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

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

2 Connection and Function Test

Table of Contents 1 Power Supply Check 5

1.1 MPC fuse specification 5

2 ID-key Boot Loader Program 5

2.1 Operation 5 2.1.1 Connections and settings – normal operation 6 2.1.2 Start-up normal operation 7

2.2 Programming the ID-key (Network Address) 8 2.2.1 Connections and settings – programming. 8 2.2.2 Programming Sequence for ID-Key 9

2.3 2.3 Troubleshooting LED messages 10

3 Network Test 11

3.1 3.1 Access to Service Terminal 12

4 Updating and Archiving MPC Parameters from the MOP 14

4.1 MPC Parameter update 14 4.2 Archiving Parameter Files 15 4.3 4.3 How to make a copy of ECU-A into ECU-B: 16 4.4 (for Soft Ware version 1.34 or later) 16 4.5 18

5 Connection test of I/O 18

6 Check of Serial Communication between RCS and ECS 18

6.1 How to inspect Serial communication between RCS and ECS 18 6.2 How to simulate values from ECS to RCS 18

7 Adjustment of encoder 19

7.1 Check Tacho system cable 19 7.2 Check of encoder adjustment. 20 7.3 Adjustment of encoder-clockwise 21 7.4 Check of tacho sensor at flywheel. 23

8 Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm 23

8.1 Connection test of ELFI valve without hydraulic pressure 23 8.2 Connection test of ELVA valve without hydraulic pressure 24 8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar) 24 8.4 Connection test of FIVA valve with hydraulic pressure (app. 175 bar) 25 8.5 Connection test of starting air valves 25 8.6 Test of main starting air valve manually on the MOP 25 8.7 Connection test of HCU oil leakage alarm 26 8.8 Hints for connection test and fault finding: 26

9 Test of Swash-plate pumps (Hydraulic-Pressure On) 29

9.1 Functions test 29 9.2 Troubleshooting 30

10 ME Alpha Lubricator Quick Guide 32

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10.2. MOP Screen “Cylinder Lubricators” 32 10.3 Lubrication Amount Calculation: 34 10.4 ALPHA LUBRICATOR WITH ME ENGINES - BREAKING-IN/RUNNING-IN FEED RATE SETTING 36

11 Appendix 38

11.1 Opening and setting up the Hyper Terminal program 38 11.2. Swash plate position values 39 11.3. Tools for commissioning 39 11.4. Overview MPC connections 40 11.5. MPC LED Indication 41 11.6. Settings of Liquiphant level switch 44 11.7. Connection test scheme 1

Document History: Date Author Changes 2005-06-09 AAJ ACU4 added

F9 6A » 10A F4 2A » 3,15A Connection test scheme for CCU, ACU,EICU & ECU changed signal text and signal ID

2005-07-20 AAJ Adjustment of encoder updated

2005-08-04 AAJ 2.2.1 Connections and settings - program is updated 4.1 “MPC Parameter update” is updated for s-paf file. “Network address= Sum of activated Dipswitch” is deleted “ECS Network address” is deleted in Appendix 9 Introducing 6.1 “Check of tacho system cable”

2005-08-29 AAJ 9. ME Alpha lubricator quick guide added 4.3 How to make a copy of ECU A into ECU B added

2005-09-14 AAJ Picture of MOP-screen insert regarding new ArcHive/update tool 4.0 and

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Network status 3.0 2005-09-27 AAJ Updated 2.2.1 Connections

and settings-programming (DIP-switch)

2005-10-29 AAJ Updated 2.2.1 Connections and settings-programming (DIP-switch) (CCU8)

2006-07-11 AAJ Update 9 ME Alpha lubricator quick guide text

2006-07-11 AAJ Added 6 Check of Serial communication between RCS and ECS

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Pre-conditions:

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

• Measurements for earth fault must be made, with multi-meter on all cable connections. • All cables mounted on plugs for MPC must be marked with plug number and terminal number, and all

cables mounted according to actual plant electrical diagram. • All cables/plugs to be mounted on MPC-print must be disconnected. • Battery mounted on MPC board (See chapter 2.1.1) • Tools according to appendix 10.3

1 Power Supply Check On all MPC units check polarity and voltage on plug J1: (A power): A = - / B = + (B power): A = - / C= +, the voltage must be in the range 20-30Vdc. On Main Operating Panel (MOP A), check the polarity and voltage. The voltage must be in the range 20-30Vdc. On Main Operating Panel (MOP B), check that the 220/110VAC switch is set according to the power supply.

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

2 ID-key Boot Loader Program The control network on the ME Engine contains several MPC units called nodes. Each MPC has a corresponding ID-key attached to it(se page xxxx). This ID-key contains a unique ID, which identifies what type of controller it is associated with. When the ID-key is plugged into its corresponding sub-D connector (J206) on the MPC, the controller reads the ID-key, ID number to determine what type of software it should contain. Each ID-key, ID number is matched to specific controller software. If the MPC determines that it does not contain the correct software image it will not boot. The ID-key, ID is also used by the MPC to determine what type of software it should upload from the MOP. The following describes the features contained in the bootloader program. The purpose of the program is to:

• Check the validity of the ID-key, ID before boot is allowed. • Provide facilities for the Service Technician to change the ID-key, ID number.

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

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2.1.1 Connections and settings – normal operation See below figures for DIP-switch settings and location of LED, ID-key and service terminal plug on MPC board. View of MPC board with ID-key connected.

Battery mounted on MPC board LED ( Led Emitting Diode) ID-key Mounted on MPC (J206) Service Terminal Connection (J67) DIP-switch S1 on MPC-board.

DIP-switch S1

DIP-switch S1: Neutral ⇒ All in off position

• ON ⇒ Binary 1

• OFF ⇒ Binary 0

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

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

• OFF

• ON

2.1.2 Start-up normal operation LED messages: Error(red) -> Init(Orange) -> Normal(Green). See appendix 10.5 for details During start-up, the MPC verifies if the ID-key is connected. It reads the ID number and checks if the ID-key ID is in the correct format and has a valid range, it reads the DIP-switch S1 value and verifies if it is 0 (Off). The program completes the ID-key verification and is now ready to continue the boot sequence. Any deviations will send an error message via the LED. Figure 1: Messages sent to a portable PC with Windows Hyperterminal program that is connected to the service terminal plug J67 on an MPC using a zero modem cable.

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

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2.2 Programming the ID-key (Network Address)

2.2.1 Connections and settings – programming. DIP-switch S1 set to value to be programmed. The service technician can program the ID-key with a new ID using the DIP-switch S1. Any previous value in the ID-key will be erased.

Switch on DIP-

switch S1 1 2 3 4 5 6 7 8

MPC Network Address

DIP switch S1 Settings

ACU 1 224 Off Off Off Off Off On On On ACU 2 225 On Off Off Off Off On On On ACU 3 226 Off On Off Off Off On On On ACU 4 239 On On On On Off On On On ECU A 208 Off Off Off Off On Off On On ECU B 209 On Off Off Off On Off On On EICU A 192 Off Off Off Off Off Off On On EICU B 193 On Off Off Off Off Off On On CCU 1 240 Off Off Off Off On On On On CCU 2 241 On Off Off Off On On On On CCU 3 242 Off On Off Off On On On On CCU 4 243 On On Off Off On On On On CCU 5 244 Off Off On Off On On On On CCU 6 245 On Off On Off On On On On CCU 7 246 Off On On Off On On On On CCU 8 247 On On On Off On On On On CCU 9 248 Off Off Off On On On On On CCU 10 249 On Off Off On On On On On CCU 11 250 Off On Off On On On On On CCU 12 251 On On Off On On On On On CCU 13 252 Off Off On On On On On On CCU 14 253 On Off On On On On On On CCU 15 254 Off On On On On On On On CCU16 255 On On On On On On On On

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2.2.2 Programming Sequence for ID-Key LED messages: Code 4,2 and 4,3 (see chapter 2.3 and appendix 11.5) The program first verifies if the ID-key is connected (2a). In this case, it confirms that the ID-key is not connected and sends error code 42 through the LED. The service technician may now connect the ID-key for programming. The program switches to programming mode and reads the DIP-switch S1 value to determine the new ID number that the user wants to program the ID-key (2b). This value must be a valid ID-key, ID number or the program will halt. Before programming, the program verifies if the ID-key is connected (2c) and proceeds to program the new ID number. The MPC is then ready to continue booting and sends code 43 to the LED. This signals the technician to change the DIP-switch (S1) back to its neutral position (2d). When the DIP-switch S1 is set to neutral (off), the MPC is now ready to continue normal booting operation. Figure 2: Messages from the service terminal of the MPC when programming ID-key with DIP-switch.

Starting Basic System... Testing RAM... RAM OK Initialising BES kernel...OK Starting dongle verification Reading Dongle ID......not connected! Switching to programming mode. Reading DIP-switch... Value = 240 Programming Dongle with DIP-switch value. Dongle not connected! Please connect dongle. Dongle programmed successfully Preparing to boot... DIP-switch not neutral. Please set DIP-switch to neutral. Reading DIP-switch... Value = 0 Dongle verification done. Continuing boot sequence...

