engine operating instructions type m25maytau.ut.edu.vn/userfiles/files/mak-m25.part3.pdf · manual...

Engine operating instructions

TypeM25

42 470

42 471

42 472

Engine operating instructions

A0

M25

en / 23.11.2004 AA000535 1/1

�

271357

Engine No.: Record No.:

Three-position ControllerConsole Mounting

C5.05.05.09.16.01

-

en / 18.03.2004 FD024024 1/1

�

Three-position Controller

Console Mounting

Pleiger Elektronik GmbH & Co. KG

D-58456 Witten - Im Hammertal 51

D-58423 Witten - P.O.Box 32 63

Telephon (0 23 24) *3 98- 0

Telefax (0 23 24) 3 98- 3 89

Internet www.pleiger.de/pe

e-mail [email protected]

PLEIGER ELECTRONICS 362MC

Manual

ü Operation

ü Installation

ü Connection

ü Technical data

ü Hardware extensions

ü Functional extensions

ü Commissioning help

No. 9360000120

Edition: 2/00

JXLJUK1

BG 0.00.6-98.14.00-06_en

Pleiger Elektronik

GmbH & Co. KG

Page: 2 Manual for 362MC Nr. 9360000120 Edition: 2/00 Subject to modifications

Contents Page

1 Introduction..................................................................................................... 4

2 Display and operating elements .................................................................... 5

2.1 Display .................................................................................................... 6

2.2 Operation ................................................................................................ 6

3 Operating modes............................................................................................ 7

3.1 Automatic mode ...................................................................................... 7

3.1.1 Setpoint entry ............................................................................... 7

3.2 Switching between Manual/Automatic.................................................... 7

4 Manual / Emergency manual mode ............................................................... 8

5 Commissioning extension .............................................................................. 9

5.1 Password entry ....................................................................................... 9

5.2 Commissioning menu ............................................................................. 10

5.3 Setpoint menu......................................................................................... 11

5.3.1 Explanatory note on setpoints ...................................................... 12

5.3.2 Explanatory note on the switching filter ....................................... 12

5.3.3 Explanatory note on the limit value alarm .................................... 12

5.4 Controller profile menu ........................................................................... 13

5.4.1 Entering parameters for two controllers ....................................... 13

5.4.2 Entering parameters for one controller only ................................. 13

5.5 Controller parameters menu ................................................................... 14

5.5.1 Explanatory note on controller types............................................ 15

5.5.2 Explanatory note on controller structure ...................................... 17

5.5.3 Explanatory note on controller output parameters....................... 18

5.6 Input menu .............................................................................................. 19

5.6.1 Explanatory note on calibration .................................................... 20

5.6.2 Explanatory note on scaling ......................................................... 20

5.7 Output menu ........................................................................................... 21

5.8 Display menu .......................................................................................... 22

5.8.1 Explanatory note on controller inputs/outputs.............................. 22

6 Monitoring functions and error messages ..................................................... 23

6.1 System monitoring functions .................................................................. 23

6.1.1 Explanatory note on Param error ................................................. 23

6.1.2 Explanatory note on ROM error and RAM error........................... 23

6.1.3 Explanatory note on the Reset function for the controller ........... 24

6.1.4 Explanatory note on Watchdog error ........................................... 24

6.2 Sensor monitoring functions ................................................................... 24

7 Service interface ............................................................................................ 25

7.1 Service programme McDiag ................................................................... 25

8 Installation ...................................................................................................... 26

9 Connection ..................................................................................................... 27

9.1 Terminal assignments ............................................................................. 27

9.2 Connection of supply voltage ................................................................. 28

9.3 Connection of the switching outputs ...................................................... 28

9.3.1 Connection with AC switching output contacts ............................ 28

