Electrical Syst Me

MAN B&W Diesel A/S

Connection and Function Test of electrical system for ME Engine

July 2006

MAN B&W Diesel A/S

Table of Contents 1

Power Supply Check 1.1

2

MPC fuse specification

2.2

5

Connections and settings – normal operation Start-up normal operation

6 7

Programming the ID-key (Network Address)

2.2.1 2.2.2

2.3

5

Operation

2.1.1 2.1.2

8

Connections and settings – programming. Programming Sequence for ID-Key

8 9

2.3 Troubleshooting LED messages

10

Network Test 3.1

4

5

ID-key Boot Loader Program 2.1

3

5

11

3.1 Access to Service Terminal

12

Updating and Archiving MPC Parameters from the MOP 4.1 4.2 4.3 4.4 4.5

14

MPC Parameter update Archiving Parameter Files 4.3 How to make a copy of ECU-A into ECU-B: (for Soft Ware version 1.34 or later) 18

14 15 16 16

5

Connection test of I/O

18

6

Check of Serial Communication between RCS and ECS

18

6.1 6.2 7

Adjustment of encoder 7.1 7.2 7.3 7.4

8

Check Tacho system cable Check of encoder adjustment. Adjustment of encoder-clockwise Check of tacho sensor at flywheel.

19 20 21 23

Connection test of ELFI valve without hydraulic pressure Connection test of ELVA valve without hydraulic pressure Connection test of ELVA valve with hydraulic pressure (app. 175 bar) Connection test of FIVA valve with hydraulic pressure (app. 175 bar) Connection test of starting air valves Test of main starting air valve manually on the MOP Connection test of HCU oil leakage alarm Hints for connection test and fault finding:

Test of Swash-plate pumps (Hydraulic-Pressure On) 9.1 9.2

Functions test Troubleshooting

23 23 24 24 25 25 25 26 26 29 29 30

10 ME Alpha Lubricator Quick Guide Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

18 18 19

Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

9

How to inspect Serial communication between RCS and ECS How to simulate values from ECS to RCS

32 2

Connection and Function Test

MAN B&W Diesel A/S 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 11.1 11.2. 11.3. 11.4. 11.5. 11.6. 11.7.

38

Opening and setting up the Hyper Terminal program Swash plate position values Tools for commissioning Overview MPC connections MPC LED Indication Settings of Liquiphant level switch Connection test scheme

Document History: Date 2005-06-09

Author AAJ

2005-07-20

AAJ

2005-08-04

AAJ

38 39 39 40 41 44 1

Changes ACU4 added F9 6A » 10A F4 2A » 3,15A Connection test scheme for CCU, ACU,EICU & ECU changed signal text and signal ID Adjustment of encoder updated 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

2005-09-14

Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

AAJ

9. ME Alpha lubricator quick guide added 4.3 How to make a copy of ECU A into ECU B added Picture of MOP-screen insert regarding new ArcHive/update tool 4.0 and

AAJ

3

Connection and Function Test

MAN B&W Diesel A/S

2005-09-27

AAJ

2005-10-29

AAJ

2006-07-11

AAJ

2006-07-11

AAJ

Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

Network status 3.0 Updated 2.2.1 Connections and settings-programming (DIP-switch) Updated 2.2.1 Connections and settings-programming (DIP-switch) (CCU8) Update 9 ME Alpha lubricator quick guide text Added 6 Check of Serial communication between RCS and ECS

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MAN B&W Diesel A/S

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: • •

2.1

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.

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

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•

ON ⇒ Binary 1

•

OFF ⇒ Binary 0

Connection and Function Test

MAN B&W Diesel A/S 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.

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

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.

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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 DIPswitch S1 MPC Network Address ACU 1 ACU 2 ACU 3 ACU 4 ECU A ECU B EICU A EICU B CCU 1 CCU 2 CCU 3 CCU 4 CCU 5 CCU 6 CCU 7 CCU 8 CCU 9 CCU 10 CCU 11 CCU 12 CCU 13 CCU 14 CCU 15 CCU16

224 225 226 239 208 209 192 193 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255

1

2

3

4

5

6

7

8

DIP switch S1 Settings

Off On Off On Off On Off On Off On Off On Off On Off On Off On Off On Off On Off On

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Off Off On On Off Off Off Off Off Off On On Off Off On On Off Off On On Off Off On On

Off Off Off On Off Off Off Off Off Off Off Off On On On On Off Off Off Off On On On On

Off Off Off On Off Off Off Off Off Off Off Off Off Off Off Off On On On On On On On On

8

Off Off Off Off On On Off Off On On On On On On On On On On On On On On On On

On On On On Off Off Off Off On On On On On On On On On On On On On On On On

On On On On On On On On On On On On On On On On On On On On On On On On

On On On On On On On On On On On On On On On On On On On On On On On On

Connection and Function Test

MAN B&W Diesel A/S

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 DIP-switch (S1) back to its neutral position (2d). When the DIPswitch S1 is set to neutral (off), the MPC is now ready to continue normal booting operation.

2a Starting Basic System... Testing RAM... RAM OK Initialising BES kernel...OK Starting dongle verification

2b 2c

Reading Dongle ID......not connected!

2d

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...

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

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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 ID-key, ID from the DIP-switch S1, but cannot program the IDkey 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-ofrange. 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 DIPswitch S1 to Program the ID-key, ID”. Cause: ID-key is defective. Solution: Replace ID-key.

Error code 4,2

Description ID-key not connected Invalid Dongle ID Invalid DIP-switch S1 value Programming ID-key failed DIP-switch S1 not neutral

4,3

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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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MAN B&W Diesel A/S

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 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 ++. The first column is the first value after 0x, the top row is the second value, i.e. CCU1 = (0x)F0.

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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 Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

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Connection and Function Test

MAN B&W Diesel A/S The same procedure is used to copy ECUA into ECUB.

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MAN B&W Diesel A/S 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 as described below. Access to Service Terminal (System test): 1 2 3 4 5 6

Type followed by pressing enter. Select . Select . Answer y to continue followed by pressing enter Select 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 •

• •

6.2

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).

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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MAN B&W Diesel A/S •

•

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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MAN B&W Diesel A/S

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 Pick Up Conn. T.Box Plug T. Box MPC Plug

7.2

13 Q1B TSA-B J1 J46

14 Q2B TSA-B J2 J47 On before Q1B

10 Q2A TSA-A J2 J43 On before Q1A

11 MMB TSA-B J3 J44 45-225 deg

12 MSB TSA-B J4 J45 135-315 deg.

1 MMA TSA-A J3 J40 0-180 deg.

2 MSA TSA-A J4 J41 90-270 deg.

9 Q1A TSA-A J1 J42

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). Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

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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 Pick Up Conn. T.Box Plug T. Box MPC Plug

13 Q1B TSA-B J1 J46

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14 Q2B TSA-B J2 J47 On before Q1B

10 Q2A TSA-A J2 J43 On before Q1A

11 MMB TSA-B J3 J44 45-225 deg

22

12 MSB TSA-B J4 J45 135-315 deg.

1 MMA TSA-A J3 J40 0-180 deg.

2 MSA TSA-A J4 J41 90-270 deg.

9 Q1A TSA-A J1 J42

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MAN B&W Diesel A/S

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 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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Connection and Function Test

MAN B&W Diesel A/S 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. The output channel 49 should be set to ON when finish testing.

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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. 2.

8.6

During output test channel 50 is activated and it is controlled that the valve reacts (click or extern magnetic field tester). The test is repeated for every single cylinder.

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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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 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).

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.

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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. 2. 3. 4.

Unmonitored fuse has blown. (See fuse specification Appendix 9.4) Cabling and plugs, loose or wrong connections. Sensor failure/adjustment is not correct. Defective MPC (input channel).

Actuator error 1. 2. 3. 4.