2a

2b

2c

2d

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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 ID-key because it is not connected. Solution: Connect the ID-key to the MPC. Cause: The MPC has read the requested new ID-key, ID from the DIP-switch S1, but found it to be out-of-range. Solution: Disconnect the ID-key. Verify that the DIP-switch S1 is set to a valid value and reset the MPC. Cause: DIP-switch S1 is set to neutral for normal boot, but the ID-key is not connected. Solution: Connect the ID-key and reset the MPC. Cause: The ID number read into the ID-key is invalid. Solution: Proceed to reprogram the ID-key. Remove the ID-key, set the DIP-switch S1 to the new dongle ID number and reboot the MPC. Follow the steps used to program the ID-key under section 2.2.1, “Use DIP-switch S1 to Program the ID-key, ID”. Cause: ID-key is defective. Solution: Replace ID-key. Error code Description 4,2 ID-key not connected

Invalid Dongle ID Invalid DIP-switch S1 value Programming ID-key failed

4,3 DIP-switch S1 not neutral

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

In ECU A & B, a 120 ohm terminating resistor must be mounted at the end of the arcnet line A and B net. Terminating resistor, net B plug No. 66.

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

Network status on the MOP screen

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

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

3.1 3.1 Access to Service Terminal

• Opening and setting up the Hyper Terminal program (see appendix 11.1) • Connect a PC to the service terminal plug J67. • Type <manbw> and press enter. • Use the keyboard arrows to remove the cursor to ‘Control Network Management’ and press enter. • Use the keyboard arrows to remove the cursor to ‘View Network Map Segment 0 (Arcnet A). • Check that all MPC’s on the network are ON and that the MPC connected to the service terminal is

shown as MY. See appendix 10.4 for a description of MPC type and HEX network address. • If an MPC is not ON, check the network cabling and status of the LED on the MPC. • Repeat the above procedure for Network Map Segment 1 (Archnet B).

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



4 Updating and Archiving MPC Parameters from the MOP Preconditions

• The MOP and the MPC’s must be connected by ArcNet. • The MOP must have the BES_SERVER running and the MPC’s must be set-up according to

chapter 2. • The node table on the MOP must correspond to the actual system connected. • The archive files can also be up- or down-loaded using the service terminal on the MPC, but

this scenario is out of the scope of this document.

4.1 MPC Parameter update This section describes how to update MPC parameters using parameter archive files. The update can be done running the MPC Archive tool. On the MOP PC, press “Ctrl” “Esc” at the same time on the keyboard. When windows start menu appears,. choose “explore” and open: C:\Program Files\MANBW\MOP\Tools

1. Start the MPCArchive program (MpcArchive.exe) and select the “Update” tab. 2. Version a) to be used if the update file is MANBW-spaf and you will update all MPC`c, and version b) if

you only want to update MANB-paf file on one or some MPC`s.

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

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

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

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

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4.2 Archiving Parameter Files This section describes how to extract parameter files from the MPCs.

1. Open the MPC Archive tool. 2. Select a destination directory for the archive files, i.e. C:\temp. 3. Press “Get All” or select one or more MPCs and press “Get Selected” to start extraction of the

parameter archive files. The status of the operation can be seen in the ‘Upload Status’ column.

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

4.4 (for Soft Ware version 1.34 or later) For system file: xx.manbw-spaf Open the parameter file in the Arcedit. Extract to second (2). level - mark the ECUB and delete: edit - Drop MPC. Mark ECUA end copy: edit - clone MPC - A dialog box is shown: enter node name (ECUB) and Arc. net adress (209) and push clone. The ECUB is created. For MPC file: xx.manbw-paf

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The same procedure is used to copy ECUA into ECUB.

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4.5

5 Connection test of I/O The purpose of the connection test is to check all cable connections, and function test, to such a degree that the engine after completing the connection test can be started without any electrical malfunctions. Begin by checking if there is any alarm indications on the MOP, if errors are displayed, refer to the Alarms documentation chapter 24 in ECS commissioning book, for a description and suggested solution to the alarm. All signals to and from the MPC’s can be tested separately. This test is done with the Service Terminal connected to the MPC/unit to be tested. Connect a PC to the service terminal plug J67, and enter <System test> as described below.

Access to Service Terminal (System test): 1 Type <manbw> followed by pressing enter. 2 Select <Node Mode>. 3 Select <Test>. 4 Answer y to continue followed by pressing enter 5 Select <System Test> 6 Then choose Input or Output

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

6 Check of Serial Communication between RCS and ECS

6.1 How to inspect Serial communication between RCS and ECS

• Select ‘Adjust Parameters’ and browse to: ‘I/O Configuration -> Configuration Options -> Non or Old Application Options -> Modbus-RCS Connection Test’ Verify that this parameter is set to ‘No’. If not Use ‘Node Mode Control’ menu to Set EICU in ‘Configuration’ mode and change the parameter to ‘No’.

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

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

6.2 How to simulate values from ECS to RCS

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

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

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

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

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

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

• Use ‘Node Mode Control’ menu to Set EICU in ‘Normal’ mode

• Note when testing EICU-B:

•

7 Adjustment of encoder

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

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

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

The LED can be used to connection test the tacho cabling by following the procedure below:

Prepare a dummy plug as shown below:

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

Mount the dummy plug in J1 TSA-A and observe that LED number 9 is ON in PCB.




Mount the dummy plug in J1 TSA-B and observe that LED number 13 is ON in PCB.




DIODE BOARD 13 14 10 11 12 1 2 9 Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1 MPC Plug J46 J47 J43 J44 J45 J40 J41 J42 On

before Q1B

On before Q1A

45-225 deg

135-315 deg.

0-180 deg.

90-270 deg.

7.2 Check of encoder adjustment. It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommendations. Turning gear engaged. Indicator cocks open. Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC. Check that the indicator light for the inner encoder turns ‘ON’ on the TSA-A , when cyl.1 reaches TDC. Turn engine a few degrees back and forth, confirm that LED turns on/off. If the above is not in order see below for adjustment of encoder (Chapter 7.3). INNER encoder is adjusted correctly. Turn engine 45degrees in the engines rotational direction. I.e. clockwise 45 degrees clockwise and anticlockwise 45 degrees anticlockwise. Check that the indicator light for the outer encoder turns ‘ON’ on the TSA-B. If the above is not in order see below for adjustment of encoder (Chapter 7.3).

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OUTER encoder is adjusted correctly. Check of encoders complete

7.3 Adjustment of encoder-clockwise It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommend-ations. Turning gear engaged. Indicator cocks open. Clamp screw on encoder loose. Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC. Turn the inner encoder (A) until the Indicator light for the encoder is off (TSA-A). Turn the encoder in AHEAD direction until the LED on TSA-A just starts to light, and then fasten the encoder to the shaft with the clamp screw. Inner encoder adjusted. Turn engine 45 degrees in AHEAD direction. Turn the outer encoder (B) until the Indicator light for the encoder is off (TSA-B). Turn the encoder in AHEAD direction until the LED on TSA-B just starts to light, then fasten the encoder to the shaft with the clamp screw. Outer encoder adjusted. Function Encoders:

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ECU; CCU connection ENCODER: DIODE BOARD 13 14 10 11 12 1 2 9 Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1 MPC Plug J46 J47 J43 J44 J45 J40 J41 J42 On

before Q1B

On before Q1A

45-225 deg

135-315 deg.

0-180 deg.

90-270 deg.

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

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

• The Hydraulic system must be flushed and ready for operation. • Network- and connection-test completed. • Connect a portable PC with Windows Hyperterminal program that is connected to the service

terminal plug J67 on an MPC using a zero modem cable, and enter <System test> as described above in chapter 5.

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

8.1 Connection test of ELFI valve without hydraulic pressure Check the 24V supply to the LVDT before connecting the CANNON cables to the ELFI valve. Use a test box as shown below or a voltmeter. 24V must be measured between A (24V) and B (0V) on the CANNON plug.

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

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Use the following sequence on each ELFI valve: Service terminal in Input / output

1. Check that ‘Shut Down’ (input ch. 32) is Off 2. Disconnect power supply for ELFI amplifier (J9) 3. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is Off 4. Reconnect power supply for ELFI amplifier (J9) 5. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is On

-------------------------------------------------------------------------------------------------- 6. Set amplifier enable (output ch. 60) to On 7. Set ‘InFi_AMP. Setpoint’ (output ch. 70) to 0V 8. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA 9. Check ‘ELFI Actual Current’ (input ch. 33) is 0V 10. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to Maximum 1.3V 11. Check ‘ELFI Position Feedback’ (input ch.30) is 18-20mA 12. Check ‘ELFI Actual Current’ (input ch. 33) is 1.3 V 13. Set shut down On via safety system 14. Check ‘Shut Down’ (input ch. 32) is On 15. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA 16. Check ‘ELFI Actual Current’ (input ch. 33) is 0V 17. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to 0V

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

8.2 Connection test of ELVA valve without hydraulic pressure Use the test box shown in chapter 8.1 or the following procedure: During the test, set output channel 49 ON/OFF two or three times and check that the valve reacts (clicks). During input test, check that channel 23 (Exhaust valve alive) is ON. The output channel 49 should be set to ON when finish testing.