9.3.2 Connection with floating switching output contacts ..................... 28

9.4 Connection of the alarm output .............................................................. 29

9.5 Connection of the binary inputs .............................................................. 29

9.6 Connection of the remote resistance-type sensor ................................. 29

9.7 Connection of a U/I measured-value transmitter.................................... 29

Pleiger Elektronik

GmbH & Co. KG

Manual for 362MC Nr. 9360000120 Edition: 2/00 Subject to modifications Page: 3

Contents Page

9.8 Connection of the PT100 sensor ............................................................ 30

9.9 Connection of a I -value transmitter at the 1st linear input ..................... 30

9.10 Connecting cable ................................................................................... 30

10 Technical data ............................................................................................... 31

Appendix A: Reference overview

Appendix A1: Overview of menu structure for standard functions ..................... 32

Appendix A2: Parameters from A to Z for standard functions ............................ 33

Appendix A3: Value assignments from A to Z for standard functions ................ 34

Appendix A4: Error displays and messages from A to Z .................................... 35

Appendix A5: Symbols employed in this manual ................................................ 35

Appendix B: Hardware extensions for the 362MC

Appendix B1: Hardware extension - 2nd relay set ............................................... 36

Appendix B2: Hardware extension - Linear outputs ........................................... 37

Appendix B3: Hardware extension - RS485/RS422 communication interface .. 38

Appendix C: Functional extensions for the 362MC

Appendix C1: Special function - Trend compensation ........................................ 39

Appendix C2: Functional extension - Disturbance compensation ...................... 41

Appendix C3: Functional extension - Setpoint programme ................................ 45

Appendix D: Commissioning help

Appendix D1: Steps for commissioning .............................................................. 49

Appendix D2: Profile memories and factory presets........................................... 50

Appendix D3: Programme entries table for setpoint programmes...................... 57

362MC Delivery configurations

Pleiger Elektronik

GmbH & Co. KG


1 Introduction

The Pleiger multi-function controller 263MC combines a large number of controller functions in a single

compact housing designed for installation in a control panel. A powerful microcontroller, a large param-

eter memory and a two-line alphanumeric display support simple and swift operation and commissioning

of the controller.

The 362MC incorporates the following controller functions in one unit:

• Two-point controller

• Three-point controller with separate parameter sets for both outputs

• Three-point step controller, with optional feedback of controller output

• Continuous controller

• Cascade step controller

Two independent control loops can be operated with one controller unit, provided that the controller is

permissible for the application concerned.

The 362MC incorporates a large number of special features, such as:

• an actual-value display and manual controller output adjustment which function

independently of the microcontroller to enable manual emergency operation for

switching controllers, even in the event of processor failure;

• a large non-volatile parameter memory to enable storage of up to 50 different controller

configurations for frequently required applications;

• a two-line alphanumeric LCD display for process data and easily comprehensible operating

prompting;

• a serial service interface which is accessible via the front panel of the controller, to enable

connection of a terminal or a PC to the Pleiger service programme 362McDiag.

In addition to the user-friendly operating and display functions, the 362MC does, of course, also provide

additional control functions to enable the safe and reliable control of complex systems, such as:

• differential trend compensation via the second measuring sensor, for enhanced control of

systems with large dead times;

• switch-over to a second setpoint via an external signal;

• inputs for an external setpoint and for logical adjustments and interlocks.

The 362 MC can be supplied in a configuration geared specifically to the application concerned, by

means of different voltage variants (230V AC, 115V AC) and different component variants for the

inputs (PT100, 0(4)-20mA, 0-(5)10V) and outputs (relays with supply voltage or floating contacts).

Hardware extensions are also available, such as

• a 2nd relay group for switching outputs,

• a module with 2 linear outputs - 0(4)-20mA or 0-10V,

• a module with RS 485/422 serial data interface

and functional extensions, such as

• additive disturbance compensation weighted via any characteristic with five interpolation

points for advance compensation of the controlled system and

• setpoint programmes for time-dependent setpoint adjustments.

In the appropriate configuration, the single 362MC unit is thus able to replace the Pleiger controllers and

supplementary modules 361-D, 362-D, 366-D and 366-V.