Unmonitored fuse has blown. Cabling and plugs, loose or wrong connections. Sensor failure/adjustment is not correct. 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 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).

o

“System Test => Connection Test => Input Test” now follow the 3 points below

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MAN B&W Diesel A/S 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)

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,SwashPlate Position => Scaling => Row 2 Input (mA)

Adjust parameters => Edit parameters => IOConfig => Ch34,1222-1,SwashPlate Position => Scaling => Row 1 Input (mA)

ACU 1 ACU 2 ACU 3 Parameter path on the MPC in Service Terminal

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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The correct position of the jumpers are illustrated below:

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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” Activates Prelubrication on all cylinders and evaluates feedback from the lubricators. Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

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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 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 is constant and independent of load. Because of the relation between speed and load the actual feedrate will increase when load is decreasing with a constant activation Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

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MAN B&W Diesel A/S 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. The calculation of the activation rate depending on load and speed is performed in this way:

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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% BasicFeedRate MinFeedRate FeedRate Adjust 1.1 MinIndexWithPowerLube 0.4 MCR Speed MCR Load per cyl. InjectionMass Index [0;1]

Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

3.2 1.09 g/kWh 0.7 g/kWh

105 rpm 2260 kW 1.0 g

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M nominel (Activation frequency) =(BasicFeedRate(g/kWh)*MCRLoad(kW))/(60*MCRSpeed(rpm)*InjectionMass) =0.39 If no limiters are active and “Running In” =0%, not LCD and Index >0.4. M(actual)=Mnominal*FeedRateAdjust*Index =0.39*1.1*Index =>(Load regulation) If no limiters are active and “Running In” =0%, not LCD and Index (Speed regulation) If no limiters are active and “Running In”=100% and not LCD M(actual)= Mnominal*FeedRateAdjust*(1+(Running In)/100) =0.39*1.1*(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: Document id: 3090532-9.4.7 Resp.:2300/AAJ/LLL 2006-07-11

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MAN B&W Diesel A/S 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) dependent.

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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 o Flow control: Xon/Xoff

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Swash plate position values 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 = Full angle Astern =

mA mA

11.3. Tools for commissioning 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

PC with Hyper terminal installed and a zero modem cable Electronic or mechanic tool for measuring of highest/lowest point on trigger/tacho rings. Tacho sensor adjusting tool (marked). Portable pressure measuring tool for the hydraulic system (mini-mesh connection). Multimeter oscilloscope and mA signaller. Magnetic field indicator for Solenoid valve spools. A number of plugs for I/O fault finding. Test box for testing ELVA/ELFI. Programs and data files for the whole system. 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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MAN B&W Diesel A/S 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 2 3-9 10 20-37 40-47 48-53 60-61 65-66 67 70-71 80-85 206 210

Powersupply Powerfailure Power Out 24V Connecting terminals (Loop etc.) Analog In Fast Digital In(Galv. Isolated) Fast Digital In/out(Galv. Isolated) Digital Out(Galv. Isolated) Network connections Service terminal Analog Out(Galv. Isolated) Digital Out(Galv. Isolated) Dongle Key connect Battery

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

Short name ERROR INIT

Green

NORMAL

Flashing Digits (1,1) (2,1) (2,2)

Short name CTRL_PRG APPLOAD_SCAN APPLOAD_DOWNLOAD

(2,3)

APPLOAD_DIP

(3,1) (3,2)

BOOTLOAD_SCAN BOOTLOAD_DOWNLOAD

(4,1) (4,2) (4,3)

DONGLE_VERIFY DONGLE_ERROR DONGLE_DIP

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Short description Either early initialization or fatal error Initialization, no parameters available or non-normal node mode Application up and running

Short description Onboard control programming in progress Application download in progress – scanning for server Application download in progress – downloading program Application download completed – reset yellow DIP switch set to ON Bootloader download in progress – scanning for server Bootloader download in progress – downloading program Checking node ID-key ID-key error – missing, broken or not programmed Node ID DIP switch not correctly reset – reset it to 0x00

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MAN B&W Diesel A/S 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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MAN B&W Diesel A/S Flowchart Error code LED 4,2 Missing dongle or invalid value or invalid checksum

Copy dongle value to RAM

[error]

Indicate dongle error via LED

[ok]

Copy DIP-switch value to RAM

Invalid DIP switch value (neutral or outof-range)

[error] Halt [ok] Check DIP switch setting

Program value from DIP-switch to dongle Remains here until dongle has been programmed!

[not neutral]

[neutral] Indicate nonneutral DIPswitch via LED

Wait for neutral DIP-switch

Return LED to previous state

Error code LED 4,3

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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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MAN B&W Diesel A/S Settings of dipswitch:

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11.7. Connection test scheme

ACU 1 Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8 9

WPACU1 WPACU1

Power input A Power input B Power failure 2A output unfilt. 3.15 output unfilt. 2A output unfilt. 2A output unfilt. 2A output unfilt. 2A output unfilt 10A output filtered

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

Check A= - / B= + Check A= - / C= +

Power for Engine not ready Plug J83 Power for Start air distr. system in service Plug J84 Power for Main starting valve in service Plug J85 Power for prop-valve control amplifier Plug J90

Check A= - / B= + Check A= -/ B= + Check A= -/ B= + Check C= -/ D= +

Channel Type

Signal ID

W1202-A WLOP3 WLOP3 WLOP3 Intern to J90

Check

Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

Type

20 21 22 23 24 25

Intern to J91 W1111-A W1109-A W1109-A W1112-A W1116-A

Low BW Low BW Low BW Low BW Low BW Low BW

1224-1 1111-A 1110-A 1109-A 1112-A 1116-A

Prop valve amp. O.k. (DI) Main starting Valve Blocked input (DI superv) Turning gear engaged input (indication) (DI superv) Turning gear disengaged input (DI superv) Main Starting valve "In Service" input (DI superv) Start Air Distribution system in service (DI superv)

26

WLOP3

Low BW

2158-A

27

W1236

Low BW

1236

Lamp test Lekage from hydraulic unit-leak shutdown level SHD (NO) (DI superv)

Action Power on = reading in service terminal is on Activate valve Activate turning gear Activate turning gear Activate valve Activate valve Activate push buttom on LOP Activate the sensor

Check

MAN B&W Diesel A/S

ACU 1 Loop Terminals

Plug No.

Cabel ID

10 10 10 10 10 10 10 10 10 10

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Channel Type

Signal ID

Type

Action

Check

A B C D E F G H I J

2

Connection and Function Test

MAN B&W Diesel A/S

ACU 1 Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

Channel Type

Signal ID

30

W1238-1.1

High/Low BW

1238-1

Type Proportional valve position feedback (AL)

31

W1201-1

High/Low BW

1201-1

Hydraulic pressure after non-return valve (AL)

32

W1204-A

High/Low BW

1204-A

Lube oil pressure at pump inlet after filter (AL)

33

W1208-A

High/Low BW

1208-A

Hydraulic booster pressure (AL)

34 35

W1222-1.1

High/Low BW High/Low BW

1222-1

Swash-plate position feedback (AL)

36

W8503-A

High/Low BW

8503-A

Control air pressure (AL)

37

W8501-A

High/Low BW

8501-A

Starting air pressure (AL)

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

3

Action Dismount the plug on valve and the reading in service terminal to be app. 12mA Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal

Check

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

Connection and Function Test

MAN B&W Diesel A/S

ACU 1 Fast Digital Input Plug No.

