Electrical Syst Me

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MAN B&W Diesel A/S

Connection

and

Function Test

of electrical system

for ME Engine

July 2006

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Document id: 3090532-9.4.7 Connection and Function Test

1 Power Supply Check

5

1.1 MPC fuse specification

5

2 ID-key Boot Loader Program

5

2.1 Operation 5

2.1.1 Connections and settings – normal operation 6

2.1.2 Start-up normal operation 7

2.2 Programming the ID-key (Network Address)

8

2.2.1 Connections and settings – programming. 8

2.2.2 Programming Sequence for ID-Key 9

2.3 2.3 Troubleshooting LED messages

10

3 Network Test

11

3.1 3.1 Access to Service Terminal

12

4 Updating and Archiving MPC Parameters from the MOP

14

4.1 MPC Parameter update

14

4.2 Archiving Parameter Files

15

4.3 4.3 How to make a copy of ECU-A into ECU-B:

16

4.4 (for Soft Ware version 1.34 or later)

16 4.5 18

5 Connection test of I/O

18

6 Check of Serial Communication between RCS and ECS

18

6.1 How to inspect Serial communication between RCS and ECS

18

6.2 How to simulate values from ECS to RCS

18

7 Adjustment of encoder

19

7.1 Check Tacho system cable

19

7.2 Check of encoder adjustment.

20

7.3 Adjustment of encoder-clockwise

21

7.4 Check of tacho sensor at flywheel.

23

8 Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm

23

8.1 Connection test of ELFI valve without hydraulic pressure

23

8.2 Connection test of ELVA valve without hydraulic pressure

24

8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar)

24

8.4 Connection test of FIVA valve with hydraulic pressure (app. 175 bar)

25

8.5 Connection test of starting air valves

25

8.6 Test of main starting air valve manually on the MOP

25

8.7 Connection test of HCU oil leakage alarm

26

8.8 Hints for connection test and fault finding:

26

9 Test of Swash-plate pumps (Hydraulic-Pressure On)

29

9.1 Functions test

29

9.2 Troubleshooting 30

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10.2. MOP Screen “Cylinder Lubricators”

32 10.3 Lubrication Amount Calculation:

34 10.4 ALPHA LUBRICATOR WITH ME ENGINES - BREAKING-IN/RUNNING-IN FEED

RATE SETTING

36 11 Appendix

38 11.1 Opening and setting up the Hyper Terminal program

38 11.2. Swash plate position values

39 11.3. Tools for commissioning

39 11.4. Overview MPC connections

40 11.5. MPC LED Indication

41 11.6. Settings of Liquiphant level switch

44 11.7. Connection test scheme

1 Document History:

Date Author

Changes

2005-06-09 AAJ

ACU4

added

F9 6A » 10A

F4 2A » 3,15A

Connection test scheme for

CCU, ACU,EICU & ECU

changed signal text and

signal ID

2005-07-20

AAJ

Adjustment of encoder

updated

2005-08-04

AAJ

2.2.1 Connections and

settings - program is updated

4.1 “MPC Parameter update”

is updated for s-paf file.

“Network address= Sum of

activated Dipswitch” is

deleted

“ECS Network address” is

deleted in Appendix 9

Introducing 6.1 “Check of

tacho system cable”

2005-08-29

AAJ

9. ME Alpha lubricator quick

guide added

4.3 How to make a copy of

ECU A into ECU B added

2005-09-14

AAJ

Picture of MOP-screen insert

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Network status 3.0

2005-09-27 AAJ

Updated

2.2.1 Connections

and settings-programming

(DIP-switch)

2005-10-29 AAJ

Updated 2.2.1 Connections

and settings-programming

(DIP-switch) (CCU8)

2006-07-11 AAJ

Update 9 ME Alpha

lubricator quick guide text

2006-07-11 AAJ

Added 6 Check of Serial

communication between

RCS and ECS

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Pre-conditions:

• All MPC (Multi - Purpose Controller) – print cards must be mounted in the respective mounting boxes on the engine.

• Measurements for earth fault must be made, with multi-meter on all cable connections.

• All cables mounted on plugs for MPC must be marked with plug number and terminal number, and all cables mounted according to actual plant electrical diagram.

• All cables/plugs to be mounted on MPC-print must be disconnected. • Battery mounted on MPC board (See chapter 2.1.1)

• Tools according to appendix 10.3

1 Power Supply Check

On all MPC units check polarity and voltage on plug J1: (A power): A = - / B = + (B power): A = - / C= +, the voltage must be in the range 20-30Vdc.

On Main Operating Panel (MOP A), check the polarity and voltage. The voltage must be in the range 20-30Vdc. On Main Operating Panel (MOP B), check that the 220/110VAC switch is set according to the power supply.

1.1 MPC

fuse

specification

In Appendix 11.4 explanation of MPC fuse specification and MPC fuse function.

2 ID-key

Boot

Loader Program

The control network on the ME Engine contains several MPC units called nodes. Each MPC has a

corresponding ID-key attached to it(se page xxxx). This ID-key contains a unique ID, which identifies what type of controller it is associated with. When the ID-key is plugged into its corresponding sub-D connector (J206) on the MPC, the controller reads the ID-key, ID number to determine what type of software it should contain. Each ID-key, ID number is matched to specific controller software. If the MPC determines that it does not contain the correct software image it will not boot. The ID-key, ID is also used by the MPC to determine what type of software it should upload from the MOP.

The following describes the features contained in the bootloader program. The purpose of the program is to: • Check the validity of the ID-key, ID before boot is allowed.

• Provide facilities for the Service Technician to change the ID-key, ID number.

2.1 Operation

The following does not require a PC connected to the service terminal of the MPC. Connecting a PC is optional and provides additional information or insight into the boot operation. When programming a new ID-key ID, the user need only rely on the LED messages. A description of the LED messages is found in the appendix 11.5.

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2.1.1 Connections and settings – normal operation

See below figures for DIP-switch settings and location of LED, ID-key and service terminal plug on MPC board.

View of MPC board with ID-key connected.

Battery mounted on MPC board

LED ( Led Emitting Diode)

ID-key Mounted on MPC (J206)

Service Terminal Connection (J67)

DIP-switch S1 on MPC-board.

DIP-switch S1

DIP-switch S1: Neutral ⇒ All in off position

• ON ⇒ Binary 1 • OFF ⇒ Binary 0

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Multi colour DIP-switch on side of MPC board, settings for connection test and normal service

DIP-switch Nos. 1& 8 must be in off position.

• OFF • ON

2.1.2 Start-up

normal

operation

LED messages: Error(red) -> Init(Orange) -> Normal(Green). See appendix 10.5 for details

During start-up, the MPC verifies if the ID-key is connected. It reads the ID number and checks if the ID-key ID is in the correct format and has a valid range, it reads the DIP-switch S1 value and verifies if it is 0 (Off). The program completes the ID-key verification and is now ready to continue the boot sequence. Any deviations will send an error message via the LED.

Figure 1: Messages sent to a portable PC with Windows Hyperterminal

program that is connected to the service terminal plug J67 on an MPC using a zero modem cable.