8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar) Use a test box shown in chapter 8.1 or the following procedure: Set output channel 49 ON/OFF two or three times If ELVA valve is alive (input ch.23 is ON), reset ELVA valve by powering CCU on/off ⇒ Check that ELVA valve alive is not active ( input ch. 23 is OFF). Note Exhaust valve pos. (input channel 34) (range 4-9 mA). Activate Exhaust valve by output channel 49 and check that alive goes ON (input channel 23). Activate Exhaust valve a few times by output channel 34 and determine the lifting height, reading in the service terminal is between 7 - 9 mA. The output channel 49 should be set to ON when finish testing.

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

• The Hydraulic stand-by pumps is ON (175 Bar) • The F.O. Supply is ON (7-8 Bars) • Spring air Exhaust valve is ON • Check the Type of Amplifier- It has to be a FIVA Amplifier (See it on the type label on the back side of

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

1. Disconnect power supply for FIVA amplifier (J9) 2. Check that ‘Value Amplifier OK’ signal (Input ch.20)=OFF 3. Reconnect power supply for FIVA amplifier (J9) 4. Check that ‘Value Amplifier OK’ signal (Input ch.20)=ON 5. Set ‘Amplifier Enable’ (Output ch.60)=ON 6. Set ‘4107V, Set Point’ (Output ch.70)=0V 7. Check ‘Prop. Valve position feedback’ (Input ch.30)=4-7mA 8. Check ‘Prop. Valve Actual Current’ (Input ch.33)=0V 9. Set ‘4107V, Set Point’ (Output ch.70)=3.5V 10. F.O. valve on unit opens (Sound) [Only test this once] 11. Check ‘Prop. Valve position feedback’ (Input ch.30)=18-20mA 12. Check ‘Prop. Valve Actual Current’ (Input ch.33)=3.5V 13. Set ‘4107V, Set Point’ (Output ch.70)=0V 14. Exhaust valve on unit opens (Sound)

Repeat the above procedure for all cylinders.

8.5 Connection test of starting air valves

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

2. The test is repeated for every single cylinder.

8.6 Test of main starting air valve manually on the MOP

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

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

3. Turning-gear engaged. 4. Main starting air valve is activated manually (on pilot-valve) ⇒ no reaction means that the

pneumatic turning-gear interlock is ok. 5. Turning-gear disengaged. 6. Activate both activating-valves (V-1 & V-2), for the main starting-valve (one at a time via the MOP)

⇒ Main starting valve must open (after an eventually fault, point 1 – 2 is repeated). 7. The Slow turn valve is activated (via MOP) manually. Start is activated either by handle or push

button. ⇒ Only the Slow turning valve must open.

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8.7 Connection test of HCU oil leakage alarm Service Terminal in input / output in the CCU, check that channel 27 is OFF. (Because this is an option it can be done by means of a “cheat” plug). Cheat Plug mounted in channel 27 on MPC board.

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

8.8 Hints for connection test and fault finding: In general: All electronic components are pre-adjusted before delivery. They are only to be adjusted mechanically at initialisation, and the written values are to be entered in the relevant parameters.

Connection test:

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

• When changing to input view, you must answer “no” to “reboot”, otherwise all outputs will be reset. MOP: A short “power-off” can block restart, therefore turn off the power and wait for at least 10 seconds until the MOP has a black screen, and then turn the voltage on. LVDT amplifiers for pump-regulation:

• The amplifier must show 12 mA in the service terminal with the sensor disconnected. • The Swash-plate sensor must be mounted correctly. If the signal is “out of range” at one end, it has to

be adjusted mechanically. (Electrical adjustment of the LVDT amplifier must only be done after consulting MAN B&W Diesel A/S).

ELVA:

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

Manual activation of ELFI and ELVA:

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

Manually activate ELVA valve by: During test, set channel 49 ON/OFF two or three times and check that the valve reacts (clicks). During input test, check that channel 23 (Exhaust valve alive) is ON. Tacho error: With Tacho errors after Stop/Slow-turning, the engine can be run at air run or simply started. The ME Engine control system does not supply fuel unless at least one Tacho system is OK. A start attempt is therefore the fastest way to clarify if there is a problem. If the engine does not rotate, the ECU/CCU units must be reset (see picture below) before a new start attempt is made.

Manually activate the ELFI valve by pushing the piston upwards by hand. (Note if fuel oil pressure is on, each activation of the piston will inject fuel in the cylinder).

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Reset button for MPC (The reset button on the side on the MPC board)

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

1. Unmonitored fuse has blown. (See fuse specification Appendix 9.4) 2. Cabling and plugs, loose or wrong connections. 3. Sensor failure/adjustment is not correct. 4. Defective MPC (input channel).

Actuator error

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

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

9.1 Functions test Follow the procedure below to calibrate the engine driven hydraulic pumps:

• Turn on the startup pumps on the startup pump switchboard by switching to “Local Control” and press “Manual start” to enable swivelling with the swashplate. The hydraulic System pressure must be above 50 bar.

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

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

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

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

o “System Test => Connection Test => Output Test” set ch. 48 to On.

o “System Test => Connection Test => Output Test” set ch. 70 to 0V.

o “System Test => Connection Test => Input Test”

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

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

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

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

o “System Test => Connection Test => Output Test” make sure that ch. 48 is set to On.

o “System Test => Connection Test => Output Test” set ch. 70 to Maximum 2.6V. (on pumps larger than 500 cc, the value should be Maximum 3.8V).

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

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

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

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

• Insert the parameters in ACU 1 – 3 using the Service Terminal parameters as given below in the table.

• The values should be noted in table in Appendix 11.2

MPC Proportional valve max. value (mA)

Proportional valve min. value (mA)

Swashplate max. value (mA)

Swashplate min. value (mA)

ACU 1 ACU 2 ACU 3

Parameter path on the

MPC in Service

Terminal

Adjust parameters => Edit parameters =>

IOConfig => Ch30,1238-x,Prop. Valve Feedback => Scaling => Row 2

Input (mA)


IOConfig => Ch30,1238-x,Prop. Valve Feedback => Scaling => Row 1

Input (mA)


IOConfig => Ch34,1222-x,Swash-

Plate Position => Scaling => Row 2

Input (mA)

Adjust parameters => Edit parameters

=> IOConfig => Ch34,1222-1,Swash-

Plate Position => Scaling => Row 1

Input (mA)

9.2 Troubleshooting

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

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

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

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

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

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

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

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

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

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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.

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Note: Can only be activated if hydraulic pressure is present. This demands that engine is in “Standby” state or manual operation of the hydraulic start-up pumps.

4. Indicator “LCD” Indicates if Load Change Dependent lubrication is active.

5. Button “S%”

Fuel sulphur % used for the Adaptive Cylinder oil Control (ACC). Se Service Letter SL05-455 /HRJ September 2005 Note: When running on diesel fuel (Engine Shop) set the S%=3.2

6. Button “Feed Rate Factor” Used together with S% to calculate the Basic FeedRate setting.

7. Indicator “Basic FeedRate”

The Basic FeedRate setting = S%*(FeedRate Factor). Note: This value is very important to observe before Engine Start as this value is the basic factor in calculating the feedrate amount. The Basic FeedRate is converted to a Basic Activation frequency.

8. Button “Min. Feed Rate”

Minimum feedrate limiter that secures the feedrate will never be below this amount even if the S% or FeedRate Factor or adjust factor is set low. Note: The limiter is converted to a minimum activation frequency that means that the actual feedrate (g/kW) can be higher at load’s <100%.

9. Indicator “Actual FeedRate” Cylinder 1..N The actual ordered feedrate after the influence of limiters, load control ect. Note: When running in the FeedRate(g/kW) increases when load decreases.

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

Adjust the Basic Feedrate Setting for the cylinders Individually.

11. Button “Running In” Cylinder 1..N Is used for running in piston rings and cylinder liners. Note: For Running In=0% the lubrication amount regulator make load regulated lubrication when Index is > approx 40% and changes to speed regulation when Index is < 40%. This leads to an almost constant feedrate down to 40% index. For Running In >0% the lubrication amount regulator changes from load regulated lubrication to speed (rpm) regulated lubrication. This means that activation frequency 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

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frequency.

12. Button “ Lubricator Test Sequence” Start’s a continuous activation ( app.1000 activations) of the lubricator. Note: Can only be activated if hydraulic pressure is present. This demands that engine is in “Standby” state or manual operation of the hydraulic start-up pumps.