Channel Type

Signal ID

Type

Action

40 41 42 43

TPU ch.0 TPU ch.1 TPU ch.2 TPU ch.3

TPU ch.4

45 46

TPU ch.5 TPU ch.6

Blower 1 remote/local-fail (DI) Blower 1 running (DI) Blower 4 remote/local-fail (DI) Blower 4 running (DI) Start Up pump or El. Driven pump 1 remote/local-fail (DI) Start up pump running or El. Driven pump 1 running (DI)

Check on / off signal in service teminal Check on / off signal in service teminal Check on / off signal in service teminal Check on / off signal in service teminal

44

8621-1 8623-1 8621-4 8623-4 1212-A or 1218-1 1213-A or 1219-1

47

Cabel ID

Intern to J80

TPU ch.7

System by-pass 1202-A supervision

Check

Change of switch in starter box for Start-up pump

Check on / off signal in service teminal When on in J47 it must be off in J80 and visa versa

Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

Channel Type

Signal ID

Type

48 49 50 51 52 53

Intern to J91 WLOP3 WLOP3 WLOP3 WLOP3 WLOP3

TPU ch.8 TPU ch.9 TPU ch.10 TPU ch.11 TPU ch.12 TPU ch.13

1223-1 2106-A 2107-A 1264-A 1263-A 2181-A

Prop valve amplifier enabel (DO) Load Limitation-Local indication (DO) Start failure (DO) Aux. Blowers Warning (DO) Aux. Blowers Running (DO) Turning Gear Disengaged (DO)

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

4

Action See internal elctric drawning 0794621-8.1and check fysical. Activate in sevice terminal and check in LOP Activate in sevice terminal and check in LOP Activate in sevice terminal and check in LOP Activate in sevice terminal and check in LOP Activate in sevice terminal and check in LOP

Check

Connection and Function Test

MAN B&W Diesel A/S

Switch Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

1210-1 or 1217-1

Start blocked (LOP indication) (DO) Start Up Pump start/stop or El.driven pump 1 start/stop(DO)

60

61

WSTS1

Action Simulate a start block ad check indication in LOP

Check

Check pump start / stop

ACU 1 Control Network Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

Check

65 65 66 66

WNACU2A WNACU1A WNACU2B WNACU1B

Line A Line A Line B Line B

-

Network line A Network line A Network line B Network line B

Check with service terminal in EICU Check with service terminal in EICU Check with service terminal in EICU Check with service terminal in EICU

Signal ID

Type

Action

Check

Signal ID

Type

Action

Check

1240-1

Swash-plate command (set point) (AO) Hydraulic pressure (for LOP indication ) (AO)

Serial communication Plug No.

Cabel ID

Channel Type

68 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No.

Cabel ID

70

Intern to J91

71

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

Channel Type

1250

5

Set output to valve and check on pump feedback is the same on ch.34

Connection and Function Test

MAN B&W Diesel A/S

ACU 1 Contact Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

System by-pass valve solenoid A (DOsuperv) Blower 4 start/stop (DO) (option)

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

80 81

W1202-A

1202-A 8620-4

82

WAUXB1

8620-1

83

WLOP3

2210-A

84

WLOP3

1170-A

85

WLOP3

1171-A

Blower 1 start/stop (DO) Engine not ready output for the LOP (DO) Start air distribution system in service (DO) Main starting valve in service position (DO)

Plug No.

Cabel ID

Signal ID

Type

90

W1238-P1 Intern to J20-4870+resistor 6K8

91

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

Channel Type

Supply for prop.valve via amplifier

Check

Give command to blower from service terminal Give command from service terminal and check in LOP Give command from service terminal and check in LOP Give command from service terminal and check in LOP Action 0 Amper. =full ah and 1.5 Amper. = full astern.on swash plate. Remember hydraulic pressure

Check

See internal elctric drawning 0794621-8.1and check fysical.

6

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8

WPACU2 WPACU2

Power input A Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

A= - / B= + A= - / C= +

Intern to J90

10A output filtered

Supply for prop-valve control amp.

C= - / D= +

9

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

7

Check

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

20

Channel Type

Signal ID

Type

Action

Low BW

1224-2

Prop valve amp. O.k. (DI) Main starting Valve Blocked input (DI superv) Turning gear engaged input (DI superv) Turning gear disengaged input (DI superv) Main Starting valve "In Service" input (DI superv) Start Air Distribution system in service (DI superv) Lamp test Leakage from hydraulic unit-leak alarm level (NO) (DI superv)

Power on = reading in service terminal is on

21 22

W1111-B W1109-B

Low BW Low BW

1111-B 1110-B

23

W1109-B

Low BW

1109-B

24

W1112-B

Low BW

1112-B

25 26

W1116-B

Low BW Low BW

1116-B 2158-B

27

W1235

Low BW

1235

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

8

Check

Activate valve Activate turning gear Activate turning gear Activate valve Activate valve Activate push buttom in LOP Activate the sensor

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Loop Terminals Plug No.

Cabel ID

10 10 10 10 10 10 10 10 10 10 10

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

Channel Type

Signal ID

Type

Action

Check

A B C D E F G H I J J

9

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

Channel Type

Signal ID

30

W1238-2.1

High/Low BW

1238-2

Type Proportional valve position feedback (AL)

31

W1201-2

High/Low BW

1201-2

Lube oil pressure at pump inlet after filter (AL)

32

W1204-B

High/Low BW

1204-2

Lube oil pressure at pump inlet after filter (AL)

33

1208-B

High/Low BW

1208-4

Hydraulic booster pressure (AL)

34 35

W1222-2.1

High/Low BW High/Low BW

1222-2

Swash-plate position feedback (AL)

36

W8503-B

High/Low BW

8503-B

Control air pressure (AL)

37

W8501-B

High/Low BW High/Low BW

8501-B

Starting air pressure (AL)

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

10

Action Dismount the plug on valve and the reading in service terminal to be app. 12mA Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading in service terminal

Check

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

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Fast Digital Input Plug No.

Channel Type

Signal ID

Type

Action

40 41 42 43

Cabel ID

TPU ch.0 TPU ch.1 TPU ch.2 TPU ch.3

TPU ch.4

45 46 47

TPU ch.5 TPU ch.6 TPU ch.7

Blower 2 remote/local-fail (DI) Blower 2 running (DI) Blower 5 remote/local-fail (DI) Blower 5 running (DI) Start Up pump remote/local-fail or El. Driven pump 2 remote/local-fail(DI) Start up pump running or El. Driven pump2 running(DI)

Check on / off signal in service teminal Check on / off signal in service teminal Check on / off signal in service teminal Check on / off signal in service teminal

44

8621-2 8623-2 8621-5 8623-5 1212-B or 1218-2 1213-B or 1219-2

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

11

Check

Change of switch in starter box for Start-up pump

Check on / off signal in service teminal

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

48 49 50 51 52 53

Intern to J91

Channel Type

Signal ID

Type

TPU ch.8 TPU ch.9 TPU ch.10 TPU ch.11 TPU ch.12 TPU ch.13

1223-2 2106-B 2107-B 1264-B 1263-B 2181-B

Prop valve amplifier enabel (DO) Load limitation (local indc) (DO) Start failure (DO) Aux.blower Warning (DO) Aux.blower Warning (DO) Turning Gear Disengaged (DO)

Action

Check

See internal elctric drawning 0794621-8.1and check fysical.

Switch Output (memory mapped latch) Plug No.

Cabel ID

60

W1216-A

61

WSTS2

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

Channel Type

Signal ID

Type

Action

1210-2 or 1217-2

Start Up Pump start/stop or El.driven pump 2 start / stop(DO)

Check pump start / stop

12

Check

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 Control Network Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

65 65 66 66

WNACU3A WNACU2A WNACU3B WNACU2B

Line A Line A Line B Line B

-

Network line A Network line A Network line B Network line B

Check with service terminal in EICU Check with service terminal in EICU Check with service terminal in EICU Check with service terminal in EICU

Signal ID

Type

Action

Check

Serial communication Plug No.