Initialising BES kernel...OK Starting dongle verification Reading Dongle ID...Value = 192 Reading DIP-switch S1... Value = 0 Dongle verification done.

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2.2 Programming the ID-key (Network Address)

2.2.1 Connections

and

settings – programming.

DIP-switch S1 set to value to be programmed.

The service technician can program the ID-key with a new ID using the DIP-switch S1. Any previous value in the ID-key will be erased.

Switch on DIP-switch S1 1 2 3 4 5 6 7 8 MPC Network Address

DIP switch S1 Settings

ACU 1 224 Off Off Off Off Off On On On

ACU 2 225 On Off Off Off Off On On On

ACU 3 226 Off On Off Off Off On On On

ACU 4 239 On On On On Off On On On

ECU A 208 Off Off Off Off On Off On On

ECU B 209 On Off Off Off On Off On On

EICU A 192 Off Off Off Off Off Off On On

EICU B 193 On Off Off Off Off Off On On

CCU 1 240 Off Off Off Off On On On On

CCU 2 241 On Off Off Off On On On On

CCU 3 242 Off On Off Off On On On On

CCU 4 243 On On Off Off On On On On

CCU 5 244 Off Off On Off On On On On

CCU 6 245 On Off On Off On On On On

CCU 7 246 Off On On Off On On On On

CCU 8 247 On On On Off On On On On

CCU 9 248 Off Off Off On On On On On

CCU 10 249 On Off Off On On On On On

CCU 11 250 Off On Off On On On On On

CCU 12 251 On On Off On On On On On

CCU 13 252 Off Off On On On On On On

CCU 14 253 On Off On On On On On On

CCU 15 254 Off On On On On On On On

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2.2.2 Programming Sequence for ID-Key

LED messages: Code 4,2 and 4,3 (see chapter 2.3 and appendix 11.5)

The program first verifies if the ID-key is connected (2a). In this case, it confirms that the ID-key is not

connected and sends error code 42 through the LED. The service technician may now connect the ID-key for programming. The program switches to programming mode and reads the DIP-switch S1 value to determine the new ID number that the user wants to program the ID-key (2b). This value must be a valid ID-key, ID number or the program will halt. Before programming, the program verifies if the ID-key is connected (2c) and proceeds to program the new ID number. The MPC is then ready to continue booting and sends code 43 to the LED. This signals the technician to change the switch (S1) back to its neutral position (2d). When the DIP-switch S1 is set to neutral (off), the MPC is now ready to continue normal booting operation.

Figure 2: Messages from the service terminal of the MPC when programming ID-key with DIP-switch. Starting Basic System...

Testing RAM... RAM OK

Initialising BES kernel...OK Starting dongle verification

Reading Dongle ID...not connected! Switching to programming mode. Reading DIP-switch... Value = 240

Programming Dongle with DIP-switch value. Dongle not connected! Please connect dongle. Dongle programmed successfully

Preparing to boot...

DIP-switch not neutral. Please set DIP-switch to neutral. Reading DIP-switch... Value = 0

Dongle verification done. Continuing boot sequence...

2a

2b

2c

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2.3 2.3

Troubleshooting LED messages

Problem: The LED flashes code 4,3.

Cause: DIP-switch S1 is not set to neutral. The connected ID-key may have a valid number or a new ID-key ID number has been programmed. DIP-switch S1 in the MPC must be set to neutral (OFF) for the boot operation to continue.

Solution: Set DIP-switch S1 to neutral (OFF).

Problem: The LED flashes code 4,2.

Cause: The MPC has read the requested new key, ID from the DIP-switch S1, but cannot program the ID-key because it is not connected.

Solution: Connect the ID-key to the MPC.

Cause: The MPC has read the requested new ID-key, ID from the DIP-switch S1, but found it to be out-of-range.

Solution: Disconnect the ID-key. Verify that the DIP-switch S1 is set to a valid value and reset the MPC. Cause: DIP-switch S1 is set to neutral for normal boot, but the ID-key is not connected.

Solution: Connect the ID-key and reset the MPC. Cause: The ID number read into the ID-key is invalid.

Solution: Proceed to reprogram the ID-key. Remove the ID-key, set the DIP-switch S1 to the new dongle ID number and reboot the MPC. Follow the steps used to program the ID-key under section 2.2.1, “Use DIP-switch S1 to Program the ID-key, ID”.

Cause: ID-key is defective. Solution: Replace ID-key.

Error code Description

4,2 ID-key not connected

Invalid Dongle ID

Invalid DIP-switch S1 value Programming ID-key failed

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3 Network

Test

The network must not be crossed, i.e. net A terminated in plug 65 and net B in plug 66. Check all cable connections visually and mount the terminating resistor to net A and B as shown below.

In ECU A & B, a 120 ohm terminating resistor must be mounted at the end of the arcnet line A and B net.

Terminating resistor, net B plug No. 66.

In MOP A & B a 120 ohm terminating resistor must be mounted at the end of the arcnet line A and B net in the SUB-D9 plug.

Screen for network cable Terminating resistor.

Network status on the MOP screen

The network status screen contains information on the accessibility of the nodes on the network and on the status of the cabling of the individual nodes.

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The network connection can also be checked using a service terminal, i.e. portable PC with Windows HyperTerminal program that is connected to the service terminal plug J67 on an MPC using a zero modem cable.

3.1 3.1

Access to Service Terminal

• Opening and setting up the Hyper Terminal program (see appendix 11.1) • Connect a PC to the service terminal plug J67.

• Type <manbw> and press enter.

• Use the keyboard arrows to remove the cursor to ‘Control Network Management’ and press enter. • Use the keyboard arrows to remove the cursor to ‘View Network Map Segment 0 (Arcnet A). • Check that all MPC’s on the network are ON and that the MPC connected to the service terminal is

shown as MY. See appendix 10.4 for a description of MPC type and HEX network address. • If an MPC is not ON, check the network cabling and status of the LED on the MPC.

• Repeat the above procedure for Network Map Segment 1 (Archnet B).

In the example below the service terminal is connected to CCU 1(0xF0)->MY, ACU 1(0xE0), ACU 2(0xE1), ACU 3(0xE2), ECU A(0xD0), ECU B(0xD1), EICU A(0xC0) and EICU B(0xC1) are ON. CCU 2-> are not connected indicated by ++.

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4 Updating and Archiving MPC Parameters from the MOP

Preconditions

• The MOP and the MPC’s must be connected by ArcNet.

• The MOP must have the BES_SERVER running and the MPC’s must be set-up according to chapter 2.

• The node table on the MOP must correspond to the actual system connected.

• The archive files can also be up- or down-loaded using the service terminal on the MPC, but this scenario is out of the scope of this document.

4.1 MPC

Parameter

update

This section describes how to update MPC parameters using parameter archive files. The update can be done running the MPC Archive tool.

On the MOP PC, press “Ctrl” “Esc” at the same time on the keyboard. When windows start menu appears,. choose “explore” and open: C:\Program Files\MANBW\MOP\Tools

1. Start the MPCArchive program (MpcArchive.exe) and select the “Update” tab.

2. Version a) to be used if the update file is MANBW-spaf and you will update all MPC`c, and version b) if you only want to update MANB-paf file on one or some MPC`s.

a.