2 Display and operating elements

The 362MC controller incorporates a 2½-digit LED actual-value display for the 1st controller which is

clearly legible at a distance. For special applications, the display is also available as a 3½-digit variant

(with decimal digit or for special measuring ranges).

Pleiger Elektronik

GmbH & Co. KG


The 362MC additionally features an two lines LCD process data and parameter display. During normal

operation of the controller, this display is employed to display various process variables. The display also

provides easily comprehensible operator prompting for all entry operations.

Eight buttons are integrated in the foil of the front panel to control the display, to enter data, to switch the

operating mode and to activate emergency manual mode. The buttons are arranged in three groups.

A practical, replaceable labelling field is provided under the foil for identification of the measuring point.

After removing the front frame and

lifting the lower part of the foil, the

fuse for switching outputs and the

connector for the service interface

are also accessible after installation

of the controller.

The labelling field is simple to

replace. Fuse F2 Connector for service interface Front frame

LED actual-value display

LED Auto Actual value X of 1st controller

ON = Automatic mode without decimal place

OFF= Manual / Emergency (1st PT100 input direct)

manual mode

LCD display lines 1 + 2

(Operating display and

operator prompting)

Switching output buttons

+u = actuator OPEN

t- = actuator CLOSED

(only by Emergency

manual mode)

Selection + entry buttons

Man and Auto buttons p = Select+ increase value

Man = Manual / Emergency q = Select+decrease value

manual mode Prgm=Select+save

(only together with Exit) Exit =Cancel+abort

Auto = Automatic mode (Exit+Man=Manual /

Emergency manual mode)

Labelling field

for identification of

measuring points

Pleiger Elektronik

GmbH & Co. KG


2.1 Display

On power up, the controller always displays the type and version no. first of all, before

switching to menu 1, the operational display. Here the process data are shown in the

two-line LCD display. Display lines 1 and 2 are visible in normal operating

mode. By pressing the Prgm button, the display can be switched to a

second mode (2nd line 1 and 2nd line 2)

for as long as the button is held.

The user can assign the process data

in the operational display to the lines via

the commissioning menu Display (5.8).

2.2 Operation

Operation of the controller, configuration and setting of the controller

parameters are carried out with operator prompting in 3 selection levels.

Menu selection constitutes the highest selection level. In normal

operating mode the menu selection remains hidden and the process

data are shown on the LCD display. The desired menu is selected via the q and p buttons.

The menu name is now shown in the 1st line of the LCD display instead of the process data . Each menu

groups together entry items and parameters which are closely linked. The Prgm button can be used to

branch to the desired menu and the parameter selection function. The desired parameter is selected

here in the same manner, using the q and p buttons.

The 1st line of the display shows the name and the 2nd line the value of the selected parameter. If the

selected value now requires to be altered, the Prgm button must be pressed to branch to the parameter

entry function. Here the value can

be altered with the q and p buttons.

The value is entered and saved via

the Prgm button.

If the Exit button is pressed at any

point, the current selection will be

aborted. From the parameter entry

function the system will branch back

without altering the set value to

the parameter selection function,

from parameter selection the system

will always branch back to he menu

selection function, and from menu

selection menu 1 - the operational

display - will always be activated.

Should no button be pressed over a

period of 60 seconds during the

selection or entry process, the

operational display will be

re-activated automatically.

Menu 1 Menu 2 Menu n

Parameter

1

Parameter

2

Parameter

n

Value

Param. 2

Value+1

Value-1

Save

value

Menu selection

Para

mete

r sele

cti

on

Parameter entry

Menu name

Parameter name

Parameter value

Value entry

Example of display

at selection and entry

Example of

operational display

Line 1

Line 2

2nd L1

2nd L2

On power up, the

362MC always

displays the type and version no.

?