Cabel ID

Channel Type

Check

68

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

13

Connection and Function Test

MAN B&W Diesel A/S

ACU 2 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. 70 71

Cabel ID Intern to J91

Channel Type

Signal ID

Type

1240-2 8601

Swash-plate command (set point) (AO) Scavenge air pressure (AO)

Signal ID 2108 8620-5

Type Start blocked (for LOP indication) (DO) Blower 5 start/stop (DO)

Action Set output to valve and check on pump feedback is the same on ch.34

Check

Action

Check

Contact Output (memory mapped latch) Plug No. 80 81

Cabel ID

82 83

WAUXB2 WLOP3

8620-2 2210-B

84

WLOP3

1116-B

85

WLOP3

1112-B

Blower 2 start/stop (DO) Engine not ready (LOP indication) (DO) Start air distribution system in service for LOP indication Main Starting Valve in service position for LOP indication

Plug No.

Cabel ID

Signal ID

Type

Action

Supply for prop.valve via amplifier

0 Amper. =full ah and 1.5 Amper. = full astern.on swash plate. Rember hydrulic pressure

90

91

W1238-P2 Intern to J20-4870+resistor 6K8

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

Channel Type

Channel Type

Give command to blower from service terminal Give command from service terminal and check in LOP Give command from service terminal and check in LOP Check

See internal elctric drawning 0794621-8.1and check fysical.

14

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8

WPACU3 WPACU3

Power input A Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

A= - / B= + A= - / C= +

9

Intern ti J90

Supply for prop-valve control amp.

C= - / D= +

W1202-B

10A output filtered

Check

Control Main I/O Board Analog/Digital Input Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

20 21 22

Low BW Low BW Low BW

1224-3 1234 1233

Power on = reading in service terminal is on

23 24 25 26 27

Low BW Low BW Low BW Low BW Low BW

1231 1232 1237 1239

Prop valve amplifier O.k. (DI) High pressure leak flow (NO) (DI superv) High pressure leak pressure (AL superv) Filter failure (basck fluhsing filter) (NC) (DI) Filter by-pass open (NC) (DI) HCU common leak - oil (DI) HCU common leak - fuel (DI)

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

15

Check

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 Loop Terminals Plug No. Cabel ID 10 10 10 10 10 10 10 10 10 10

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

Channel Type

Signal ID

Type

Action

Check

A B C D E F G H I J

16

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 Control Main I/O Board Analog/Digital Input Plug No. Cabel ID

Channel Type

Signal ID

30

W12383.1

High/Low BW

1238-3

31

W1201-3

High/Low BW

1201-3

32

W1204C

High/Low BW

1204-3

33

W1221

High/Low BW

1204-5

High/Low BW High/Low BW High/Low BW High/Low BW

1222-3

34 35 36 37

W12223.1

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

Type

Action

Check

Dismount the plug on valve and the reading in service terminal to be app. 12mA Dismount the plug on valve and see the Hydraulic pressure after non-return valve change of setting from mA to #value# reading (AI-superv) in service terminal Dismount the plug on valve and see the Lube oil pressure at pump inlet after filter change of setting from mA to #value# reading (AI) in service terminal Dismount the plug on valve and see the Lube oil pressure at pump inlet after filter change of setting from mA to #value# reading (AI) in service terminal Dismount the plug on valve and see the change of setting from mA to #value# reading Swash-plate position feedback (AI) in service terminal Proportional valve position feedback (AI)

17

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 Fast Digital Input Plug No. Cabel ID 40 41 42 43 44 45 46

Channel Type

Signal ID

Type

TPU ch. 0 TPU ch.1 TPU ch. 2 TPU ch. 3 TPU ch. 4 TPU ch. 5 TPU ch. 6

8621-3 8623-3

Blower 3 remote/local-fail (DI) Blower 3 running (DI)

1218-3 1219-3

El. Driven pump 3 remote/local-fail El. Driven pump 3 running

Intern to 47 J80 TPU ch.7 Control Main I/O Board

System by-pass 1202-B supervision

Action

Check

Change of DO in Service terminal parameter 80

Fast Digital Output Plug No.

Cabel ID

48 49 50 51 52 53

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

Channel Type

Signal ID

Type

TPU ch.8 TPU ch.9 TPU ch.10 TPU ch.11 TPU ch.12 TPU ch.13

1223-3

Prop valve amplifier enabel (DO)

18

Action See internal elctric drawning 0794621-8.1and check fysical.

Check

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 Switch Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

Check

1217-3

El. Driven pump 3 start/stop (DO)

Channel Type Line A

Signal ID -

Type Network line A

Action Check with service terminal in EICU

Check

Line A Line B

-

Network line A Network line B

Check with service terminal in EICU Check with service terminal in EICU

Line B

-

Network line B

Check with service terminal in EICU

Channel Type

Signal ID

Type

Action

60 61 Control Network Plug No. 65 65 66 66

Cabel ID WN-XA WNACU3 A WN-XB WNACU3 B

Serial communication Plug No.

Cabel ID

Check

68

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

19

Connection and Function Test

MAN B&W Diesel A/S

ACU 3 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID 70 71

Channel Type

Intern to J91 WALCU

Signal ID

Type

Action

1240-3 8230

Swash-plate command (set point) (AO) Actual Handel position for LCD AO)

Set output to valve and check on pump feedback is the same on ch.34 See in Alpha lub procedure

Signal ID 1202-B 8231 8620-3 8232 8233 8234

Type System by-pass valve solonoide (DOsuperv) Ahead/Astern (DO) Blower 3 start/stop (DO) Engine stop MCU (DO) Engine stop BCU (DO) Prelubrication command (DO)

Action When on in J47 it must be off in J80 and visa versa See in Alpha lub procedure

Signal ID

Type

Action 0 Amper. =full ah and 1.5 Amper. = full astern.on swash plate. Rember hydrulic pressure

Check

Contact Output (memory mapped latch) Plug No. Cabel ID 80 81 82 83 84 85

W1202-B WALCU WALCU WALCU WALCU

Plug No. Cabel ID

90

91

Channel Type

W1238P3 Intern to J-20-4870+resist or 6K8

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

Channel Type

Supply for prop.valve via amplifier

Check

See in Alpha lub procedure See in Alpha lub procedure See in Alpha lub procedure

Check

See internal elctric drawning 0794621-8.1and check fysical.

20

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8

WPACU3 WPACU3

Power input A Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

A= - / B= + A= - / C= +

9

Intern ti J90

Supply for by-pass valve motor control amplifier

C= - / D= +

10A output filtered

Check

Control Main I/O Board Analog/Digital Input Plug No. Cabel ID 20 21 22 23 24 25 26 27

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

Channel Type

Signal ID

Type

Action

Low BW Low BW Low BW Low BW Low BW Low BW Low BW Low BW

8750 8751 8752 8753 8762 8763

Var. Bypass Amp. OK. (DI) Var. Bypass Position (AI) Var. Bypass Open (DI) Var. Bypass Closed (DI) On/Off Bypass Open (DI) On/Off Bypass Closed (DI)

Power on = reading in service terminal is on

21

Check

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 Loop Terminals Plug No. Cabel ID 10 10 10 10 10 10 10 10 10 10

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

Channel Type

Signal ID

Type

Action

Check

A B C D E F G H I J

22

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 Control Main I/O Board Analog/Digital Input Plug No. Cabel ID 30 31 32 33 34 35 36 37

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

Channel Type

Signal ID

Type

Action

Check

High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW

23

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 Fast Digital Input Plug No. Cabel ID

Channel Type

40 41 42 43 44 45 46 47 Control Main I/O Board

Signal ID

Type

Action

Check

Action

Check

TPU ch. 0 TPU ch.1 TPU ch. 2 TPU ch. 3 TPU ch. 4 TPU ch. 5 TPU ch. 6 TPU ch.7

Fast Digital Output Plug No.