Add the archive files by pressing the “Update system” button and select the s-paf file to be used for the update (see picture below).

b.

Add the archive files by pressing the “Add Files” button and select the file(s) to be used for the update. If download is to be made to several MPC’s, press the ‘Shift’ button on the keyboard and select all the files. The files can be located in a folder on the harddisk or on another media. The application will attach each file to an MPC, by comparing the ArcNet addresses in the files with the dongle ID’s/addresses of the MPC’s.

3. Select the MPC(s) to be updated (press the ‘Shift’ button on the keyboard to select more than one MPC) and press the “Update Par.” button. The MPC(s) will reboot in configuration mode thereby stopping the application, and the parameter files will be downloaded. The status of the operation can be seen in the ‘Download Status’ column.

4. After completion (Online Status ->Normal), select the MPC(s) in question and restart the MPC(s) by pressing “Restart App.”. This will start the application using the new parameters.

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4.2 Archiving Parameter Files

This section describes how to extract parameter files from the MPCs. 1. Open the MPC Archive tool.

2. Select a destination directory for the archive files, i.e. C:\temp.

3. Press “Get All” or select one or more MPCs and press “Get Selected” to start extraction of the parameter archive files. The status of the operation can be seen in the ‘Upload Status’ column.

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4.3 4.3

How to make a copy of ECU-A into ECU-B:

4.4 (for Soft Ware version 1.34 or later)

For system file: xx.manbw-spaf

Open the parameter file in the Arcedit.

Extract to second (2). level - mark the ECUB and delete: edit - Drop MPC.

Mark ECUA end copy: edit - clone MPC - A dialog box is shown: enter node name (ECUB) and Arc. net adress (209) and push clone.

The ECUB is created. For MPC file: xx.manbw-paf

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4.5 5 Connection test of I/O

The purpose of the connection test is to check all cable connections, and function test, to such a degree that the engine after completing the connection test can be started without any electrical malfunctions. Begin by checking if there is any alarm indications on the MOP, if errors are displayed, refer to the Alarms

documentation chapter 24 in ECS commissioning book, for a description and suggested solution to the alarm. All signals to and from the MPC’s can be tested separately. This test is done with the Service Terminal connected to the MPC/unit to be tested.

Connect a PC to the service terminal plug J67, and enter <System test> as described below. Access to Service Terminal (System test):

1 Type <manbw> followed by pressing enter. 2 Select <Node Mode>.

3 Select <Test>.

4 Answer y to continue followed by pressing enter 5 Select <System Test>

6 Then choose Input or Output

The Connection test must be done according to the connection test scheme (Appendix 11.7 Connection Test Scheme).

6 Check of Serial Communication between RCS and ECS

6.1 How to inspect Serial communication between RCS and ECS

• Select ‘Adjust Parameters’ and browse to:

‘I/O Configuration -> Configuration Options -> Non or Old Application Options -> Modbus-RCS Connection Test’

Verify that this parameter is set to ‘No’. If not Use ‘Node Mode Control’ menu to Set EICU in ‘Configuration’ mode and change the parameter to ‘No’.

• If not already in ‘Normal Mode’ use ‘Node Mode Control’ menu to Set EICU in ‘Normal mode’. • Choose ‘View/Edit Data tree’ and browse to:

System ->RCS Interface -> IO Variant A -> Data to/from RCS

In some situations ‘IO Variant B’ or ‘Modbus-RCS’ must be selected instead of ‘IO Variant A’. Choose the active menu (passive menu’s are marked by a square).

6.2 How to simulate values from ECS to RCS

• Use ‘Node Mode Control’ menu to Set EICU in ‘Configuration’ mode. (After the MPC is in configuration mode type “MANBW + enter).

• Select ‘Adjust Parameters’ and browse to:

‘I/O Configuration -> Configuration Options -> Non or Old Application Options -> Modbus-RCS Connection Test’. Set parameter to ‘Yes’ and activate.

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• Use ‘Node Mode Control’ menu to Set EICU in ‘Normal’ mode (After the MPC is in Normal mode type “MANBW + enter).

• Select ‘Adjust Parameters’ and browse to

‘I/O Configuration -> MODBUS Data -> Modbus-RCS Connection Test’ Select value of interest, change it and activate.

• When test is completed use ‘Node Mode Control’ menu to Set EICU in ‘Configuration mode’ • Select ‘Adjust Parameters’ and browse to:

‘I/O Configuration -> Configuration Options -> Non or Old Application Options -> Modbus-RCS Connection Test’. Set parameter to ‘No’ and activate.

• Use ‘Node Mode Control’ menu to Set EICU in ‘Normal’ mode • Note when testing EICU-B:

•

7 Adjustment of encoder

7.1 Check Tacho system cable

To check the tacho system cable the special tacho cable box can be used, both for CW and ACW running engines by using this box all tacho cables will be checked.

Another way to check the tacho system cable between TSA box and MPC`s, the following can be done but by this method the cable between encoder and TSA box will not be checked.

On each MPC that is connected to the tacho system there is 8 LED indicators on the PCB see the sketch below.

The LED can be used to connection test the tacho cabling by following the procedure below: Prepare a dummy plug as shown below:

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Disconnect J1-J2-J3-J4 in both TSA-A & TSA-B

Mount the dummy plug in J1 TSA-A and observe that LED number 9 is ON in PCB. Mount the dummy plug in J2 TSA-A and observe that LED number 10 is ON in PCB. Mount the dummy plug in J3 TSA-A and observe that LED number 1 is ON in PCB. Mount the dummy plug in J4 TSA-A and observe that LED number 2 is ON in PCB.

Mount the dummy plug in J1 TSA-B and observe that LED number 13 is ON in PCB. Mount the dummy plug in J2 TSA-B and observe that LED number 14 is ON in PCB. Mount the dummy plug in J3 TSA-B and observe that LED number 11 is ON in PCB. Mount the dummy plug in J4 TSA-B and observe that LED number 10 is ON in PCB.

DIODE BOARD 13 14 10 11 12 1 2 9

Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A

Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A

Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1 MPC Plug J46 J47 J43 J44 J45 J40 J41 J42 On before Q1B On before Q1A 45-225 deg 135-315 deg. 0-180 deg. 90-270 deg.

7.2 Check of encoder adjustment.

It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommendations. Turning gear engaged.

Indicator cocks open.

Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC.

Check that the indicator light for the inner encoder turns ‘ON’ on the TSA-A , when cyl.1 reaches TDC. Turn engine a few degrees back and forth, confirm that LED turns on/off. If the above is not in order see below for adjustment of encoder (Chapter 7.3).

INNER encoder is adjusted correctly.

Turn engine 45degrees in the engines rotational direction. I.e. clockwise 45 degrees clockwise and anticlockwise 45 degrees anticlockwise.

Check that the indicator light for the outer encoder turns ‘ON’ on the TSA-B. If the above is not in order see below for adjustment of encoder (Chapter 7.3).

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OUTER encoder is adjusted correctly. Check of encoders complete

7.3 Adjustment of encoder-clockwise

It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommend-ations. Turning gear engaged.