13. Check of the activation sequence of the Alpha lubricator

The activation frequency can be checked via the HyperTerminal for each cylinder (CCU) in the following picture and read “Activations Without Error”:

10.3 Lubrication Amount Calculation: The lube oil amount Is calculated individually for each cylinder. On basis of the FeedrateFactor and the S% a basicfeedrate is calculated, this is converted to Mnominal act/rev at MCR. All the limiters are also calculated at MCR and converted to act/rev. 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% 3.2 BasicFeedRate 1.09 g/kWh MinFeedRate 0.7 g/kWh FeedRate Adjust 1.1

MinIndexWithPowerLube 0.4 MCR Speed 105 rpm MCR Load per cyl. 2260 kW InjectionMass 1.0 g Index [0;1]

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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 <=0.4. M(actual)=Mnominal*FeedRateAdjust* MinIndexWithPowerLube =0.39*1.1*0.4 =>(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:

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Step 1: 1.7 g/kWh for the first 5 hours Step 2: 1.5 g/kWh for 5 hours to 250 hours Step 3: 1.2 g/kWh for 250 hours to 500 hours For step 1, 2, and 3 : Part load reduction proportional to engine load (power). We propose to obtain this in the following way: a/ Set feed rate factor to 0.34 g/kWh b/ Set S% to 3 ~ (2.94 exactly) c/ Step 1: Set feed rate adjust factor to 1.7 Step 2: Set feed rate adjust factor to 1.5 Step 3: Set feed rate adjust factor to 1.2 2/ "How do the following MOP fields influence on Basic Feed Rate: a/ "Feed Rate Adjust Factor", b/ "Running In [%] ?" Neither "Feed Rate Adjust Factor" nor "Running In [%] influence the basic feed rate. The basic feed rate is calculated as "S%" times "Feed Rate Factor". However when the "running in [%]" differs from 0 the amount calculation algorithm changes from load (power) to RPM. The setting of "Feed Rate Adjust Factor" has no influence on the algorithm. 3/ "Part-load control for breaking-in / Running-in period. ?" With the introduction of SL05-455/HRJ our recommendation for part load amount calculation during running in has changed from the previous RPM dependent to load (power) 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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11.2. Swash plate position values

MPC Proportional valve max. value (mA)

Proportional valve min. value (mA)

Swashplate max. value (mA)

Swashplate min. value (mA)

ACU 1 ACU 2 ACU 3

Indication adjustment: Readings in: Main Menu / View / edit data-tree / I/O Configuration-channel 34 / Swash plate position.

Full angle Ahead = mA Full angle Astern = mA

11.3. Tools for commissioning

1. PC with Hyper terminal installed and a zero modem cable 2. Electronic or mechanic tool for measuring of highest/lowest point on trigger/tacho rings. 3. Tacho sensor adjusting tool (marked). 4. Portable pressure measuring tool for the hydraulic system (mini-mesh connection). 5. Multimeter oscilloscope and mA signaller. 6. Magnetic field indicator for Solenoid valve spools. 7. A number of plugs for I/O fault finding. 8. Test box for testing ELVA/ELFI. 9. Programs and data files for the whole system.

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

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

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11.4. Overview MPC connections

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

J-plug number Function of fuse 1 Powersupply 2 Powerfailure

3-9 Power Out 24V 10 Connecting terminals (Loop etc.)

20-37 Analog In 40-47 Fast Digital In(Galv. Isolated) 48-53 Fast Digital In/out(Galv. Isolated) 60-61 Digital Out(Galv. Isolated) 65-66 Network connections

67 Service terminal 70-71 Analog Out(Galv. Isolated) 80-85 Digital Out(Galv. Isolated) 206 Dongle Key connect 210 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 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 secondpause

Second digit

1 secondpause

For identification of the indication the user must therefore note the number of red and green pulses. The first digit is the number of red pulses and the second digit is the number of green pulses. In the illustration above, the indication code would thus be (2,3). Indications Constant Colour Short name Short description Red ERROR Either early initialization or fatal error Orange INIT Initialization, no parameters available or non-normal

node mode Green NORMAL Application up and running Flashing Digits Short name Short description (1,1) CTRL_PRG Onboard control programming in progress (2,1) APPLOAD_SCAN Application download in progress – scanning for server (2,2) APPLOAD_DOWNLOAD Application download in progress – downloading

program (2,3) APPLOAD_DIP Application download completed – reset yellow DIP

switch set to ON (3,1) BOOTLOAD_SCAN Bootloader download in progress – scanning for server (3,2)

BOOTLOAD_DOWNLOAD Bootloader download in progress – downloading program

(4,1) DONGLE_VERIFY Checking node ID-key (4,2) DONGLE_ERROR ID-key error – missing, broken or not programmed (4,3) DONGLE_DIP Node ID DIP switch not correctly reset – reset it to 0x00

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

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Detailed Description of LED indications ERROR (Red) This code is used primarily for indicating if the MPC has experienced a fatal error. However, the MPC will also use this indicating during early initialization. Therefore the user should only take this code as an indication of error if it persists more than 10 seconds. INIT (Orange) Generally this code is used for indicating initialization. But the MPC may also use this indication to signal one of the following conditions: No parameters: No valid parameters are available to the application software. Configuration or test mode: The MPC is in a non-normal node mode. Generally if the INIT code is shown longer than 10 seconds this would indicate one of the latter conditions. NORMAL (Green) Application is up and running. CTRL_PGM (1,1) One of the on-board micro controllers is being programmed. This is a part of the MPC initialization process. APPLOAD_SCAN (2,1) The application software download program (bootloader) is trying to find a server from which it can download its application program. If this code persists it indicates either that no application program server is connected to the network or the network is broken. APPLOAD_DOWNLOAD (2,2) An application program is being downloaded. APPLOAD_DIP (2,3) The yellow DIP-switch on the MPC CPU board can be used for forcing download of new application software. To avoid looping it is therefore required that the yellow DIP-switch be reset on completion of such a forced download. Reset it to ON/down. BOOTLOAD_SCAN (3,1) This indication is analogous to the APPLOAD_SCAN indication except that this code indicates that there is not server available from which the MPC can download a new bootloader. This code should only be indicated if attempts are being made to update the bootloader using the special update program. BOOTLOAD_DOWNLOAD (3,2) A new bootloader program is being downloaded and programmed. ID-key_VERIFY (4,1) The ID-key is being checked. This should only take a couple of seconds. ID-key_ERROR (4,2) A ID-key error has been identified. Either the ID-key is missing, broken or holds an invalid value. Try to reprogram it. ID-key_DIP (4,3) The DIP-switch mounted on the CMI/O board is used for programming the ID-key. The programming process requires that this DIP-switch be reset before completing. This code is used for indicating this to the user. Reset the CMI/O board DIP switches to OFF/down.

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Flowchart Error code LED 4,2

Copy donglevalue to RAM

[error] Indicate dongleerror via LED

Copy DIP-switchvalue to RAM

[error]

Program valuefrom DIP-switch

to dongle

[ok]

Halt

Wait for neutralDIP-switch

[not neutral]

[neutral]

Check DIP switchsetting

[ok]

Indicate non-neutral DIP-

switch via LED

Remains here untildongle has been

programmed!

Missing dongle orinvalid value or

invalid checksum

Invalid DIP switchvalue (neutral or out-

of-range)

Return LED toprevious 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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Settings of dipswitch:

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 Check

1 WPACU1 Power input A Power Supply Input A Analog 24 Vdc Check A= - / B= + 1 WPACU1 Power input B Power Supply Input B Analog 24 Vdc Check A= - / C= + 2 Power failure 3 W1202-A 2A output unfilt. 4 3.15 output unfilt. 5 WLOP3 2A output unfilt. 6 WLOP3 2A output unfilt. Power for Engine not ready Plug J83 Check A= - / B= + 7 WLOP3 2A output unfilt. Power for Start air distr. system in service Plug J84 Check A= -/ B= + 8 2A output unfilt Power for Main starting valve in service Plug J85 Check A= -/ B= + 9 Intern to J90 10A output filtered Power for prop-valve control amplifier Plug J90 Check C= -/ D= +

Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Intern to J91 Low BW 1224-1 Prop valve amp. O.k. (DI) Power on = reading in service terminal is on

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

26 WLOP3 Low BW 2158-A Lamp test Activate push buttom

on LOP

27 W1236 Low BW 1236 Lekage from hydraulic unit-leak shutdown level SHD

(NO) (DI superv) Activate the sensor

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


ACU 1 Loop Terminals

Plug No. Cabel ID Channel

Type Signal ID Type Action Check 10 A 10 B 10 C 10 D 10 E 10 F 10 G 10 H 10 I 10 J

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ACU 1 Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

30 W1238-1.1 High/Low BW 1238-1 Proportional valve position feedback

(AL) Dismount the plug on valve and the reading in

service terminal to be app. 12mA

31 W1201-1 High/Low BW 1201-1 Hydraulic pressure after non-return

valve (AL)