Cabel ID

48 49 50 51 52 53

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

Channel Type

Signal ID

Type

TPU ch.8 TPU ch.9 TPU ch.10 TPU ch.11 TPU ch.12 TPU ch.13

8754

Var. By-pass amplifier enabel (DO)

24

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 Switch Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

Check

Channel Type Line A

Signal ID -

Type Network line A

Action Check with service terminal in EICU

Check

Line A Line B

-

Network line A Network line B

Check with service terminal in EICU Check with service terminal in EICU

Line B

-

Network line B

Check with service terminal in EICU

Channel Type

Signal ID

Type

Action

60 61 Control Network Plug No. 65 65 66 66

Cabel ID WN-XA WNACU3 A WN-XB WNACU3 B

Serial communication Plug No.

Cabel ID

Check

68

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

25

Connection and Function Test

MAN B&W Diesel A/S

ACU 4 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID

Channel Type

70 71

Signal ID

Type

8755

Var. Bypass Amp. (Set point) (AO)

Action

Check

Contact Output (memory mapped latch) Plug No. Cabel ID 80 81 82 83 84 85

Channel Type

Signal ID 8765

Type On/Off Bypass (Set point) (DO)

Action

Check

Plug No. Cabel ID 90 91

Channel Type

Signal ID

Type

Action

Check

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

26

Connection and Function Test

MAN B&W Diesel A/S

CCUs Power Filter Board Power input/Output plugs etc. Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

A= - / B= + A= - / C= +

Supply to ELVA amplifier. Polarity on ELVA plug = B+ og C-

Polarity on plug J4 A= - / B= +

1 1 2 3

WPCCU1 WPCCU1

Power input A Power input B Power failure 2A out

4 5 6 7 8

W4108-1

3.15A out 2A out 2A out 2A out 2A out

W41021.1

10A output filtered

9

Supply to ELFI / FIVA amplifier

Check

Polarity on plug J9 A= - / B= +

Control Main I/O Board Analog/Digital Input Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

20 21 22

Internal

Low BW Low BW

4105 8285

ELFI / FIVA amplifier OK (DI) Cyl. Lube Oil Supply Fail (DI-superv)

23 24 25 26

W4108-1

Low BW

4109

ELVA valve OK (DI)

Check cabling between ELVA plug and plug J 23, please refer to chapter 6.3

Low BW

4112

H.P. Fuel Pipe Leakage (NO) (DIsuperv)

option (check by dummy plug), Please refer to chapter 6.6

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

27

Check

Disconect plug J9 and see change of value in service terminal, Please refer to chapter 6.1

Connection and Function Test

MAN B&W Diesel A/S

CCUs Loop Terminals Plug No. 10 10 10 10 10 10 10 10 10 10

Cabel ID

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

Channel Type A B C D E F G H I J

Signal ID

Type

28

Action

Check

Connection and Function Test

MAN B&W Diesel A/S

CCUs Control Main I/O Board Analog/Digital Input Plug No. Cabel ID

Channel Type

Signal ID

Type

30

W41021.2

High/Low BW

4102

ELFI/FIVA Position feedback (AI)

31

W4114-1

High/Low BW

4114

Fuel pump Plunger Position (AI-superv)

32

WSCCU1

High/Low BW

2002

Shut Down Saftey system (DI- Special superv)

33

Internal

High/Low BW

4106

ELFI/FIVA Amp. actuel current (AI)

34 35 36 37

W4111-1

High/Low BW

4111

Exhaust valve position (AI-superv)

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

29

Action

Check

Check cabling between ELFI plug and plug J 30, Please refer to chapter 6.1 Check cabling between Fuel pump plunger plug and plug J 31 Simulate shut down in safty system and check in service terminal. And check ELFI and ELVA feedback go to zero, Please refer to chapter 6.1 Same mA value as in ch.70, Please refer to chapter 6.1 Check cabling between Exhaust Valve plug and plug J 34, Please refer to chapter 6.3

Connection and Function Test

MAN B&W Diesel A/S

CCUs Fast Digital Input Check of cabling between TSA-A / B and MPC Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

40BC 41BC 42BC 43BC 44BC 45BC 46BC 47BC

WTCCU1A WTCCU1A WTCCU1A WTCCU1A WTCCU2B WTCCU2B WTCCU2B WTCCU2B

TPU ch.0 TPU ch.1 TPU ch.2 TPU ch.3 TPU ch.4 TPU ch.5 TPU ch.6 TPU ch.7

4001-A 4002-A 4003-A 4004-A 4001-B 4001-B 4003-B 4004-B

Marker Master - Tacho set A (Di) Marker Slave - Tacho set A (Di) Quadrature 1 - Tacho set A (Di) Quadrature 2 - Tacho set A (Di) Marker Master - Tacho set B(Di) Marker Slave - Tacho set B(Di) Quadrature 1 - Tacho set B (Di) Quadreture 2 - Tacho set B (Di)

Simulate tacho signal in TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B

Channel Type

Signal ID

Type

Action

Check

Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

48

TPU ch. 8

Data Aq.Synchronization (internal signal)

49

W4108-1

TPU ch.9

4108

ELVA Valve (DO)

50 51 52

W1120-1

TPU ch.10 TPU ch.11 TPU ch. 12

1120 8281 8282 8283 or

Start air pilot valve (DO) Cyl. Lubricator Pilot Valve (DO) Cyl. Lubricator Feedback (movement)

53

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

TPU ch. 13

Check

Check cabling between ELVA plug and plug J 49, Please refer to chapter 6.2 Change value and check solenoid valve (ZV1121-A item 30), Please refer to chapter 6.4

Cyl. Lubricator Feedback (Flow) (DI) Or Cylinder TDC Pulse (for commissioning)(DO)

30

Connection and Function Test

MAN B&W Diesel A/S

CCUs Switch Output (memory mapped latch) Plug No. Cabel ID 60 61

Channel Type

Signal ID

Type

Action

4104

ELFI/FIVA Amplifier Enable (DO)

Must be on when it is o.k. Please refer to chapter 6.1

Channel Type

Signal ID

Type

Action

Line A

-

Network line A

Check with Service terminal in EICU

Line A

-

Network line A

Check with Service terminal in EICU

Line B

-

Network line B

Check with Service terminal in EICU

Line B

-

Network line B

Check with Service terminal in EICU

Channel Type

Signal ID

Type

Action

Check

Action

Check

Internal

Check

Control Network Plug No. Cabel ID WNCCU 65 1A WNCCU 65 2A WNCCU 66 2B WNCCU 66 1B

Check

Serial communication Plug No. Cabel ID 68 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. 70 71

Cabel ID Internal

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

Channel Type

Signal ID 4107

Type ELFI/FIVA Valve Control (AO) Reserved for commisioning

31

Same mA value as in ch.70 (output value 1.2 to 1.5), Please refer to chapter 6.1

Connection and Function Test

MAN B&W Diesel A/S

CCUs Contact Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

Check

Plug No.

Cabel ID

Channel Type

Signal ID

Type

Check

90

Internal Intern to J20-32-33-70

Action Value between 0 Amper. and 1.5 Amper. Output. See internal elctric drawning and check fysical.

80 81 82 83 84 85

91

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

Supply for ELFI valve via amplifier

32

Connection and Function Test

MAN B&W Diesel A/S

ECU A Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8

WPECUB WPECUB

Power input A Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input A Power Supply Input B

Analog 24 Vdc Analog 24 Vdc

A= - / B= + A= - / C= +

Check

Slow turning valve (J80) Main starting valve (J82) Manuel slow down request-at LOP (J83) Forced command take over (J84)

10A output filtered

9 Control Main I/O Board Plug No. Cabel ID 20 21 22 23 24 25

26 27

Channel Type

Signal ID

Type

WLOP2 WLOP2 WLOP2 WLOP2

Low BW Low BW Low BW Low BW Low BW

1218-4 2152-A 2151-A 2114-A 2115-A

El. Driven pump 4 remote / local-fail (DI) Increase limiter (DI superv) Stop Switch LOP (DI superv) Air Run LOP (DI superv) Slow Turning LOP (DI superv)

WLOP2

Low BW

2153-A 2156-A or 2150-A

Take Command (LOP) (DI superv)

Press Increase Limiter button on LOP Turne stop switch on LOP Activate air run switch on LOP Activate slow turning switch on LOP Activate Forced take control button on LOP

Speed Set Up button Or Speed set from local control panel(DI superv) Speed Set Down button (DI Superv)

Activate speed up switch on LOP Activate speed down switch on LOP

WLOP2 WLOP2

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

Low BW Low BW

2157-A

33

Action

Check

Connection and Function Test

MAN B&W Diesel A/S

ECU A Loop Terminals Plug No.