Indicator cocks open. Clamp screw on encoder loose.

Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC. Turn the inner encoder (A) until the Indicator light for the encoder is off (TSA-A). Turn the encoder in AHEAD direction until the LED on TSA-A just starts to light, and then fasten the encoder to the shaft with the clamp screw.

Inner encoder adjusted.

Turn engine 45 degrees in AHEAD direction. Turn the outer encoder (B) until the Indicator light for the encoder is off (TSA-B). Turn the encoder in AHEAD direction until the LED on TSA-B just starts to light, then fasten the encoder to the shaft with the clamp screw.

Outer encoder adjusted. Function Encoders:

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ECU; CCU connection ENCODER:

DIODE BOARD 13 14 10 11 12 1 2 9

Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A

Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A

Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1 MPC Plug J46 J47 J43 J44 J45 J40 J41 J42 On before Q1B On before Q1A 45-225 deg 135-315 deg. 0-180 deg. 90-270 deg.

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7.4 Check of tacho sensor at flywheel.

Turning gear engaged and indicator cocks open. Run out on marker ring checked and found OK. Turn the engine 90 degrees from TDC cylinder 1, and check that the LED on the sensor is ‘on’. Check of Tacho sensor complete.

8 Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm

Preconditions:

• The Hydraulic system must be flushed and ready for operation. • Network- and connection-test completed.

• Connect a portable PC with Windows Hyperterminal program that is connected to the service terminal plug J67 on an MPC using a zero modem cable, and enter <System test> as described above in chapter 5.

Note: The hydraulic supply pressure must be zero before starting tests 8.1 and 8.2.

8.1 Connection test of ELFI valve without hydraulic pressure

Check the 24V supply to the LVDT before connecting the CANNON cables to the ELFI valve. Use a test box as shown below or a voltmeter. 24V must be measured between A (24V) and B (0V) on the CANNON plug.

Cannon Plug / Connection test box. MBD Info no. 6 91 100 MBD Part no. 1880536-0

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Use the following sequence on each ELFI valve:

Service terminal in Input / output

1. Check that ‘Shut Down’ (input ch. 32) is Off 2. Disconnect power supply for ELFI amplifier (J9)

3. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is Off 4. Reconnect power supply for ELFI amplifier (J9)

5. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is On ---

6. Set amplifier enable (output ch. 60) to On 7. Set ‘InFi_AMP. Setpoint’ (output ch. 70) to 0V

8. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA 9. Check ‘ELFI Actual Current’ (input ch. 33) is 0V

10. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to Maximum 1.3V 11. Check ‘ELFI Position Feedback’ (input ch.30) is 18-20mA 12. Check ‘ELFI Actual Current’ (input ch. 33) is 1.3 V 13. Set shut down On via safety system

14. Check ‘Shut Down’ (input ch. 32) is On

15. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA 16. Check ‘ELFI Actual Current’ (input ch. 33) is 0V

17. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to 0V

Reset the safety system and check that channel 32 (shutdown signal) goes OFF. Repeat the above procedure for all cylinders.

8.2 Connection test of ELVA valve without hydraulic pressure

Use the test box shown in chapter 8.1 or the following procedure:

During the test, set output channel 49 ON/OFF two or three times and check that the valve reacts (clicks). During input test, check that channel 23 (Exhaust valve alive) is ON.

The output channel 49 should be set to ON when finish testing.

8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar)

Use a test box shown in chapter 8.1 or the following procedure:

Set output channel 49 ON/OFF two or three times

If ELVA valve is alive (input ch.23 is ON), reset ELVA valve by powering CCU on/off ⇒ Check that ELVA valve alive is not active ( input ch. 23 is OFF).

Note Exhaust valve pos. (input channel 34) (range 4-9 mA).

Activate Exhaust valve by output channel 49 and check that alive goes ON (input channel 23).

Activate Exhaust valve a few times by output channel 34 and determine the lifting height, reading in the service terminal is between 7 - 9 mA.

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8.4 Connection test of FIVA valve with hydraulic pressure (app. 175 bar)

Preconditions:

• The Hydraulic stand-by pumps is ON (175 Bar) • The F.O. Supply is ON (7-8 Bars)

• Spring air Exhaust valve is ON

• Check the Type of Amplifier- It has to be a FIVA Amplifier (See it on the type label on the back side of Amplifier).

Repeat the above procedure for all cylinders. Service terminal in Input/Output:

1. Disconnect power supply for FIVA amplifier (J9)

2. Check that ‘Value Amplifier OK’ signal (Input ch.20)=OFF 3. Reconnect power supply for FIVA amplifier (J9)

4. Check that ‘Value Amplifier OK’ signal (Input ch.20)=ON 5. Set ‘Amplifier Enable’ (Output ch.60)=ON

6. Set ‘4107V, Set Point’ (Output ch.70)=0V

7. Check ‘Prop. Valve position feedback’ (Input ch.30)=4-7mA 8. Check ‘Prop. Valve Actual Current’ (Input ch.33)=0V 9. Set ‘4107V, Set Point’ (Output ch.70)=3.5V

10. F.O. valve on unit opens (Sound) [Only test this once] 11. Check ‘Prop. Valve position feedback’ (Input ch.30)=18-20mA 12. Check ‘Prop. Valve Actual Current’ (Input ch.33)=3.5V 13. Set ‘4107V, Set Point’ (Output ch.70)=0V

14. Exhaust valve on unit opens (Sound) Repeat the above procedure for all cylinders.

8.5 Connection

test

of

starting air valves

1. During output test channel 50 is activated and it is controlled that the valve reacts (click or extern magnetic field tester).

2. The test is repeated for every single cylinder.

8.6 Test of main starting air valve manually on the MOP

1. Starting-air is cut of manually – Turning gear disengaged – Control air on – Main Starting Valve in service position.

2. Main Starting Valve is activated manually; either by handle or push bottom. ⇒ Main starting air valve must open.

3. Turning-gear engaged.

4. Main starting air valve is activated manually (on pilot-valve) ⇒ no reaction means that the pneumatic turning-gear interlock is ok.

5. Turning-gear disengaged.

6. Activate both activating-valves (V-1 & V-2), for the main starting-valve (one at a time via the MOP) ⇒ Main starting valve must open (after an eventually fault, point 1 – 2 is repeated).

7.

The Slow turn valve is activated (via MOP) manually. Start is activated either by handle or push button. ⇒ Only the Slow turning valve must open.

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8.7 Connection test of HCU oil leakage alarm

Service Terminal in input / output in the CCU, check that channel 27 is OFF. (Because this is an option it can be done by means of a “cheat” plug).

Cheat Plug mounted in channel 27 on MPC board.

Jumper between terminal A and B

Resistor between terminal C and D ( 6,8 k ohm)

8.8 Hints for connection test and fault finding:

In general:

All electronic components are pre-adjusted before delivery. They are only to be adjusted mechanically at initialisation, and the written values are to be entered in the relevant parameters.

Connection test:

• The required output set point has to be entered using the service terminal, in order to achive the correct analogue output.