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

in service terminal

32 W1204-A High/Low BW 1204-A Lube oil pressure at pump inlet after

filter (AL)


in service terminal

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


in service terminal

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


in service terminal 35 High/Low BW

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


in service terminal

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


in service terminal

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ACU 1 Fast Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

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

44 TPU ch.4

1212-A or

1218-1

Start Up pump or

El. Driven pump 1 remote/local-fail (DI) Change of switch in starter box for Start-up

pump

45 TPU ch.5

1213-A or

1219-1

Start up pump running or

El. Driven pump 1 running (DI) Check on / off signal in service teminal 46 TPU ch.6

47 Intern to

J80 TPU ch.7 System by-pass 1202-A supervision When on in J47 it must be off in J80 and visa

versa Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 Intern to J91 TPU ch.8 1223-1 Prop valve amplifier enabel (DO) See internal elctric drawning 0794621-8.1and

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

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Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 Start blocked (LOP indication) (DO) Simulate a start block ad check indication in

LOP

61 WSTS1

1210-1 or

1217-1

Start Up Pump start/stop or

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

ACU 1 Control Network Plug No. Cabel ID Channel Type Signal ID Type Action Check

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

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

68 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70 Intern to

J91 1240-1 Swash-plate command (set point) (AO) Set output to valve and check on pump

feedback is the same on ch.34

71 1250 Hydraulic pressure (for LOP indication )

(AO)

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ACU 1 Contact Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

80 W1202-A 1202-A System by-pass valve solenoid A (DO-

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

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

82 WAUXB1 8620-1 Blower 1 start/stop (DO) Give command to blower from service

terminal

83 WLOP3 2210-A Engine not ready output for the LOP

(DO) Give command from service terminal and

check in LOP

84 WLOP3 1170-A Start air distribution system in service


check in LOP

85 WLOP3 1171-A Main starting valve in service position


check in LOP Plug No. Cabel ID Channel Type Signal ID Type Action Check

90 W1238-P1 Supply for prop.valve via amplifier

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

pressure

91

Intern to J-20-48-

70+resistor 6K8

See internal elctric drawning 0794621-8.1and check fysical.

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1 WPACU2 Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPACU2 Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out

9 Intern to

J90 10A output

filtered Supply for prop-valve control amp. C= - / D= +

MAN B&W Diesel A/S




20 Low BW 1224-2 Prop valve amp. O.k. (DI) Power on = reading in service terminal is on

21 W1111-B Low BW 1111-B Main starting Valve Blocked input (DI

superv) Activate valve 22 W1109-B Low BW 1110-B Turning gear engaged input (DI superv) Activate turning gear

23 W1109-B Low BW 1109-B Turning gear disengaged input (DI

superv) Activate turning gear

24 W1112-B Low BW 1112-B Main Starting valve "In Service" input

(DI superv) Activate valve

25 W1116-B Low BW 1116-B Start Air Distribution system in service

(DI superv) Activate valve 26 Low BW 2158-B Lamp test Activate push buttom in LOP

27 W1235 Low BW 1235 Leakage from hydraulic unit-leak alarm

level (NO) (DI superv) Activate the sensor

MAN B&W Diesel A/S



ACU 2 Loop Terminals Plug No. Cabel ID Channel Type Signal ID Type Action Check

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

MAN B&W Diesel A/S




30 W1238-2.1 High/Low BW 1238-2 Proportional valve position feedback

(AL) Dismount the plug on valve and the reading in


31 W1201-2 High/Low BW 1201-2 Lube oil pressure at pump inlet after

filter (AL)


in service terminal

32 W1204-B High/Low BW 1204-2 Lube oil pressure at pump inlet after

filter (AL)


in service terminal

33 1208-B High/Low BW 1208-4 Hydraulic booster pressure (AL)


in service terminal

34 W1222-2.1 High/Low BW 1222-2 Swash-plate position feedback (AL)


in service terminal 35 High/Low BW

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


in service terminal

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


in service terminal High/Low BW

MAN B&W Diesel A/S




40 TPU ch.0 8621-2 Blower 2 remote/local-fail (DI) Check on / off signal in service teminal 41 TPU ch.1 8623-2 Blower 2 running (DI) Check on / off signal in service teminal 42 TPU ch.2 8621-5 Blower 5 remote/local-fail (DI) Check on / off signal in service teminal 43 TPU ch.3 8623-5 Blower 5 running (DI) Check on / off signal in service teminal

44 TPU ch.4

1212-B or

1218-2

Start Up pump remote/local-fail or

El. Driven pump 2 remote/local-fail(DI) Change of switch in starter box for Start-up

pump

45 TPU ch.5

1213-B or

1219-2

Start up pump running or

El. Driven pump2 running(DI) Check on / off signal in service teminal 46 TPU ch.6 47 TPU ch.7

MAN B&W Diesel A/S



ACU 2 Control Main I/O Board Fast Digital Output


Type Signal ID Type Action Check

48 Intern to J91 TPU ch.8 1223-2 Prop valve amplifier enabel (DO) See internal elctric drawning 0794621-8.1and

check fysical. 49 TPU ch.9 2106-B Load limitation (local indc) (DO) 50 TPU ch.10 2107-B Start failure (DO) 51 TPU ch.11 1264-B Aux.blower Warning (DO) 52 TPU ch.12 1263-B Aux.blower Warning (DO) 53 TPU ch.13 2181-B Turning Gear Disengaged (DO)


60 W1216-A

61 WSTS2

1210-2 or

1217-2

Start Up Pump start/stop or

El.driven pump 2 start / stop(DO) Check pump start / stop

MAN B&W Diesel A/S



ACU 2 Control Network Plug No. Cabel ID Channel Type Signal ID Type Action Check

65 WNACU3A Line A - Network line A Check with service terminal in EICU 65 WNACU2A Line A - Network line A Check with service terminal in EICU 66 WNACU3B Line B - Network line B Check with service terminal in EICU 66 WNACU2B Line B - Network line B Check with service terminal in EICU


68

MAN B&W Diesel A/S



ACU 2 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70 Intern to


feedback is the same on ch.34 71 8601 Scavenge air pressure (AO)

Contact Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

80 2108 Start blocked (for LOP indication) (DO) 81 8620-5 Blower 5 start/stop (DO)

82 WAUXB2 8620-2 Blower 2 start/stop (DO) Give command to blower from service

terminal 83 WLOP3 2210-B Engine not ready (LOP indication) (DO)

84 WLOP3 1116-B Start air distribution system in service for

LOP indication Give command from service terminal and

check in LOP

85 WLOP3 1112-B Main Starting Valve in service position for

LOP indication Give command from service terminal and

check in LOP Plug No. Cabel ID Channel Type Signal ID Type Action Check

90 W1238-P2 Supply for prop.valve via amplifier

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

pressure

91

Intern to J-20-48-

70+resistor 6K8

See internal elctric drawning 0794621-8.1and check fysical.

MAN B&W Diesel A/S




1 WPACU3 Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPACU3 Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 W1202-B 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out

9 Intern ti J90 10A output

filtered Supply for prop-valve control amp. C= - / D= + Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Low BW 1224-3 Prop valve amplifier O.k. (DI) Power on = reading in service terminal is on 21 Low BW 1234 High pressure leak flow (NO) (DI superv) 22 Low BW 1233 High pressure leak pressure (AL superv)

23 Low BW 1231 Filter failure (basck fluhsing filter) (NC)

(DI) 24 Low BW 1232 Filter by-pass open (NC) (DI) 25 Low BW 1237 HCU common leak - oil (DI) 26 Low BW 1239 HCU common leak - fuel (DI) 27 Low BW

MAN B&W Diesel A/S




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

MAN B&W Diesel A/S




30 W1238-

3.1 High/Low BW 1238-3 Proportional valve position feedback (AI) Dismount the plug on valve and the reading in


31 W1201-3 High/Low BW 1201-3 Hydraulic pressure after non-return valve

(AI-superv)


in service terminal

32 W1204-

C High/Low BW 1204-3 Lube oil pressure at pump inlet after filter

(AI)


in service terminal

33 W1221 High/Low BW 1204-5 Lube oil pressure at pump inlet after filter

(AI)


in service terminal

34 W1222-

3.1 High/Low BW 1222-3 Swash-plate position feedback (AI)


in service terminal 35 High/Low BW 36 High/Low BW 37 High/Low BW

MAN B&W Diesel A/S




40 TPU ch. 0 8621-3 Blower 3 remote/local-fail (DI) 41 TPU ch.1 8623-3 Blower 3 running (DI) 42 TPU ch. 2 43 TPU ch. 3 44 TPU ch. 4 1218-3 El. Driven pump 3 remote/local-fail 45 TPU ch. 5 1219-3 El. Driven pump 3 running 46 TPU ch. 6

47 Intern to

J80 TPU ch.7 System by-pass 1202-B supervision Change of DO in Service terminal parameter

80 Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 TPU ch.8 1223-3 Prop valve amplifier enabel (DO) See internal elctric drawning 0794621-8.1and

check fysical. 49 TPU ch.9 50 TPU ch.10 51 TPU ch.11 52 TPU ch.12 53 TPU ch.13

MAN B&W Diesel A/S



ACU 3 Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 61 1217-3 El. Driven pump 3 start/stop (DO)