Cabel ID

10 10 10 10 10 10 10 10 10 10 10 10 10

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

Channel Type

Signal ID

Type

Action

Check

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

34

Connection and Function Test

MAN B&W Diesel A/S

ECU A Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

30 31

WLOP1

High/Low BW High/Low BW

2155-A 2103-A

32 33 34 35 36 37

W1117-A

High/Low BW

1117-A

Activate switch for Start From remote control Activate switch for Start Air Distributer valve

WSS-EUA W8601-A

High/Low BW High/Low BW High/Low BW High/Low BW

2001-A 8601-A 2195-A 5350-A

Start Switch-Local (DI superv) Actual Pitch (Analog) Start Air Distribution System blocked (DI superv) Astern - local (DI superv) Shut down from Safty System (DI superv) Scavenge air pressure (Analog) Clutch status (DI superv) Limiter signal from Dual Fuel Control

Action A= - / D= + Simulate tacho signal in TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B

Check

Signal from safty system Sensor PT 8601-A

Fast Digital Input Check of cabling between TSA-A / B and MPC Plug No. 40AD 40BC

Cabel ID WTP-A WTECUA

Channel Type

Signal ID

TPU ch.0

4001-A

Type 24Vdc to TSA-A Marker Master - Tacho set A (Di)

41BC 42BC 43BC 44BC 45BC 46BC 47BC

WTECUA WTECUA WTECUA WTCCU1B WTCCU1B WTCCU1B WTCCU1B

TPU ch.1 TPU ch.2 TPU ch.3 TPU ch.4 TPU ch.5 TPU ch.6 TPU ch.7

4002-A 4003-A 4004-A 4001-B 4002-B 4003-B 4004-B

Marker Slave - Tacho set A (Di) Quadrature 1 - Tacho set A (Di) Quadrature 2 - Tacho set A (Di) Marker Master - Tacho set B(Di) Marker Slave - Tacho set B (Di) Quadrature 1 - Tacho set B (Di) Quadreture 2 - Tacho set B (Di)

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

35

Check

Connection and Function Test

MAN B&W Diesel A/S

ECU A Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

Channel Type

Signal ID

48

TPU ch.8

4030-A

49

TPU ch.9

4031-A

50

TPU ch.10

4032-A

51 52 53

TPU ch.11 TPU ch.12 TPU ch.13

4033-A 8287-A 1219-4

Type

Action

Check

Action

Check

Check

Extra input for dual speed measurment (DI) Extra input for dual speed measurment (DI) Extra marker for dual speed measurment (DI) Extra marker for dual speed measurment (DI) Lube back-up (DO) El.driven pump 4 running (DI)

Switch Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID

Type

2146-A 2005-A

Zero pitch request (DO) Reset shut down-from ECS (DI superv)

Channel Type

Signal ID

Type

Action

Line A Line B

-

Network line A Network line B

Check with Service terminal in EICU Check termination resistor

Line B

-

Network line B

Check with Service terminal in EICU

60 61 Control Network Plug No. 65 66 66

Cabel ID WNCCU1 A 120 OHM WNCCU1 B

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

36

Connection and Function Test

MAN B&W Diesel A/S

Serial communication Plug No.

Cabel ID

Channel Type

Signal ID

Type

Signal ID

Type

Action

Check

Action

Check

68

ECU A AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. 70

Cabel ID

Channel Type

LUB R1

2184

71

8501

Calculated Governor Index (AO) Starting air Pressure for LOP Indication. (AO)

Change value and check in HMI-panel for Alpha Lub.

Contact Output (memory mapped latch) Plug No. 80

Cabel ID

Signal ID

Type

W1114

1114 1243-A or 1217-4

Slowturning valve (Do) Astern signal for 4. Trukne pumpe or El.driven pump 4 start/stop(DO)

W1121-A

1121-A

Main Starting Valve (Do) Slow Down Request-Manual at local (DO) Forced Command Take over-LOP (DO) Increase limitation-feedback for LOP indication (DO)

81 82

Channel Type

83 84

2206-A 2154-A

85

2159-A

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

37

Action

Check

Change value and check solonoid valve (ZV1114 item 36)

Change value and check solonoid valve (ZV1121-A item 30)

Connection and Function Test

MAN B&W Diesel A/S

ECU B Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

1

WPECUB

Power input A

Power Supply Input A

Analog 24 Vdc

A= - / B= +

1 2 3 4 5 6 7 8

WPECUB

Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input B

Analog 24 Vdc

A= - / C= +

Main Starting valve J82

A= - / B= +

Action

W1121-B

Type

Action

Check

10A output filtered

9 Control Main I/O Board Plug No. Cabel ID

Channel Type

Signal ID

Type

WLOP2 WLOP2 WLOP2 WLOP2

Low BW Low BW Low BW Low BW Low BW

1218-5 2152-B 2151-B 2114-B 2115-B

El.driven pump 5 remote/local-fail (DI) Increase limiter (DI superv) Stop Switch (DI superv) Air Run (DI superv) Slow Turning (DI superv)

25

WLOP2

Low BW

26 27

WLOP2 WLOP2

Low BW Low BW

2153-B 2156-B or 2150-B 2157-B

Take Command (DI superv) Speed Set Up button (DI superv) or Speed set from local control panel Speed Set Down button (DI Superv)

20 21 22 23 24

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38

Check

Press Increase Limiter button on LOP Turne stop switch on LOP Activate air run switch on LOP Activate slow turning switch on LOP Activate Forced take control button on LOP

Activate speed up switch on LOP Activate speed down switch on LOP

Connection and Function Test

MAN B&W Diesel A/S

ECU B Loop Terminals Plug No.

Cabel ID

10 10 10 10 10 10 10 10 10 10 10 10 10

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

Channel Type

Signal ID

Type

Action

Check

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

39

Connection and Function Test

MAN B&W Diesel A/S

ECU B Control Main I/O Board Analog/Digital Input Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

Start Switch-Local (DI superv) Actual Pitch (Analog) Start Air Distribution System blocked (DI superv) Astern-Local (DI superv)

Activate switch for Start on LOP From remote control Activate switch for Start Air Distributer valve

Shut down from Safty System (DI superv) Scavenge air pressure (Analog) Clutch status (DI superv) Limiter signal from Dual Fuel Control (AL superv)

Signal from safty system Sensor PT 8601-B

Type Marker Master - Tacho set A (Di) Marker Slave - Tacho set A (Di) Quadrature 1 - Tacho set A (Di) Quadrature 2 - Tacho set A (Di) 24Vdc to TSA-B Marker Master - Tacho set B(Di) Marker Slave - Tacho set B (Di) Quadrature 1 - Tacho set B (Di) Quadreture 2 - Tacho set B (Di)

Action Simulate tacho signal in TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A Simulate tacho signal i TSA-A A= - / D= + Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B Simulate tacho signal i TSA-B

30 31

WLOP2

High/Low BW High/Low BW

2155-B 2103-B

32 33

W1117-B

High/Low BW High/Low BW

1117-B 2135-B

High/Low BW High/Low BW High/Low BW

2001-B 8601-B 2195-B

High/Low BW

5350-B

34 35 36

WSSEUA W8601-B

37

Check

Fast Digital Input Check of cabling between TSA-A / B and MPC Plug No. 40BC 41BC 42BC 43BC 44AD 44BC 45BC 46BC 47BC