• When changing to input view, you must answer “no” to “reboot”, otherwise all outputs will be reset.

MOP:

A short “power-off” can block restart, therefore turn off the power and wait for at least 10 seconds until the MOP has a black screen, and then turn the voltage on.

LVDT amplifiers for pump-regulation:

• The amplifier must show 12 mA in the service terminal with the sensor disconnected.

• The Swash-plate sensor must be mounted correctly. If the signal is “out of range” at one end, it has to be adjusted mechanically. (Electrical adjustment of the LVDT amplifier must only be done after consulting MAN B&W Diesel A/S).

ELVA:

• The ELVA valve may indicate an error alarm if the plug has been disconnected or the power to the relevant CCU has been off. The alarm can be terminated by function-test of the valve, or by starting the engine and seeing if the alarm resets (no fuel is supplied until the valve functions).

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After the oil has been drained from one (or all) HCUs, it may be necessary to activate the ELFI & ELVA valves manually. (Slow turn with the indicator valves open before starting as the engine will otherwise start

unintentionally during air run).

Manually activate ELVA valve by:

During test, set channel 49 ON/OFF two or three times and check that the valve reacts (clicks). During input test, check that channel 23 (Exhaust valve alive) is ON.

Tacho error:

With Tacho errors after Stop/Slow-turning, the engine can be run at air run or simply started. The ME Engine control system does not supply fuel unless at least one Tacho system is OK.

A start attempt is therefore the fastest way to clarify if there is a problem. If the engine does not rotate, the ECU/CCU units must be reset (see picture below) before a new start attempt is made.

Manually activate the ELFI valve by

pushing the piston upwards by hand.

(Note if fuel oil pressure is on, each

activation of the piston will inject fuel

in the cylinder).

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Reset button for MPC

(The reset button on the side on the

MPC board)

Sensor and actuator error:

At sensor or actuator error, there can be four (4) main error sources:

Sensor error

1. Unmonitored fuse has blown. (See fuse specification Appendix 9.4) 2. Cabling and plugs, loose or wrong connections.

3. Sensor failure/adjustment is not correct. 4. Defective MPC (input channel).

Actuator error

1. Unmonitored fuse has blown.

2. Cabling and plugs, loose or wrong connections. 3. Sensor failure/adjustment is not correct. 4. Defective MPC (output channel).

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9 Test of Swash-plate pumps (Hydraulic-Pressure On)

9.1 Functions

test

Follow the procedure below to calibrate the engine driven hydraulic pumps:

• Turn on the startup pumps on the startup pump switchboard by switching to “Local Control” and press “Manual start” to enable swivelling with the swashplate. The hydraulic System pressure must be

above 50 bar.

• Set the MPC in connection test mode via the service terminal: Access to service terminal:

o Open and set up the Hyper terminal program (see appendix 11.1) o Connect a PC to the service terminal plug J67 on the MPC o Type <manbw> and press enter

• Start ACU x (x= 1 – 3) in “Test” mode. The Service Terminal path for this operation is “Node Mode Control => Test”.

• Move the proportional valve to its fail-safe position and check the feedback signals from the swashplate and the proportional valve. The swashplate feedback position is a 4-20mA sensor. The proportional valve feedback is a 6-18mA sensor.

Use the following procedure to move the proportional valve to fail safe position: o “System Test => Connection Test => Output Test” set ch. 48 to On. o “System Test => Connection Test => Output Test” set ch. 70 to 0V. o “System Test => Connection Test => Input Test”

1. In the below table, note the signal value of the proportional valve feedback, ch. 30. This value should be close to 18mA. If this is not the case, see the Trouble Shooting section below.

2. In the below table, note the signal value of the swashplate feedback, ch. 34. This value should be close to 20mA. If this is not the case, see the Trouble Shooting section below.

3. Check that the swashplate physically is in its full ahead position via the indicator on the pump (15 deg in the AH direction).

• Move the proportional valve to the opposite end position and check the feedback signals from the swashplate and the proportional valve.

o “System Test => Connection Test => Output Test” make sure that ch. 48 is set to On. o “System Test => Connection Test => Output Test” set ch. 70 to Maximum 2.6V. (on pumps

larger than 500 cc, the value should be Maximum 3.8V).

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1. In the table below, note the signal value of the proportional valve feedback, ch. 30. This value should be close to 6mA. If this is not the case, see the Trouble Shooting section 9.2 below.

2. In the below table, note the signal value of the swashplate feedback, ch. 34. This value should be close to 4mA. If this is not the case, see the Trouble Shooting section 8.2 below.

3. Check that the swashplate physically is in its full astern position via the indicator on the pump (15 deg in the AS direction).

• Insert the parameters in ACU 1 – 3 using the Service Terminal parameters as given below in the table. • The values should be noted in table in Appendix 11.2

MPC Proportional valve

max. value (mA)

Proportional valve min. value (mA)

Swashplate max. value (mA) Swashplate min. value (mA) ACU 1 ACU 2 ACU 3 Parameter path on the MPC in Service Terminal Adjust parameters => Edit parameters => IOConfig => Ch30,1238-x,Prop. Valve Feedback => Scaling => Row 2 Input (mA) Adjust parameters => Edit parameters => IOConfig => Ch30,1238-x,Prop. Valve Feedback => Scaling => Row 1 Input (mA) Adjust parameters => Edit parameters => IOConfig => Ch34,1222-x,Swash-Plate Position => Scaling => Row 2 Input (mA) Adjust parameters => Edit parameters => IOConfig => Ch34,1222-1,Swash-Plate Position => Scaling => Row 1 Input (mA)

9.2 Troubleshooting

If one of the swashplate position feedback sensors mA indications are far away from the two other swashplate mA values:

• Tighten the swashplate position indicator LVDT sensor on that pump.

If, when moving the proportional valve to the end position, the proportional valve position feedback or the swashplate position feedback value displayed remains constant (typically around 12 mA):

• Proportional valve: Check connections between the proportional valve position feedback sensor and the H.F. Jensen LVDT amplifier for the proportional valve

• Swashplate: Check connections between the proportional valve position feedback sensor and the H.F. Jensen LVDT amplifier for the proportional valve

• when the proportional valve is tried forced to the end positions, it is most likely caused by missing connection between the sensor at the pump and the sensor’s LVDT amplifier. This could be a missing connection between the proportional valve position feedback sensor and the H.F. Jensen LVDT amplifier for the proportional valve. In the case of constant swashplate indication it could be caused by a missing connection between the swashplate position feedback sensor and the H.F. Jensen LVDT amplifier for the swashplate.

• If, during the calibration, the feedback signals of the swashplate and the proportional valve is reversed, jumpers in the position feedback LVDT amplifiers are not correctly positioned. This can be observed as:

o When the proportional valve is supposed to signify its max. value position (e.g 18mA) and the feedback indicates min. value (e.g. 6mA), then the signal range has been reversed.

o When the swashplate is supposed to signify its max. value position (e.g 20mA) and the feedback indicates min. value (e.g. 4mA), then the signal range has been reversed.

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10 ME Alpha Lubricator Quick Guide

10.1. Testbed ME Lubricator test procedure

10.2. MOP

Screen

“Cylinder Lubricators”

1. Indicator “Flow”

Shows the ordered lube oil amount (l/h).