Pleiger Elektronik

GmbH & Co. KG


3 Operating modes

The 362MC incorporates two operating modes - Automatic and Manual / Emergency manual mode. A

modified menu is provided for each operating mode. Both operating modes offer an extended version of

the menu for commissioning purposes. This extension to the menus for configuration and

parameterisation of the controller is protected by a password to prevent unauthorised use.

3.1 Automatic mode

The green Auto LED lights up; the controllers are operating in a closed-loop system. The setpoints can

be altered via the setpoint entry or the commissioning menus can be activated via the menu selection

function, provided that the valid password has been entered.

3.1.1 Setpoint entry

After selecting the Setpoint Entry

menu under the menu selection

option in Automatic mode, the

setpoints and the alarm limits of

both controllers can be altered.

The 1st character of the name

displayed under the entry option

denotes the number of the

controller - 1 or 2. The letter A or

B appears as the final character,

to distinguish between the main

setpoint (A) and the second setpoint

(B) that becomes active in the case

of external setpoint switching.

The value for the lower alarm limit

of each controller is indicated by -

and the value for the upper alarm

limit is indicated by +.

See also Explanatory note on limit alarm (5.3.1).

This presentation of the setpoint entry procedure is based on the assumption that both controllers have

been configured as fixed setpoint controllers with setpoint type �fixed value�. The 1st controller setpoint is

101.0°C for Setp A and Setp B, irrespective of the setpoint switching function. 82.0°C is defined under

Setp A for the 2nd controller. When external setpoint switching applies, Setp B is set at 65.0°C. When a

different setpoint type is configured, the setpoint entry display has a different appearance.

In the case of the setpoint type external setpoint (extern), an external value connected

at the input becomes the setpoint. It is thus not possible to alter this value by entering a

different value. When the controller is implemented with a setpoint programme, the user

can switch between the stored programme numbers 1 to 5 (in this example 2).

See also Functional extensions (Appendix).

3.2 Switching between Manual/Automatic

Manual / Emergency Manual mode will only be activated if the user presses the Man and Exit button

simultaneously. This eliminates the possibility of Automatic mode being deactivated unintentionally or

by mistake. The green �AUTO� LED turns off, and the text MANUAL is shown in the 1st line of the LCD

display in alternation with the process value. Manual operation of the outputs and emergency manual

mode for the switching output of the 1st controller are active.

Display example

with password

entry to the

commissioning

menu

Operational display Setpoint menu Password menu

Menu selection in automatic mode

En

try s

ele

cti

on

A

bo

rt

Value+1

Value-1

Save

new value

Alter value

Pleiger Elektronik

GmbH & Co. KG


Automatic mode is activated again by pressing the Auto button. The green LED marked �Auto� lights up.

4 Manual / Emergency manual mode

When Manual / Emergency manual mode is active, buttons t- and +u are used to adjust the

1st controller´s switching output. When the +u button is pressed, the output is switched to +, as a result

of which the connected actuator is operated in OPEN direction. When the t- button is pressed, the

output is switched to -, as a result of which the actuator is operated in CLOSED direction.

This Emergency manual mode for the 1st controller operates irrespective of whether the micro-

controller is operational. The 2½-digit actual-value LED display of the 1st controller is also available for

Emergency manual mode independently of the microcontroller.

Manual mode is activated via the Manual menu to enable adjustment of a continuous controller output

of the 1st controller or to adjust a controller output of the 2nd controller. This menu can only be activated in

Manual mode, following the operational display.

Outputs are adjusted immediately. The percentage output value of a linear output is altered from its

current value in accordance with the value entered by the user and is output directly. The switching

output on the 2nd controller is adjusted for as long as the button remains depressed.

Operational display Setpoint menu Password menu

Menu selection in Manual / Emergency manual mode

alternate

each second

Manual menu

En

try s

ele

cti

on

A

bo

rt

Value+1

to output

Linear output

adjust1st controller

Switching or linear output

Value-1

to output

Emergency manual

adjust

with

2nd controller

Switching or linear outputSwitching output

adjust

The buttons are provided only for the manual adjustment of switching

outputs on the 1st controller in Emergency manual mode, and have no other functions.?