Cabel ID Channel Type WT-XA TPU ch.0 WT-XA TPU ch.1 WT-XA TPU ch.2 WT-XA TPU ch.3 WTP-B WTECUB TPU ch.4 WTECUB TPU ch.5 WTECUB TPU ch.6 WTECUB TPU ch.7

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

Signal ID 4001-A 4002-A 4003-A 4004-A 4001-B 4002-B 4003-B 4004-B

40

Check

Connection and Function Test

MAN B&W Diesel A/S

ECU B Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

Check

48

TPU ch.8

4030-B

49

TPU ch.9

4031-B

50

TPU ch.10

4032-B

51 52 53

TPU ch.11 TPU ch.12 TPU ch.13

4033-B 8287-B 1219-5

Extra input for dual speed measurment (DI) Extra input for dual speed measurment (DI) Extra marker for dual speed measurment (DI) Extra marker for dual speed measurment (DI) Lube back-up (DO) El. Driven pump 5 running (DI)

Signal ID

Type

Action

Check

2146-B 2005-B

Zero pitch request (DO) Reset shut down-from ECS (DI superv)

Channel Type

Signal ID

Type

Action

Check

Line A Line A

-

Network line A Network line A

Check with Service terminal in EICU Check termination resistor

Line B

-

Network line B

Check with Service terminal in EICU

Channel Type

Signal ID

Type

Action

Switch Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

60 61 Control Network Plug No. 65 65 66

Cabel ID WNACU1 A 120 OHM WNACU1 B

Serial communication Plug No.

Cabel ID

Check

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

41

Connection and Function Test

MAN B&W Diesel A/S

ECU B AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No.

Cabel ID

Channel Type

Signal ID

Type

70 71

Action

Check

Raw unsigned speed (for commissioning) WLOP2

1250

Hydraulic Pressure (AO)

Change value in service terminal and check indication on LOP

Signal ID

Type

Action

1243-B or 1217-5

Astern signal for 5. Trukne pumpe or El.driven pump 5 start/stop(DO) Output for Main Starting Valve control (DO) Slow Down Request-Manual, at local (DO) Forced Command take over-LOP (DO) Increase limitation-feedback for LOP indication (DO)

Contact Output (memory mapped latch) Plug No. 80

Cabel ID

81 82

W1121-B

Channel Type

1121-B

83 84

2206-B 2154-B

85

2159-B

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

42

Check

Change value in service terminal and check indication on LOP

Connection and Function Test

MAN B&W Diesel A/S

EICU A Power Filter Board Power input/Output plugs etc. Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

1 1 2 3 4 5 6 7 8

WPEICUA WPEICUA WAMS1A

Power input A Power input B Power failure 2A out 3.15A out 2A out 2A out 2A out 2A out

Power Supply Input A Power Supply Input B 2201-A

Analog 24 Vdc Analog 24 Vdc Power failure signal for AMS (DO)

A= - / B= + A= - / C= + Check signal in AMS (NC)

Check

10A output filtered

9 Control Main I/O Board Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

20 21

WRCS1A WRCS1A

Low BW Low BW

2163-A 2164-A

Fixed Rpm Command (DI superv) Increas limitation CPPonly (DI superv)

Check signal from RCS Check signal from RCS

22

Low BW

Increase limitation-bridge (DI superv)

23 24 25 26 27

Low BW Low BW Low BW Low BW Low BW

Increase limitation-ECR (DI superv) Slow down req. (DI superv) Slow down command (DI superv) Speed set from bridge (DI superv) Speed set from ECR (DI superv)

WAMS1A

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

2205-A

43

Check

Check signal from AMS

Connection and Function Test

MAN B&W Diesel A/S

EICU A Control Main I/O Board Analog/Digital Input Plug No.

Cabel ID

Channel Type

Signal ID

Type

30 31

High/Low BW High/Low BW

Stop-bridge (DI superv) Start-bridge (DI superv)(CPPonly)

32 33 34 35 36

High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW

37

High/Low BW

Stop-ECR (DI superv) Start-ECR (DI superv)(CPPonly) Take command ECR (DI superv) Astern-ECR (DI superv)(CPPonly) Pitch set point (AL superv)(CPPonly) Aux.systems ready (DI superv)(HWCPPonly)

Action

Check

Check

Fast Digital Input Check of cabling between TSA-A / B and MPC Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

TPU ch.0 TPU ch.1 TPU ch.2 TPU ch.3 TPU ch.4

1190-A 2112-A 2101A 2120-A 2122-A

Check signal from PMS

45 46

TPU ch.5 TPU ch.6

2121-A 2190-A 2191-A or 2129-A

47

TPU ch.7

Shaft generator req (DI) Standby request (DI) FWE request (DI) Local Control (DI) Bridge Control (DI) ECR Control- control station request (ECR Control-separate rpm for CPP) (DI) At Sea (for indication on MOP )(DI) Prepare start Or ECR Control-combinatormode for CPP (DI)

40 41 42 43 44

WPMS

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44

Connection and Function Test

MAN B&W Diesel A/S

EICU A Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

Channel Type

Signal ID

48

WRCS1A

TPU ch. 8

2171-A

49

WRCS1A

TPU ch. 9

2170-A

50 51

TPU ch. 10 TPU ch. 11

52

TPU ch. 12

2172-A 2175-A 2210-A or 2197

TPU ch. 13

2180-A

Type Fix rpm indication on bridge (CPPonly)(DO) Load limitaion indication on bridge (CPPonly)(DO) Manual slow down req. On bridge (CPPonly)(DO) Near limit (CPPonly)(DO) Engine stopped for AMS (DO) or Main engine running Load limitation indication on ECR (CPPonly)(DO)

Signal ID

Type

Action

2021-A 2202-A

Cancellable shd. Down (DO) System failure for AMS (DO)

Check indication on safty sys. (Resistor f. supervision) Check indication on RCS

53

WRCS1A

Action

Check

Check indication on RCS Check indication on RCS

Check indication on RCS

Switch Output (memory mapped latch) Plug No.

Cabel ID

60 61

WSA WAMS1A

Channel Type

Check

Control Network Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

65 66

WEICUA 120 OHM

Line A Line B

-

Network line A Network line B

Check with Service terminal in EICU Check termination resistor

66

WEICUB

Line B

-

Network line B

Check with Service terminal in EICU

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

45

Check

Connection and Function Test

MAN B&W Diesel A/S

Serial communication Plug No.

Cabel ID

Channel Type

68

WRCS2A

RS422

Signal ID

Type

Action

Serial conn to RCS

Check connection by ohming

Type

Action

Check

EICU A AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No.

Cabel ID

Channel Type

Signal ID

70

2183-0 2184-0 2401-0 1250-0 2410-0 2411-0 2402-0 2403-0 2404-0

71

2183-1 2184-1 2401-1 1250-1 2410-1 2411-1 2402-1 2403-1 2404-1

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

Check

Engine speed(AO) Fuel index (calculated governor index) (AO) Speed set point(AO) Hydraulic pressure(AO) Scavenge air pressure(AO) Start air pressure(AO) Raw unsigned speed(AO) Index Margin(AO) Actual Pitch (AO) Engine speed(AO) Fuel index (calculated governor index) (AO) Speed set point(AO) Hydraulic pressure(AO) Scavenge air pressure(AO) Start air pressure(AO) Raw unsigned speed(AO) Index Margin(AO) Actual Pitch (AO)

46

Connection and Function Test

MAN B&W Diesel A/S

Contact Output (memory mapped latch) Plug No.