Note: If one or more lubricators is not working correct (ex. Feedback Failure) this will

not show the correct value.

2. Indicator “Total”

Shows the total ordered Amount (l) since last power up of the ECU.

Note: As with “1” this indicator depends on all lubricators working correct.

3. Button “Prelube”

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Note: Can only be activated if hydraulic pressure is present. This demands that

engine is in “Standby” state or manual operation of the hydraulic start-up pumps.

4. Indicator “LCD”

Indicates if Load Change Dependent lubrication is active.

5. Button “S%”

Fuel sulphur % used for the Adaptive Cylinder oil Control (ACC). Se Service Letter

SL05-455 /HRJ September 2005

Note: When running on diesel fuel (Engine Shop) set the S%=3.2

6. Button “Feed Rate Factor”

Used together with S% to calculate the Basic FeedRate setting.

7. Indicator “Basic FeedRate”

The Basic FeedRate setting = S%*(FeedRate Factor).

Note: This value is very important to observe before Engine Start as this value is the

basic factor in calculating the feedrate amount. The Basic FeedRate is converted to a

Basic Activation frequency.

8. Button “Min. Feed Rate”

Minimum feedrate limiter that secures the feedrate will never be below this amount

even if the S% or FeedRate Factor or adjust factor is set low.

Note: The limiter is converted to a minimum activation frequency that means that the

actual feedrate (g/kW) can be higher at load’s <100%.

9. Indicator “Actual FeedRate” Cylinder 1..N

The actual ordered feedrate after the influence of limiters, load control ect.

Note: When running in the FeedRate(g/kW) increases when load decreases.

10. Button “Feedrate Factor Adjust” Cylinder 1..N

Adjust the Basic Feedrate Setting for the cylinders Individually.

11. Button “Running In” Cylinder 1..N

Is used for running in piston rings and cylinder liners.

Note:

For Running In=0% the lubrication amount regulator make load regulated lubrication

when Index is > approx 40% and changes to speed regulation when Index is < 40%.

This leads to an almost constant feedrate down to 40% index.

For Running In >0% the lubrication amount regulator changes from load regulated

lubrication to speed (rpm) regulated lubrication. This means that activation frequency

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frequency.

12. Button “ Lubricator Test Sequence”

Start’s a continuous activation ( app.1000 activations) of the lubricator.

Note: Can only be activated if hydraulic pressure is present. This demands that

engine is in “Standby” state or manual operation of the hydraulic start-up pumps.

13. Check of the activation sequence of the Alpha lubricator

The activation frequency can be checked via the HyperTerminal for each cylinder

(CCU) in the following picture and read “Activations Without Error”:

10.3 Lubrication Amount Calculation:

The lube oil amount Is calculated individually for each cylinder. On basis of the

FeedrateFactor and the S% a basicfeedrate is calculated, this is converted to Mnominal

act/rev at MCR. All the limiters are also calculated at MCR and converted to act/rev.

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Note:

MaxFeedRate, MaxFeedRateRunIn, MinActFreq, LcdFac and MinIndexWithPowerLube are

parameters that are not available on the MOP screen. These has to be set by Service

Terminal if adjustment is required.

Be aware of the limiter order.

Ex. (6S60ME-C)

Feedrate Factor:

0.34 S%

3.2 BasicFeedRate

1.09 g/kWh

MinFeedRate 0.7

g/kWh

FeedRate Adjust

1.1 MinIndexWithPowerLube

0.4 MCR

Speed

105 rpm

MCR Load per cyl.

2260 kW

InjectionMass 1.0

g

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M nominel

(Activation frequency)

=(BasicFeedRate(g/kWh)MCRLoad(kW))/(60MCRSpeed(rpm)*InjectionMass)

=0.39

If no limiters are active and “Running In” =0%, not LCD and Index >0.4.

M(actual)=MnominalFeedRateAdjustIndex

=0.391.1Index =>(Load regulation)

If no limiters are active and “Running In” =0%, not LCD and Index <=0.4.

M(actual)=MnominalFeedRateAdjust MinIndexWithPowerLube

=0.391.10.4 =>(Speed regulation)

If no limiters are active and “Running In”=100% and not LCD

M(actual)= MnominalFeedRateAdjust(1+(Running In)/100)

=0.391.1(1+(Running In)/100) =>(Speed regulation)

10.4 ALPHA LUBRICATOR WITH ME ENGINES - BREAKING-IN/RUNNING-IN FEED

RATE SETTING

1/ "How to adjust Basic Feed Rate for breaking-in / Running-in period ?"

The recommended feed rates for running in of new or reconditioned liners and coated piston

rings according to SL05-455/HRJ are:

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Step 1: 1.7 g/kWh for the first 5 hours

Step 2: 1.5 g/kWh for 5 hours to 250 hours

Step 3: 1.2 g/kWh for 250 hours to 500 hours

For step 1, 2, and 3 : Part load reduction proportional to engine load (power).

We propose to obtain this in the following way:

a/

Set feed rate factor to 0.34 g/kWh

b/

Set S% to 3 ~ (2.94 exactly)

c/

Step 1: Set feed rate adjust factor to 1.7

Step 2: Set feed rate adjust factor to 1.5

Step 3: Set feed rate adjust factor to 1.2

2/ "How do the following MOP fields influence on Basic Feed Rate:

a/ "Feed Rate Adjust Factor",

b/ "Running In [%] ?"

Neither "Feed Rate Adjust Factor" nor "Running In [%] influence the basic feed rate. The

basic feed rate is calculated as "S%" times "Feed Rate Factor".

However when the "running in [%]" differs from 0 the amount calculation algorithm changes

from load (power) to RPM. The setting of "Feed Rate Adjust Factor" has no influence on the

algorithm.

3/ "Part-load control for breaking-in / Running-in period. ?"

With the introduction of SL05-455/HRJ our recommendation for part load amount calculation

during running in has changed from the previous RPM dependent to load (power)

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11 Appendix

11.1 Opening and setting up the Hyper Terminal program

• Select ‘Start’ and ‘Run’, write hypertrm.exe in the dialogue box and select ‘OK’.

• The Hyper Terminal program will start up, and a ‘New Connection’ dialogue box will appear. Write e.g. Service Terminal and select ‘OK’.

• In the next dialogue open the ‘Connect using’ box/field and select the port to be used, i.e. COM1 and select ‘OK’.

• In the next dialogue, set up the port settings as follows and select ‘OK’: o Bits per second: 9600

o Data bits: 8 o Parity: None o Stop bits: 1

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11.2. Swash plate position values

MPC Proportional valve

max. value (mA)

Proportional valve min. value (mA)

Swashplate max. value (mA) Swashplate min. value (mA) ACU 1 ACU 2 ACU 3

Indication adjustment:

Readings in:

Main Menu / View / edit data-tree / I/O Configuration-channel 34 / Swash plate position. Full angle Ahead = mA

Full angle Astern = mA

11.3. Tools for commissioning

1. PC with Hyper terminal installed and a zero modem cable

2. Electronic or mechanic tool for measuring of highest/lowest point on trigger/tacho rings. 3. Tacho sensor adjusting tool (marked).