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

65 WN-XA Line A - Network line A Check with service terminal in EICU

65 WNACU3

A Line A - Network line A Check with service terminal in EICU 66 WN-XB Line B - Network line B Check with service terminal in EICU

66 WNACU3

B Line B - Network line B Check with service terminal in EICU Serial communication Plug No. Cabel ID Channel Type Signal ID Type Action Check

68

MAN B&W Diesel A/S




70 Intern to


feedback is the same on ch.34 71 WALCU 8230 Actual Handel position for LCD AO) See in Alpha lub procedure


80 W1202-B 1202-B System by-pass valve solonoide (DO-

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

versa 81 WALCU 8231 Ahead/Astern (DO) See in Alpha lub procedure 82 8620-3 Blower 3 start/stop (DO) 83 WALCU 8232 Engine stop MCU (DO) See in Alpha lub procedure 84 WALCU 8233 Engine stop BCU (DO) See in Alpha lub procedure 85 WALCU 8234 Prelubrication command (DO) See in Alpha lub procedure

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

90 W1238-

P3 Supply for prop.valve via amplifier

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

pressure

91

Intern to J-20-48-70+resist

or 6K8 See internal elctric drawning 0794621-8.1and

check fysical.

MAN B&W Diesel A/S




1 WPACU3 Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPACU3 Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out

9 Intern ti J90 10A output

filtered Supply for by-pass valve motor control

amplifier C= - / D= + Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Low BW 8750 Var. Bypass Amp. OK. (DI) Power on = reading in service terminal is on 21 Low BW 8751 Var. Bypass Position (AI) 22 Low BW 8752 Var. Bypass Open (DI) 23 Low BW 8753 Var. Bypass Closed (DI) 24 Low BW 8762 On/Off Bypass Open (DI) 25 Low BW 8763 On/Off Bypass Closed (DI) 26 Low BW 27 Low BW

MAN B&W Diesel A/S




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

MAN B&W Diesel A/S




30 High/Low BW 31 High/Low BW 32 High/Low BW 33 High/Low BW 34 High/Low BW 35 High/Low BW 36 High/Low BW 37 High/Low BW

MAN B&W Diesel A/S




40 TPU ch. 0 41 TPU ch.1 42 TPU ch. 2 43 TPU ch. 3 44 TPU ch. 4 45 TPU ch. 5 46 TPU ch. 6 47 TPU ch.7

Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 TPU ch.8 8754 Var. By-pass amplifier enabel (DO) 49 TPU ch.9 50 TPU ch.10 51 TPU ch.11 52 TPU ch.12 53 TPU ch.13

MAN B&W Diesel A/S



ACU 4 Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 61


65 WN-XA Line A - Network line A Check with service terminal in EICU

65 WNACU3

A Line A - Network line A Check with service terminal in EICU 66 WN-XB Line B - Network line B Check with service terminal in EICU

66 WNACU3

B Line B - Network line B Check with service terminal in EICU Serial communication Plug No. Cabel ID Channel Type Signal ID Type Action Check

68

MAN B&W Diesel A/S




70 8755 Var. Bypass Amp. (Set point) (AO) 71


80 8765 On/Off Bypass (Set point) (DO) 81 82 83 84 85


90 91

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 Check

1 WPCCU1 Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPCCU1 Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 2A out

4 W4108-1 3.15A out Supply to ELVA amplifier. Polarity on

ELVA plug = B+ og C- Polarity on plug J4 A= - / B= + 5 2A out 6 2A out 7 2A out 8 2A out

9 W4102-

1.1 10A output

filtered Supply to ELFI / FIVA amplifier Polarity on plug J9 A= - / B= + Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Internal Low BW 4105 ELFI / FIVA amplifier OK (DI) Disconect plug J9 and see change of value in service terminal, Please refer to chapter 6.1

21 Low BW 8285 Cyl. Lube Oil Supply Fail (DI-superv) 22

23 W4108-1 Low BW 4109 ELVA valve OK (DI) Check cabling between ELVA plug and plug J

23, please refer to chapter 6.3 24 25 26

27 Low BW 4112 H.P. Fuel Pipe Leakage (NO) (DI-

superv) option (check by dummy plug), Please refer to

chapter 6.6

MAN B&W Diesel A/S



CCUs Loop Terminals

Plug No. Cabel

ID Channel Type Signal ID Type Action Check 10 A 10 B 10 C 10 D 10 E 10 F 10 G 10 H 10 I 10 J

MAN B&W Diesel A/S



CCUs Control Main I/O Board Analog/Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

30 W4102-

1.2 High/Low BW 4102 ELFI/FIVA Position feedback (AI) Check cabling between ELFI plug and plug J

30, Please refer to chapter 6.1

31 W4114-1 High/Low BW 4114 Fuel pump Plunger Position (AI-superv) Check cabling between Fuel pump plunger

plug and plug J 31

32 WSCCU1 High/Low BW 2002 Shut Down Saftey system (DI- Special

superv)

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

33 Internal High/Low BW 4106 ELFI/FIVA Amp. actuel current (AI) Same mA value as in ch.70, Please refer to

chapter 6.1

34 W4111-1 High/Low BW 4111 Exhaust valve position (AI-superv) Check cabling between Exhaust Valve plug and plug J 34, Please refer to chapter 6.3

35 36 37

MAN B&W Diesel A/S



CCUs Fast Digital Input Check of cabling between TSA-A / B and MPC


Type Signal ID Type Action Check 40BC WTCCU1A TPU ch.0 4001-A Marker Master - Tacho set A (Di) Simulate tacho signal in TSA-A 41BC WTCCU1A TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Simulate tacho signal i TSA-A 42BC WTCCU1A TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Simulate tacho signal i TSA-A 43BC WTCCU1A TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Simulate tacho signal i TSA-A 44BC WTCCU2B TPU ch.4 4001-B Marker Master - Tacho set B(Di) Simulate tacho signal i TSA-B 45BC WTCCU2B TPU ch.5 4001-B Marker Slave - Tacho set B(Di) Simulate tacho signal i TSA-B 46BC WTCCU2B TPU ch.6 4003-B Quadrature 1 - Tacho set B (Di) Simulate tacho signal i TSA-B 47BC WTCCU2B TPU ch.7 4004-B Quadreture 2 - Tacho set B (Di) Simulate tacho signal i TSA-B

Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 TPU ch. 8 Data Aq.Synchronization (internal signal)

49 W4108-1 TPU ch.9 4108 ELVA Valve (DO) Check cabling between ELVA plug and plug J

49, Please refer to chapter 6.2

50 W1120-1 TPU ch.10 1120 Start air pilot valve (DO)

Change value and check solenoid valve (ZV1121-A item 30), Please refer to chapter

6.4 51 TPU ch.11 8281 Cyl. Lubricator Pilot Valve (DO) 52 TPU ch. 12 8282 Cyl. Lubricator Feedback (movement)

53 TPU ch. 13

8283 or

Cyl. Lubricator Feedback (Flow) (DI) Or

Cylinder TDC Pulse (for commissioning)(DO)

MAN B&W Diesel A/S



CCUs Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 Internal 4104 ELFI/FIVA Amplifier Enable (DO) Must be on when it is o.k. Please refer to

chapter 6.1 61


65 WNCCU

1A Line A - Network line A Check with Service terminal in EICU

65 WNCCU

2A Line A - Network line A Check with Service terminal in EICU

66 WNCCU

2B Line B - Network line B Check with Service terminal in EICU

66 WNCCU

1B Line B - Network line B Check with Service terminal in EICU Serial communication Plug No. Cabel ID Channel Type Signal ID Type Action Check

68 AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70 Internal 4107 ELFI/FIVA Valve Control (AO) Same mA value as in ch.70 (output value 1.2

to 1.5), Please refer to chapter 6.1 71 Reserved for commisioning

MAN B&W Diesel A/S



CCUs Contact Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

80 81 82 83 84 85


90 Internal Supply for ELFI valve via amplifier Value between 0 Amper. and 1.5 Amper.

Output.

91 Intern to J-

20-32-33-70 See internal elctric drawning and check

fysical.

