECS MOP. The recommended adjustment sequence is illustrated in Figure 16. First,
balance the cylinder load. Then, balance the cylinder pressure Pcomp and Pmax followed by an adjustment of
the mean pressure level by raising or lowering the mean level to within running specifications at the given
load. Each step in the figure involves taking a complete set of manual cylinder pressure measurements,
analyzing the results in the PMI PC, making the necessary adjustments in the ECS MOP panel, and verifying
the results. Steps 1 & 2 are used to balance Pi at two different engine loads.

Important: Always consult the specific adjustment procedure in the engine operation manual before
proceeding.

B.2 Adjust Key Pressure Values

B.2.1 Balance Pi Low Load (step 1, Figure 16)

Make a pressure measurement

Run engine at lowest possible load where rpm is stable.

Using the PMI Offline program, make a pressure measurement on all cylinders

In the PMI program, check the Pi balance of the measurement you just made. Note the cylinders
that require adjustment.

Adjust cylinders

In the screen shown in Figure 17, adjust the fuel index of the cylinders requiring Pi adjustment.

Follow the steps shown.

Note: Adjustments are made in % SMCR.

Verify results

Make a new pressure measurement on all cylinders. Verify changes to the Pi balance. Re-adjust
cylinders again if necessary.

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2 Select

1 Select

3 Select cylinder

Offset Low Load – Cyl. 3

5 Press to confirm
4 Adjust

Figure 17: Steps for adjusting Pi low load offset on cylinder 3

B.2.2 Balance Pi High Load (step 2)

Make a pressure measurement

Run engine at 100% SMCR

Using the PMI Offline program, make a pressure measurement on all cylinders

In the PMI program, check the Pi balance of the measurement you just made. Note the cylinders
that require adjustment.

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Adjust cylinders

In the screen shown in Figure 18, adjust the fuel index of the cylinders requiring Pi adjustment.

Follow the steps shown.

Note: Adjustments are made in % SMCR.

2 Select
3 Select cylinder

1 Select

5 Press to confirm
4 Adjust

Figure 18: Steps for adjusting Pi high load offset on cylinder 3

Verify results

Make a new pressure measurement on all cylinders. Verify changes to the Pi balance. Re-adjust
cylinders again if necessary.

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B.2.3 Balance Pcomp (step 3)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the Pcomp balance. Note the cylinders that
require adjustment.

Adjust cylinders

Pcomp is adjusted by adjusting the Pcomp/Pscav ratio.

In the screen shown in Figure 19, adjust the Pcomp/Pscav ratio of the cylinders requiring adjustment.
Follow the steps shown.

2 Select

3 Select cylinder

1 Select

5 Press to confirm
4 Adjust

Figure 19: Steps for adjusting Pcomp/Pscav offset on cylinder 3

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Verify results

Make a new pressure measurement on all cylinders and check the Pcomp/Pscav balance. Re-adjust
cylinders again if necessary.

B.2.4 Adjusting Mean Pcomp (step 4)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the mean Pcomp level.

Adjust cylinders

Mean Pcomp is adjusted by adjusting the Mean Pcomp/Pscav ratio.

Adjust the mean Pcomp/Pscav offset as shown in Figure 20. Follow the steps shown.

Verify results

Make a new pressure measurement on all cylinders and check the mean Pcomp. Re-adjust cylinders
again if necessary.

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2 Select

Select 3

1 Select

5 Press to confirm
4 Adjust

Figure 20: Steps for adjusting mean Pcomp pressure

B.2.5 Balance Pmax (step 5)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the Pmax balance. Note the cylinders that
require adjustment.

Adjust cylinders

Adjust the Pmax pressure of the cylinders requiring adjustment as shown in Figure 21. Follow the
steps shown.

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2 Select
Select cylinder 3

1 Select

5 Press to confirm
4 Adjust

Figure 21: Step for adjusting Pmax offset on cylinder 3

Verify results

Make a new pressure measurement on all cylinders and check the Pmax balance. Re-adjust cylinders
again if necessary,

B.2.6 Adjusting Mean Pmax (step 6)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the mean Pmax level.

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Adjust cylinders

In the screen shown in Figure 22, adjust the Mean Pmax offset. Follow the steps shown.

3 Select 2 Select

1 Select

5 Press to confirm
4 Adjust

Figure 22: Steps for adjusting mean Pmax pressure

Verify results

Make a new pressure measurement on all cylinders and check the Pmax balance. Re-adjust cylinders
again if necessary.

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Appendix C: MC Engine Tuning and Adjustments

C.1 General Adjustment Sequence

On MC engines, the cylinder pressure is adjusted depending on the type of fuel pump. This involves one or
more of the following manual adjustments to the fuel pump: index, shim or VIT. Figure 23 illustrates the
general adjustment procedure. The procedure may vary depending on your particular engine.

Important: Always consult the specific adjustment procedure in the engine operation manual before
proceeding.

In Figure 23, Pmax is adjusted first to prevent bearing overload followed by adjusting Pi. Each step in the
figure involves taking a complete set of cylinder pressure measurements, analysing the results, making the
necessary adjustments, and verifying the results.