4. Portable pressure measuring tool for the hydraulic system (mini-mesh connection). 5. Multimeter oscilloscope and mA signaller.

6. Magnetic field indicator for Solenoid valve spools. 7. A number of plugs for I/O fault finding.

8. Test box for testing ELVA/ELFI.

9. Programs and data files for the whole system.

10. Portable PMI equipment with special cable and inverter plug (for mounting in TSA box) for connection, (see picture below).

Portable PMI equipment with special cable and inverter plug (for mounting in TSA box) for connection.

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11.4. Overview MPC connections

• Check that each Fuse is the specified type. Overview J-Fuse plugs on MPC:

J-plug number

Function of fuse

1 Powersupply 2 Powerfailure

3-9 Power Out 24V

10 Connecting terminals (Loop etc.)

20-37 Analog In

40-47 Fast Digital In(Galv. Isolated) 48-53 Fast Digital In/out(Galv. Isolated)

60-61 Digital Out(Galv. Isolated)

65-66 Network connections

67 Service terminal

70-71 Analog Out(Galv. Isolated)

80-85 Digital Out(Galv. Isolated)

206 Dongle Key connect

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11.5. MPC

LED

Indication

This following describes MPC LED indications. The first part of the document describes the syntax of the LED indication and assigns a short description to each of the used indications. The second part presents a more detailed description of the different indications.

Syntax

The MPC LED may be issuing indications by either emitting constant light or by flashing. The LED indications are uniquely identified by the color that the MPC LED emits.

Flashing LED indication consists of two pulse trains separated in time by 1-second pauses. Each of these pulse trains represents an integer. All pulses are be set against a yellow background. The first pulse train will alternate between the yellow background and a red foreground, whilst the second will use green as foreground.

First digit 1 second pause Second digit 1 second pause

For identification of the indication the user must therefore note the number of red and green pulses. The first digit is the number of red pulses and the second digit is the number of green pulses. In the illustration above, the indication code would thus be (2,3).

Indications

Constant

Colour Short name Short description

Red ERROR Either early initialization or fatal error

Orange INIT Initialization, no parameters available or non-normal node mode

Green NORMAL Application up and running

Flashing

Digits Short name Short description

(1,1) CTRL_PRG Onboard control programming in progress

(2,1) APPLOAD_SCAN Application download in progress – scanning for server (2,2) APPLOAD_DOWNLOAD Application download in progress – downloading

program

(2,3) APPLOAD_DIP Application download completed – reset yellow DIP switch set to ON

(3,1) BOOTLOAD_SCAN Bootloader download in progress – scanning for server (3,2) BOOTLOAD_DOWNLOAD Bootloader download in progress – downloading

program

(4,1) DONGLE_VERIFY Checking node ID-key

(4,2) DONGLE_ERROR ID-key error – missing, broken or not programmed (4,3) DONGLE_DIP Node ID DIP switch not correctly reset – reset it to 0x00

Kdrev\ME_Testbed_Procedure\Proc_1\ 3090532-9.0_ver.3.21.doc

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Detailed Description of LED indications

ERROR (Red)

This code is used primarily for indicating if the MPC has experienced a fatal error. However, the MPC will also use this indicating during early initialization. Therefore the user should only take this code as an indication of error if it persists more than 10 seconds.

INIT (Orange)

Generally this code is used for indicating initialization. But the MPC may also use this indication to signal one of the following conditions:

No parameters: No valid parameters are available to the application software. Configuration or test mode: The MPC is in a non-normal node mode.

Generally if the INIT code is shown longer than 10 seconds this would indicate one of the latter conditions.

NORMAL (Green)

Application is up and running.

CTRL_PGM (1,1)

One of the on-board micro controllers is being programmed. This is a part of the MPC initialization process.

APPLOAD_SCAN (2,1)

The application software download program (bootloader) is trying to find a server from which it can download its application program. If this code persists it indicates either that no application program server is connected to the network or the network is broken.

APPLOAD_DOWNLOAD (2,2)

An application program is being downloaded.

APPLOAD_DIP (2,3)

The yellow DIP-switch on the MPC CPU board can be used for forcing download of new application software. To avoid looping it is therefore required that the yellow DIP-switch be reset on completion of such a forced download. Reset it to ON/down.

BOOTLOAD_SCAN (3,1)

This indication is analogous to the APPLOAD_SCAN indication except that this code indicates that there is not server available from which the MPC can download a new bootloader. This code should only be indicated if attempts are being made to update the bootloader using the special update program.

BOOTLOAD_DOWNLOAD (3,2)

A new bootloader program is being downloaded and programmed.

ID-key_VERIFY (4,1)

The ID-key is being checked. This should only take a couple of seconds.

ID-key_ERROR (4,2)

A ID-key error has been identified. Either the ID-key is missing, broken or holds an invalid value. Try to reprogram it.

ID-key_DIP (4,3)

The DIP-switch mounted on the CMI/O board is used for programming the ID-key. The programming process requires that this DIP-switch be reset before completing. This code is used for indicating this to the user. Reset the CMI/O board DIP switches to OFF/down.

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Flowchart

Error code LED 4,2

Copy dongle value to RAM

[error] _{Indicate dongle} error via LED

Copy DIP-switch value to RAM [error] Program value from DIP-switch to dongle [ok] Halt

Wait for neutral DIP-switch [not neutral]

[neutral]

Check DIP switch setting [ok]

Indicate non-neutral DIP-switch via LED

Remains here until dongle has been

programmed! Missing dongle or

invalid value or invalid checksum

Invalid DIP switch value (neutral or

out-of-range)

Return LED to previous state

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11.6. Settings of Liquiphant level switch

High pressure leak flow

Mounted in ACU-3 plug 21

Leakage from hydraulic unit-leak Alarm level Mounted in ACU-2 plug 27

Leakage from hydraulic unit-leak Shout down level Mounted in ACU-1 plug 27

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(46)

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ACU 1

Power Filter Board

Power input/Output plugs etc.

Plug No. Cabel ID Channel Type Signal ID Type Action Check

1 WPACU1 Power input A Power Supply Input A Analog 24 Vdc Check A= - / B= + 1 WPACU1 Power input B Power Supply Input B Analog 24 Vdc Check A= - / C= +

2 Power failure

3 W1202-A 2A output unfilt.

4 3.15 output unfilt.