Cabel ID

Channel Type

Signal ID 1191-A

Type Shaft generator Permission (DO)

80 81

WSB

82

WSB

83

84 85

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

2020-A 2005-A or 2207-A 2130-A or 2110 2131-A or 2111 2147

Non cancelabel shut down request to safety system (DO) Reset shut down from ECS (DO) or Reset shoutdown - from ECS Ahead command Or Engine blocked(HW CPP)(DO) Astern command Or Engine ready(HW CPP)(DO) Slow command (CPPonly) (DO)

47

Action

Check

Check signal in PMS Check indication on safty sys. (Resistor f. supervision) Check indication on safty sys. (Resistor f. supervision)

Connection and Function Test

MAN B&W Diesel A/S

EICU B Power Filter Board Power input/Output plugs etc. Plug No. Cabel ID Channel Type WPEICU Power input A 1 B WPEICU Power input B 1 B Power failure 2 WAMS1B 2A out 3 3.15A out 4 2A out 5 6 2A out 7 2A out 8 2A out 10A output filtered 9 Control Main I/O Board Plug No. Cabel ID Channel Type 20 Low BW 21 Low BW 22 Low BW 23 Low BW 24 Low BW 25 Low BW 26 Low BW 27 Low BW

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

Signal ID

Type

Action

Power Supply Input A

Analog 24 Vdc

A= - / B= +

Power Supply Input B 2201-B

Analog 24 Vdc Power failure signal for AMS (DO)

A= - / C= + Check signal in AMS (NC)

Signal ID 2163-B 2164-B

Type Fixed Rpm Command (DI superv) Restart switch CPPonly (DI superv) Increase limitation-bridge (DI superv) Increase limitation-ECR (DI superv) Slow down req. (Pre-warning)(DI superv) Slow down command (DI superv) Speed set from bridge (DI superv) Speed set from ECR (DI superv)

Action Check signal from RCS Check signal from RCS

2205-B

48

Check

Check

Check signal from AMS

Connection and Function Test

MAN B&W Diesel A/S

EICU B Control Main I/O Board Analog/Digital Input Plug No. Cabel ID 30 31 32 33 34

Channel Type High/Low BW High/Low BW High/Low BW High/Low BW High/Low BW

35 36

High/Low BW High/Low BW

37

High/Low BW

Signal ID

Type Stop-bridge (DI superv) Start-bridge (DI superv)(CPPonly) Stop-ECR (DI superv) Start-ECR (DI superv)(CPPonly) Take command ECR (DI superv) Astern-ECR (backup-reversing)(DI superv)(CPPonly) Pitch set point (AL superv)(CPPonly) Aux.systems ready (DI superv)(HWCPPonly)

Action

Check

Type Shaft generator req (DI) Standby request (DI) FWE request (DI) Local Control (DI) Bridge Control (DI) ECR Control- control station request (ECR Control-separate rpm for CPP) (DI) At Sea (for indication on MOP )(DI) Prepare start Or ECR Control-combinatormode for CPP (DI)

Action Check signal from PMS

Check

Fast Digital Input Check of cabling between TSA-A / B and MPC Plug No. Cabel ID 40 WPMS 41 42 43 44 45 46

Channel Type TPU ch.0 TPU ch.1 TPU ch.2 TPU ch.3 TPU ch.4

Signal ID 1190-B

TPU ch.5 TPU ch.6 2191-B or 2129-B

47

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

TPU ch.7

49

Connection and Function Test

MAN B&W Diesel A/S

EICU B Control Main I/O Board Fast Digital Output Plug No.

Cabel ID

48

WRCS1A

TPU ch. 8

2171-B or 2128

49

WRCS1A

TPU ch. 9

2170-B

TPU ch. 10 TPU ch. 11

2172-B 2175-B

TPU ch. 12

2210-B or 2126

TPU ch. 13

2180-B

Type Fix rpm indication on bridge (CPPonly) or Forced command take over-ECR indication (HW CPP)(DO) Load limitaion indication on bridge (CPPonly)(DO) Manual slow down req. On bridge (CPPonly)(DO) Near limit (CPPonly)(DO) Engine stopped for AMS (DO) or Astern back-upmode (backup reversing) to pitch control function (HW CPP only) Load limitation indication on ECR (CPPonly)(DO)

Signal ID

Type

Action

2021-B 2202-B

Cancellable shd. Down (DO) System failure for AMS (DO)

Check indication on safty sys. (Resistor f. supervision) Check indication on RCS

50 51

52 53

WRCS1A

Channel Type

Signal ID

Action

Check

Check indication on RCS Check indication on RCS

Check indication on RCS

Switch Output (memory mapped latch) Plug No.

Cabel ID

60 61

WSA WAMS1A

Channel Type

Check

Control Network Plug No.

Cabel ID

Channel Type

Signal ID

Type

Action

65 66

WEICUA 120 OHM

Line A Line B

-

Network line A Network line B

Check with Service terminal in EICU Check termination resistor

66

WEICUB

Line B

-

Network line B

Check with Service terminal in EICU

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

50

Check

Connection and Function Test

MAN B&W Diesel A/S Serial communication Plug No.

Cabel ID

Channel Type

68

WRCS2A

RS422

Signal ID

Type

Action

Serial conn to RCS

Check connection by ohming

Check

EICU B AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No.

Cabel ID

70

71

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

Channel Type

Signal ID

Type

2183-0 2184-0 2401-0 1250-0 2410-0 2411-0 2402-0 2403-0 2404-0 2183-1 2184-1 2401-1 1250-1 2410-1 2411-1 2402-1 2403-1 2404-1

Engine speed(AO) Fuel index (calculated governor index) (AO) Speed set point(AO) Hydraulic pressure(AO) Scavenge air pressure(AO) Start air pressure(AO) Raw unsigned speed(AO) Index Margin(AO) Actual Pitch (AO) Engine speed(AO) Fuel index (calculated governor index) (AO) Speed set point(AO) Hydraulic pressure(AO) Scavenge air pressure(AO) Start air pressure(AO) Raw unsigned speed(AO) Index Margin(AO) Actual Pitch (AO)

51

Action

Check

Connection and Function Test

MAN B&W Diesel A/S

Contact Output (memory mapped latch) Plug No.

Cabel ID

80 81

WSB

82

WSB

83

84

85

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

Channel Type

Signal ID 1191-B or 2127 2020-B 2005-B or 2207-B 2130-B or 2123 2131-B or 2124 2147 or 2125

Type Shaft generator Permission (DO) or SG disconnection failed (HW CPP) Non cancelabel shut down request to safety system (DO) Reset shut down from ECS (DO) or Reset shoutdown - from ECS Ahead command Or Local command take over to RCS(HW CPP)(DO) Astern command Or Local command take over to RCS(HW CPP)(DO) Slow command (CPPonly) Or Bridge command take over to RCS(DO)

52

Action

Check

Check signal in PMS Check indication on safty sys. (Resistor f. supervision) Check indication on safty sys. (Resistor f. supervision)

Connection and Function Test

MAN B&W Diesel A/S

TSA-A Fast Digital Input Plug No. Cabel ID

Channel Type

Signal ID

Type

Action

J3

WTMMA

TPU ch.0

4001-A

Marker Master - Tacho set A (Di)

J4

WTMSA

TPU ch.1

4002-A

Marker Slave - Tacho set A (Di)

J1

WTQ1A

TPU ch.2

4003-A

Quadrature 1 - Tacho set A (Di)

J2

WTQ2A

TPU ch.3

4004-A

Quadrature 2 - Tacho set A (Di)

Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel

Channel Type

Signal ID

Type

Action

Check

TSA-B Fast Digital Input Plug No. Cabel ID J3

WTMMB

TPU ch.0

4001-A

Marker Master - Tacho set A (Di)

J4

WTMSB

TPU ch.1

4002-A

Marker Slave - Tacho set A (Di)

J1

WTQ1B

TPU ch.2

4003-A

Quadrature 1 - Tacho set A (Di)

J2

WTQ2B

TPU ch.3

4004-A

Quadrature 2 - Tacho set A (Di)

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

53

Check

Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel Check when aligning the pick-up to the trigger ring on the flywheel

Connection and Function Test