Figure 23: MC engines - general tuning adjustment sequence

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C.2 Adjust Key Pressures

C.2.1 Balance Pmax (step 1, Figure 23)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the Pmax balance. Note the cylinders that
require adjustment.

Adjust cylinders

On mechanical VIT-type fuel pumps, Pmax for individual cylinders is adjusted by turning the VIT index
arm on the fuel pump. To increase Pmax, adjust to higher VIT index (advance injection). To decrease
Pmax, adjust to lower VIT index (delay injection).

On shim-type fuel pumps, Pmax is adjusted for individual cylinders by inserting or removing shims on
the fuel pump

Verify results

Make a new pressure measurement on all cylinders and check the Pmax balance. Re-adjust cylinders
again if necessary.

C.2.2 Adjust Mean Pmax (step 2)

Make a pressure measurement

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, open the measurement and check the mean Pmax level.

Adjust cylinders

For collective adjustment of Pmax on all units, adjust the VIT air pressure to obtain the correct Pmax
pressure at the given load. On shim type fuel pumps insert or remove equally sized shims from
each fuel pump.

Verify results

Make a new pressure measurement on all cylinders and check the Pmax balance. Re-adjust cylinders
again if necessary.

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C.2.3 Balance Pi High Load (step 3)

Make a pressure measurement

Run engine at 100% SMCR.

Using the PMI Offline program, make a pressure measurement on all cylinders.

In the PMI program, check the Pi balance of the measurement you just made. Note the cylinders
that require adjustment.

Adjust cylinders

The mean indicated pressure for a cylinder is adjusted on the fuel pump index arm. Increase index
for a higher pi. Decrease index for a lower pi.

Verify results

Make a new pressure measurement on all cylinders. Verify changes to the Pi balance. Re-adjust
cylinders again if necessary.

Check again the mean Pmax pressure and verify if it is within specifications.

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Appendix D: Engine Shaft Power Estimation

PMI Offline uses the traditional “Constant Mechanical Friction Loss” method - described in the MAN Diesel
instruction books - for estimating effective pressure and effective power.

A typical accuracy is assumed within 2-3%, however, for some engine designs operating under certain
conditions, an accuracy of merely 4-6% may be expected.

Constant Mechanical Friction Loss Method

Method used for estimating the effective pressure and power is based on the assumption that losses in the
system are constant throughout the engine’s operating range:

𝑝𝑒 = 𝑝𝑖 – 𝐾

𝑤ℎ𝑒𝑟𝑒,

𝑝𝑒 ∶ 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 [𝑏𝑎𝑟]

𝑝𝑖 ∶ 𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 [𝑏𝑎𝑟]

𝐾 ∶ 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑑𝑒𝑝𝑒𝑛𝑑𝑖𝑛𝑔 𝑜𝑛 𝑒𝑛𝑔𝑖𝑛𝑒 (𝑡𝑦𝑝𝑖𝑐𝑎𝑙𝑙𝑦 1 𝑏𝑎𝑟)

This assumption gives a reasonable approximation to real life conditions and provides sufficiently robust
results well suited for configuration of the ME-ECS, evaluation and adjustment of engine performance, as
well as troubleshooting the combustion process under steady state operating conditions.

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Appendix E: PMI Calibration Box Description

1 2

4 3

7 6

8 5

9 10

Figure 24: PMI Calibration Box used for PMI systems based on PMI DAU-11

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Front Panel

Button or
Number Function
Light
1 [Ready] light  On: The PMI system is ready to make a measurement and waiting for a
user action.

 Off: The device is idle.

 Blinking: A pressure measurement is being processed and the user must

wait.
2 [Error] light  Off: The device is functioning without error.

 On: An error has occurred. See the LCD display.

3 LCD display Shows status information, user instructions, and error messages.
4 [F1] button Selects the Info menu which displays measurement status and user instructions.
5 [F2] button Selects the Test menu for testing if the LCD display and all LED lights are
operational.
6 [F3] button Selects the About menu. Displays calibration box and sensor information. Press
the button repeatedly to scroll the menu.
7 [OK] button  Starts a pressure measurement in a wizard session

 Acknowledges and clears an error condition if it is clearable.

8 [Power] light Indicates that the device is on. The PMI Calibration Box must be connected to
the Calibration Junction Box to receive power from the PMI-DAU.

Connections

Number Description

9 Connection to pressure sensor

10 Connection for cable leading to Calibration Junction Box

Note: This PMI Calibration Box automatically reads the sensitivity or gain of the pressure sensor. This data
is read online once the pressure sensor is connected to the PMI Calibration Box. Therefore, unlike earlier
systems, the user does not need to key in this information.

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Appendix F: Technical Data

Pressure Sensor (Type 6013CAQ03SF, source: Kistler)

Pressure range 0 … 250 bar

Overload 400 bar
Sensitivity ~-22 pC/bar
Linearity < ± 0.4 %FSO
Shock acceleration (max) 2000 g
Operating temperature range
Front part of sensor -50...350 °C
Hex-nut to connector -50...150 °C
Electronics in plug -50...90 °C
Sensitivity variation
200 + 150/-177°C ≤ ± 2.5 %
200 ± 50°C ≤±1%
Output impedance <100 Ω
Tightening torque 15 N·m
Weight 160g
Plug type Fischer 103

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