5 WLOP3 2A output unfilt.

6 WLOP3 2A output unfilt. Power for Engine not ready Plug J83 Check A= - / B= + 7 WLOP3 2A output unfilt. Power for Start air distr. system in service Plug J84 Check A= -/ B= + 8 2A output unfilt Power for Main starting valve in service Plug J85 Check A= -/ B= + 9 Intern to J90 10A output filtered Power for prop-valve control amplifier Plug J90 Check C= -/ D= +

Control Main I/O Board

Analog/Digital Input

Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Intern to J91 Low BW 1224-1 Prop valve amp. O.k. (DI)

Power on = reading in service terminal is on 21 W1111-A Low BW 1111-A Main starting Valve Blocked input (DI superv) Activate valve 22 W1109-A Low BW 1110-A Turning gear engaged input (indication) (DI superv) Activate turning gear 23 W1109-A Low BW 1109-A Turning gear disengaged input (DI superv) Activate turning gear 24 W1112-A Low BW 1112-A Main Starting valve "In Service" input (DI superv) Activate valve 25 W1116-A Low BW 1116-A Start Air Distribution system in service (DI superv) Activate valve

26 WLOP3 Low BW 2158-A Lamp test

Activate push buttom

on LOP

27 W1236 Low BW 1236

Lekage from hydraulic unit-leak shutdown level SHD

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Document id: 3090532-9.3.4 Resp.:2300/AAJ/LLL 7/11/2006

2

Connection and Function Test

ACU 1

Loop Terminals

Plug No. Cabel ID

Channel

Type Signal ID Type Action Check

10 A 10 B 10 C 10 D 10 E 10 F 10 G 10 H 10 I 10 J

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ACU 1

Analog/Digital Input

Plug No. Cabel ID Channel Type Signal ID Type Action Check

30 W1238-1.1 High/Low BW 1238-1

Proportional valve position feedback (AL)

Dismount the plug on valve and the reading in service terminal to be app. 12mA

31 W1201-1 High/Low BW 1201-1

Hydraulic pressure after non-return valve (AL)

Dismount the plug on valve and see the change of setting from mA to #value# reading

in service terminal

32 W1204-A High/Low BW 1204-A

Lube oil pressure at pump inlet after filter (AL)

in service terminal

33 W1208-A High/Low BW 1208-A Hydraulic booster pressure (AL)

in service terminal

34 W1222-1.1 High/Low BW 1222-1 Swash-plate position feedback (AL)

in service terminal

35 High/Low BW

36 W8503-A High/Low BW 8503-A Control air pressure (AL)

in service terminal

37 W8501-A High/Low BW 8501-A Starting air pressure (AL)

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4 ACU 1

Fast Digital Input

Plug No. Cabel ID Channel Type Signal ID Type Action Check

40 TPU ch.0 8621-1 Blower 1 remote/local-fail (DI) Check on / off signal in service teminal 41 TPU ch.1 8623-1 Blower 1 running (DI) Check on / off signal in service teminal 42 TPU ch.2 8621-4 Blower 4 remote/local-fail (DI) Check on / off signal in service teminal 43 TPU ch.3 8623-4 Blower 4 running (DI) Check on / off signal in service teminal

44 TPU ch.4 1212-A or 1218-1 Start Up pump or

El. Driven pump 1 remote/local-fail (DI)

Change of switch in starter box for Start-up

pump

45 TPU ch.5

1213-A or 1219-1

Start up pump running or

El. Driven pump 1 running (DI) Check on / off signal in service teminal

46 TPU ch.6

47

Intern to

J80 TPU ch.7 System by-pass 1202-A supervision

When on in J47 it must be off in J80 and visa

versa

Fast Digital Output

48 Intern to J91 TPU ch.8 1223-1 Prop valve amplifier enabel (DO)

See internal elctric drawning 0794621-8.1and check fysical. 49 WLOP3 TPU ch.9 2106-A Load Limitation-Local indication (DO) Activate in sevice terminal and check in LOP 50 WLOP3 TPU ch.10 2107-A Start failure (DO) Activate in sevice terminal and check in LOP 51 WLOP3 TPU ch.11 1264-A Aux. Blowers Warning (DO) Activate in sevice terminal and check in LOP 52 WLOP3 TPU ch.12 1263-A Aux. Blowers Running (DO) Activate in sevice terminal and check in LOP 53 WLOP3 TPU ch.13 2181-A Turning Gear Disengaged (DO) Activate in sevice terminal and check in LOP

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Switch Output (memory mapped latch)

60 Start blocked (LOP indication) (DO)

Simulate a start block ad check indication in

LOP

61 WSTS1

1210-1 or 1217-1

Start Up Pump start/stop or

El.driven pump 1 start/stop(DO) Check pump start / stop

ACU 1

Control Network

65 WNACU2A Line A - Network line A Check with service terminal in EICU 65 WNACU1A Line A - Network line A Check with service terminal in EICU 66 WNACU2B Line B - Network line B Check with service terminal in EICU 66 WNACU1B Line B - Network line B Check with service terminal in EICU

Serial communication

Plug No. Cabel ID Channel Type Signal ID Type Action Check 68

AO-DO Daughter Board

Analog Output (controlled by QSPI)

70

Intern to

J91 1240-1 Swash-plate command (set point) (AO)

Set output to valve and check on pump

feedback is the same on ch.34

71 1250

Hydraulic pressure (for LOP indication )

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6 ACU 1

Contact Output (memory mapped latch)

80 W1202-A 1202-A

System by-pass valve solenoid A (DO-superv)

When on in J47 it must be off in J80 and visa

versa

81 8620-4 Blower 4 start/stop (DO) (option)

82 WAUXB1 8620-1 Blower 1 start/stop (DO)

Give command to blower from service

terminal

83 WLOP3 2210-A

Engine not ready output for the LOP (DO)

Give command from service terminal and

check in LOP

84 WLOP3 1170-A

Start air distribution system in service (DO)

check in LOP

85 WLOP3 1171-A

Main starting valve in service position (DO)

check in LOP

90 W1238-P1 Supply for prop.valve via amplifier

0 Amper. =full ah and 1.5 Amper. = full astern.on swash plate. Remember hydraulic

pressure 91 Intern to J- 20-48-70+resistor 6K8

See internal elctric drawning 0794621-8.1and check fysical.

(53)

ACU 2

Power Filter Board

Power input/Output plugs etc.

1 WPACU2 Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPACU2 Power input B Power Supply Input B Analog 24 Vdc A= - / C= +

2 Power failure 3 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out 9 Intern to J90 10A output

Electrical Syst Me

MAN B&W Diesel A/S

Connection

and

Function Test

of electrical system

for ME Engine

July 2006

Table of Contents

1

Power Supply Check

5

1.1

MPC fuse specification

5

2

ID-key Boot Loader Program

5

2.1

Operation 5

2.2

Programming the ID-key (Network Address)

8

2.3

2.3 Troubleshooting LED messages

10

3

Network Test

11

3.1

3.1 Access to Service Terminal

12

4

Updating and Archiving MPC Parameters from the MOP

14

4.1

MPC Parameter update

14

4.2

Archiving Parameter Files

15

4.3

4.3 How to make a copy of ECU-A into ECU-B:

16

4.4

(for Soft Ware version 1.34 or later)

16

4.5 18

5

Connection test of I/O

18

6

Check of Serial Communication between RCS and ECS

18

6.1

How to inspect Serial communication between RCS and ECS

18

6.2

How to simulate values from ECS to RCS

18

7

Adjustment of encoder

19

7.1

Check Tacho system cable

19

7.2

Check of encoder adjustment.

20

7.3

Adjustment of encoder-clockwise

21

7.4

Check of tacho sensor at flywheel.

23

8

Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm

23

8.1

Connection test of ELFI valve without hydraulic pressure