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 Check

1 WPECUB Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPECUB Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 2A out Slow turning valve (J80) 4 3.15A out Main starting valve (J82) 5 2A out Manuel slow down request-at LOP (J83) 6 2A out Forced command take over (J84) 7 2A out 8 2A out

9 10A output

filtered Control Main I/O Board Plug No. Cabel ID Channel Type Signal ID Type Action Check

20 Low BW 1218-4 El. Driven pump 4 remote / local-fail (DI) 21 WLOP2 Low BW 2152-A Increase limiter (DI superv) Press Increase Limiter button on LOP 22 WLOP2 Low BW 2151-A Stop Switch LOP (DI superv) Turne stop switch on LOP 23 WLOP2 Low BW 2114-A Air Run LOP (DI superv) Activate air run switch on LOP 24 WLOP2 Low BW 2115-A Slow Turning LOP (DI superv) Activate slow turning switch on LOP

25 WLOP2 Low BW 2153-A Take Command (LOP) (DI superv) Activate Forced take control button on

LOP

26 WLOP2 Low BW

2156-A or

2150-A

Speed Set Up button Or

Speed set from local control panel(DI superv) Activate speed up switch on LOP

27 WLOP2 Low BW 2157-A Speed Set Down button (DI Superv) Activate speed down switch on LOP

MAN B&W Diesel A/S



ECU A Loop Terminals

Plug No. Cabel ID Channel Type Signal ID Type Action Check 10 A 10 B 10 B 10 C 10 D 10 C 10 D 10 E 10 F 10 G 10 H 10 I 10 J

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 Check

30 WLOP1 High/Low BW 2155-A Start Switch-Local (DI superv) Activate switch for Start 31 High/Low BW 2103-A Actual Pitch (Analog) From remote control

32 W1117-A High/Low BW 1117-A Start Air Distribution System blocked (DI

superv) Activate switch for Start Air Distributer

valve 33 Astern - local (DI superv) 34 WSS-EUA High/Low BW 2001-A Shut down from Safty System (DI superv) Signal from safty system 35 W8601-A High/Low BW 8601-A Scavenge air pressure (Analog) Sensor PT 8601-A 36 High/Low BW 2195-A Clutch status (DI superv) 37 High/Low BW 5350-A Limiter signal from Dual Fuel Control

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

40AD WTP-A 24Vdc to TSA-A A= - / D= + 40BC WTECUA TPU ch.0 4001-A Marker Master - Tacho set A (Di) Simulate tacho signal in TSA-A

41BC WTECUA TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Simulate tacho signal i TSA-A 42BC WTECUA TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Simulate tacho signal i TSA-A 43BC WTECUA TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Simulate tacho signal i TSA-A 44BC WTCCU1B TPU ch.4 4001-B Marker Master - Tacho set B(Di) Simulate tacho signal i TSA-B 45BC WTCCU1B TPU ch.5 4002-B Marker Slave - Tacho set B (Di) Simulate tacho signal i TSA-B 46BC WTCCU1B TPU ch.6 4003-B Quadrature 1 - Tacho set B (Di) Simulate tacho signal i TSA-B 47BC WTCCU1B TPU ch.7 4004-B Quadreture 2 - Tacho set B (Di) Simulate tacho signal i TSA-B

MAN B&W Diesel A/S



ECU A Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 TPU ch.8 4030-A Extra input for dual speed measurment

(DI)

49 TPU ch.9 4031-A Extra input for dual speed measurment

(DI)

50 TPU ch.10 4032-A Extra marker for dual speed measurment

(DI)

51 TPU ch.11 4033-A Extra marker for dual speed measurment

(DI) 52 TPU ch.12 8287-A Lube back-up (DO) 53 TPU ch.13 1219-4 El.driven pump 4 running (DI)


60 2146-A Zero pitch request (DO) 61 2005-A Reset shut down-from ECS (DI superv)


65 WNCCU1

A Line A - Network line A Check with Service terminal in EICU 66 120 OHM Line B - Network line B Check termination resistor

66 WNCCU1

B Line B - Network line B Check with Service terminal in EICU

MAN B&W Diesel A/S




68 ECU A AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70 LUB R1 2184 Calculated Governor Index (AO) Change value and check in HMI-panel

for Alpha Lub.

71 8501 Starting air Pressure for LOP Indication.

(AO) Contact Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

80 W1114 1114 Slowturning valve (Do) Change value and check solonoid valve

(ZV1114 item 36)

81

1243-A or

1217-4

Astern signal for 4. Trukne pumpe or

El.driven pump 4 start/stop(DO)

82 W1121-A 1121-A Main Starting Valve (Do) Change value and check solonoid valve

(ZV1121-A item 30)

83 2206-A Slow Down Request-Manual at local

(DO) 84 2154-A Forced Command Take over-LOP (DO)

85 2159-A Increase limitation-feedback for LOP

indication (DO)

MAN B&W Diesel A/S



ECU B Power Filter Board Power input/Output plugs etc. Plug No. Cabel ID Channel Type Signal ID Type Action Check

1 WPECUB Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPECUB Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 Power failure 3 2A out 4 W1121-B 3.15A out Main Starting valve J82 A= - / B= + 5 2A out 6 2A out 7 2A out 8 2A out

9 10A output


20 Low BW 1218-5 El.driven pump 5 remote/local-fail (DI) 21 WLOP2 Low BW 2152-B Increase limiter (DI superv) Press Increase Limiter button on LOP 22 WLOP2 Low BW 2151-B Stop Switch (DI superv) Turne stop switch on LOP 23 WLOP2 Low BW 2114-B Air Run (DI superv) Activate air run switch on LOP 24 WLOP2 Low BW 2115-B Slow Turning (DI superv) Activate slow turning switch on LOP

25 WLOP2 Low BW 2153-B Take Command (DI superv) Activate Forced take control button on

LOP

26 WLOP2 Low BW

2156-B or

2150-B

Speed Set Up button (DI superv) or

Speed set from local control panel Activate speed up switch on LOP 27 WLOP2 Low BW 2157-B Speed Set Down button (DI Superv) Activate speed down switch on LOP

MAN B&W Diesel A/S



ECU B Loop Terminals Plug No. Cabel ID Channel Type Signal ID Type Action Check

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

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 Check

30 WLOP2 High/Low BW 2155-B Start Switch-Local (DI superv) Activate switch for Start on LOP 31 High/Low BW 2103-B Actual Pitch (Analog) From remote control

32 W1117-B High/Low BW 1117-B Start Air Distribution System blocked (DI

superv) Activate switch for Start Air Distributer

valve 33 High/Low BW 2135-B Astern-Local (DI superv)

34 WSS-EUA High/Low BW 2001-B Shut down from Safty System (DI superv) Signal from safty system

35 W8601-B High/Low BW 8601-B Scavenge air pressure (Analog) Sensor PT 8601-B 36 High/Low BW 2195-B Clutch status (DI superv)

37 High/Low BW 5350-B Limiter signal from Dual Fuel Control (AL

superv)


40BC WT-XA TPU ch.0 4001-A Marker Master - Tacho set A (Di) Simulate tacho signal in TSA-A 41BC WT-XA TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Simulate tacho signal i TSA-A 42BC WT-XA TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Simulate tacho signal i TSA-A 43BC WT-XA TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Simulate tacho signal i TSA-A 44AD WTP-B 24Vdc to TSA-B A= - / D= + 44BC WTECUB TPU ch.4 4001-B Marker Master - Tacho set B(Di) Simulate tacho signal i TSA-B 45BC WTECUB TPU ch.5 4002-B Marker Slave - Tacho set B (Di) Simulate tacho signal i TSA-B 46BC WTECUB TPU ch.6 4003-B Quadrature 1 - Tacho set B (Di) Simulate tacho signal i TSA-B 47BC WTECUB TPU ch.7 4004-B Quadreture 2 - Tacho set B (Di) Simulate tacho signal i TSA-B

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 Extra input for dual speed measurment

(DI)

49 TPU ch.9 4031-B Extra input for dual speed measurment

(DI)

50 TPU ch.10 4032-B Extra marker for dual speed measurment

(DI)

51 TPU ch.11 4033-B Extra marker for dual speed measurment

(DI) 52 TPU ch.12 8287-B Lube back-up (DO) 53 TPU ch.13 1219-5 El. Driven pump 5 running (DI)


60 2146-B Zero pitch request (DO) 61 2005-B Reset shut down-from ECS (DI superv)


65 WNACU1

A Line A - Network line A Check with Service terminal in EICU 65 120 OHM Line A - Network line A Check termination resistor

66 WNACU1

B Line B - Network line B Check with Service terminal in EICU Serial communication Plug No. Cabel ID Channel Type Signal ID Type Action Check

68

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 Action Check

70 Raw unsigned speed (for

commissioning)

71 WLOP2 1250 Hydraulic Pressure (AO) Change value in service terminal and

check indication on LOP Contact Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

80

81

1243-B or

1217-5

Astern signal for 5. Trukne pumpe or

El.driven pump 5 start/stop(DO)

82 W1121-B 1121-B Output for Main Starting Valve control

(DO) Change value in service terminal and

check indication on LOP

83 2206-B Slow Down Request-Manual, at local

(DO) 84 2154-B Forced Command take over-LOP (DO)

85 2159-B Increase limitation-feedback for LOP

indication (DO)

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 Check

1 WPEICUA Power input A Power Supply Input A Analog 24 Vdc A= - / B= + 1 WPEICUA Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 WAMS1A Power failure 2201-A Power failure signal for AMS (DO) Check signal in AMS (NC) 3 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out

9 10A output


20 WRCS1A Low BW 2163-A Fixed Rpm Command (DI superv) Check signal from RCS 21 WRCS1A Low BW 2164-A Increas limitation CPPonly (DI superv) Check signal from RCS

22 Low BW Increase limitation-bridge (DI superv)

23 Low BW Increase limitation-ECR (DI superv) 24 WAMS1A Low BW 2205-A Slow down req. (DI superv) Check signal from AMS 25 Low BW Slow down command (DI superv) 26 Low BW Speed set from bridge (DI superv) 27 Low BW Speed set from ECR (DI superv)

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 Action Check

30 High/Low BW Stop-bridge (DI superv) 31 High/Low BW Start-bridge (DI superv)(CPPonly)

32 High/Low BW Stop-ECR (DI superv) 33 High/Low BW Start-ECR (DI superv)(CPPonly) 34 High/Low BW Take command ECR (DI superv) 35 High/Low BW Astern-ECR (DI superv)(CPPonly) 36 High/Low BW Pitch set point (AL superv)(CPPonly)

37 High/Low BW Aux.systems ready (DI superv)(HW-

CPPonly)


40 WPMS TPU ch.0 1190-A Shaft generator req (DI) Check signal from PMS 41 TPU ch.1 2112-A Standby request (DI) 42 TPU ch.2 2101A FWE request (DI) 43 TPU ch.3 2120-A Local Control (DI) 44 TPU ch.4 2122-A Bridge Control (DI)

45 TPU ch.5 2121-A

ECR Control- control station request (ECR Control-separate rpm for CPP)

(DI) 46 TPU ch.6 2190-A At Sea (for indication on MOP )(DI)

47 TPU ch.7

2191-A or

2129-A

Prepare start Or

ECR Control-combinatormode for CPP (DI)

MAN B&W Diesel A/S



EICU A Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 WRCS1A TPU ch. 8 2171-A Fix rpm indication on bridge

(CPPonly)(DO) Check indication on RCS

49 WRCS1A TPU ch. 9 2170-A Load limitaion indication on bridge


50 TPU ch. 10 2172-A Manual slow down req. On bridge

(CPPonly)(DO) 51 TPU ch. 11 2175-A Near limit (CPPonly)(DO)

52 TPU ch. 12

2210-A or

2197

Engine stopped for AMS (DO) or

Main engine running

53 WRCS1A TPU ch. 13 2180-A Load limitation indication on ECR

(CPPonly)(DO) Check indication on RCS Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 WSA 2021-A Cancellable shd. Down (DO) Check indication on safty sys.

(Resistor f. supervision) 61 WAMS1A 2202-A System failure for AMS (DO) Check indication on RCS


65 WEICUA Line A - Network line A Check with Service terminal in EICU 66 120 OHM Line B - Network line B Check termination resistor 66 WEICUB Line B - Network line B Check with Service terminal in EICU

MAN B&W Diesel A/S




68 WRCS2A RS422 Serial conn to RCS Check connection by ohming EICU A AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70

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

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)

71

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)

MAN B&W Diesel A/S




80 1191-A

Shaft generator Permission (DO)

Check signal in PMS

81 WSB 2020-A Non cancelabel shut down request to safety

system (DO) Check indication on safty sys.

(Resistor f. supervision)

82 WSB

2005-A or

2207-A

Reset shut down from ECS (DO) or

Reset shoutdown - from ECS Check indication on safty sys.


83

2130-A or

2110

Ahead command Or

Engine blocked(HW CPP)(DO)

84

2131-A or

2111

Astern command Or

Engine ready(HW CPP)(DO) 85 2147 Slow command (CPPonly) (DO)

MAN B&W Diesel A/S



EICU B Power Filter Board Power input/Output plugs etc. Plug No. Cabel ID Channel Type Signal ID Type Action Check

1 WPEICU

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

1 WPEICU

B Power input B Power Supply Input B Analog 24 Vdc A= - / C= + 2 WAMS1B Power failure 2201-B Power failure signal for AMS (DO) Check signal in AMS (NC) 3 2A out 4 3.15A out 5 2A out 6 2A out 7 2A out 8 2A out

9 10A output


20 Low BW 2163-B Fixed Rpm Command (DI superv) Check signal from RCS 21 Low BW 2164-B Restart switch CPPonly (DI superv) Check signal from RCS 22 Low BW Increase limitation-bridge (DI superv) 23 Low BW Increase limitation-ECR (DI superv) 24 Low BW 2205-B Slow down req. (Pre-warning)(DI superv) Check signal from AMS 25 Low BW Slow down command (DI superv) 26 Low BW Speed set from bridge (DI superv) 27 Low BW Speed set from ECR (DI superv)

MAN B&W Diesel A/S



EICU B Control Main I/O Board Analog/Digital Input

Plug No. Cabel ID Channel Type Signal ID Type Action Check30 High/Low BW Stop-bridge (DI superv) 31 High/Low BW Start-bridge (DI superv)(CPPonly) 32 High/Low BW Stop-ECR (DI superv) 33 High/Low BW Start-ECR (DI superv)(CPPonly) 34 High/Low BW Take command ECR (DI superv)

35 High/Low BW Astern-ECR (backup-reversing)(DI

superv)(CPPonly) 36 High/Low BW Pitch set point (AL superv)(CPPonly)

37 High/Low BW Aux.systems ready (DI superv)(HW-

CPPonly)

Fast Digital Input Check of cabling between TSA-A / B and MPC

Plug No. Cabel ID Channel Type Signal ID Type Action Check40 WPMS TPU ch.0 1190-B Shaft generator req (DI) Check signal from PMS 41 TPU ch.1 Standby request (DI) 42 TPU ch.2 FWE request (DI) 43 TPU ch.3 Local Control (DI) 44 TPU ch.4 Bridge Control (DI)

45 TPU ch.5 ECR Control- control station request

(ECR Control-separate rpm for CPP) (DI) 46 TPU ch.6 At Sea (for indication on MOP )(DI)

47 TPU ch.7

2191-B or

2129-B

Prepare start Or

ECR Control-combinatormode for CPP (DI)

MAN B&W Diesel A/S



EICU B Control Main I/O Board Fast Digital Output Plug No. Cabel ID Channel Type Signal ID Type Action Check

48 WRCS1A TPU ch. 8

2171-B or

2128

Fix rpm indication on bridge (CPPonly) or

Forced command take over-ECR indication (HW CPP)(DO) Check indication on RCS

49 WRCS1A TPU ch. 9 2170-B Load limitaion indication on bridge


50 TPU ch. 10 2172-B Manual slow down req. On bridge

(CPPonly)(DO) 51 TPU ch. 11 2175-B Near limit (CPPonly)(DO)

52 TPU ch. 12

2210-B or

2126

Engine stopped for AMS (DO) or

Astern back-upmode (backup reversing) to pitch control function (HW CPP only)

53 WRCS1A TPU ch. 13 2180-B Load limitation indication on ECR

(CPPonly)(DO) Check indication on RCS Switch Output (memory mapped latch) Plug No. Cabel ID Channel Type Signal ID Type Action Check

60 WSA 2021-B Cancellable shd. Down (DO) Check indication on safty sys.

(Resistor f. supervision) 61 WAMS1A 2202-B System failure for AMS (DO) Check indication on RCS


65 WEICUA Line A - Network line A Check with Service terminal in EICU 66 120 OHM Line B - Network line B Check termination resistor 66 WEICUB Line B - Network line B Check with Service terminal in EICU

MAN B&W Diesel A/S




68 WRCS2A RS422 Serial conn to RCS Check connection by ohming EICU B AO-DO Daughter Board Analog Output (controlled by QSPI) Plug No. Cabel ID Channel Type Signal ID Type Action Check

70

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

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)

71

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)

MAN B&W Diesel A/S




80

1191-B or

2127

Shaft generator Permission (DO) or

SG disconnection failed (HW CPP) Check signal in PMS

81 WSB 2020-B Non cancelabel shut down request to safety

system (DO) Check indication on safty sys.


82 WSB

2005-B or

2207-B

Reset shut down from ECS (DO) or

Reset shoutdown - from ECS Check indication on safty sys.


83

2130-B or

2123

Ahead command Or

Local command take over to RCS(HW CPP)(DO)

84

2131-B or

2124

Astern command Or

Local command take over to RCS(HW CPP)(DO)

85

2147 or

2125

Slow command (CPPonly) Or

Bridge command take over to RCS(DO)

MAN B&W Diesel A/S



TSA-A Fast Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

J3 WTMMA TPU ch.0 4001-A Marker Master - Tacho set A (Di) Check when aligning the pick-up to

the trigger ring on the flywheel

J4 WTMSA TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Check when aligning the pick-up to


J1 WTQ1A TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Check when aligning the pick-up to


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 TSA-B Fast Digital Input Plug No. Cabel ID Channel Type Signal ID Type Action Check

J3 WTMMB TPU ch.0 4001-A Marker Master - Tacho set A (Di) Check when aligning the pick-up to


J4 WTMSB TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Check when aligning the pick-up to


J1 WTQ1B TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Check when aligning the pick-up to


J2 WTQ2B TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Check when aligning the pick-up to


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