Pleiger Elektronik

GmbH & Co. KG


5 Commissioning extension

The menu selection option of the 362MC can be extended for the purposes of commissioning the con-

troller. The extended functions for altering the configuration or parameterisation are available in both

Automatic and Manual / Emergency manual mode. The menu extension is accessible after entering the

password. This password lock serves to provide protection against unauthorised use.

5.1 Password entry

If no password has been entered (PW-lock=On), the password lock will be deactivated to enable access

to the extended commissioning menu by entering the currently valid password.

To this end, digits 1 to 4 have to be set to the stored

value for the password, in each case beginning from a

value of 0.

After input of the 4th digit, shown in the example here as password 1234, the value is compared against

the stored password. If the entered value corresponds to the stored password, the password lock will be

deactivated (PW-lock=Off); if the entered value does not correspond to the stored password, the pass-

word lock will remain active.

The password status is retained when the voltage supply for the controller is switched on and off.

Setpoint menu Password menu

A

bo

rt

Value+1

Value-1

Digit 1

Value entry

Value+1

Value-1

Digit 2

Value entry

Value+1

Value-1

Digit 3

Value entry

Value+1

Value-1

Digit 4

Value entry

compare

value

(example)

On delivery, the password 0362 is stored for the 362MC.

Please alter this password to protect your specific settings.?

Pleiger Elektronik

GmbH & Co. KG


When the password entry function is selected while the password lock is deactivated (PW-lock=Off), the

password lock can be activated again or the stored password can be altered.

Activation of the password lock

When this function is selected, the current status:

password lock OFF or password lock ON, is shown in the

2nd line of the display. On activation of the password lock,

the system exits the commissioningmenu again.

Changing the password

A new password is selected and

entered as already described in

detail under �Password entry�.

Any number >=0000 and <=9999 is

permissible as the value for the

password.

5.2 Commissioning menu

After entering the password (PW-lock=Off), the menu extensions can be selected for commissioning,

both in Automatic and Manual / Emergency manual mode, after entering the setpoint menu.

Display menu

A

bo

rd

Activation of the password lock

Password

lock

OFF

Password

lock

ON

Value+1

Value-1

Digit 1

Value entry

Digit 2 to 4

Value entry

save

new

password

Changing the

password

Password menu

Operational display

Example: Menu selection in Automatic mode

Setpoint menu Password menu

Menu extensions

for commissioning

Controller

profile menu

Controller

parameter menu

Input

menu

Display

menu

Output

menu

Pleiger Elektronik

GmbH & Co. KG


The following tables for the commissioning menus show the parameter (name), the value range (min/

max) and an appurtenant explanation (meaning/comment), together with the memory location in the

profile (�= profile controller 1, �= profile controller 2) and a symbol I to denote ! Adjustment in

Manual mode only !

5.3 Setpoint menu

In addition to the described setpoint entry function (3.1.1), the setpoint types, SetpTyp, and

the filter times, T-Lowp, can be parameterised here in the commissioning menu.

Setpoint

menu

Many of the range limits (min/max value) stated in the following tables are dependent

on the scaling selected for the physical variables via the parameters Scale-0 and

Scale-F. See also explanatory note on scaling (5.6.2).?

Parameter Value (min Meaning Comment

1st Controller max)

I 1SpTypA fixed Setp. type A = fixed value See also Functional extension

extern = external input Setpoint programme (Appendix)

1Setp A 0.0°C Setpoint A for type A=fixed Setpoint here e.g. 0-200°C; see also

200.0°C extern for type A=extern Explanatory note on setpoints (5.3.1)

I 1SpTypB fixed Setp. type B = fixed value The second setpoint, B, is only

extern = external input active when an external switching

1Setp B 0.0°C Setpoint B for type B=fixed input has been parameterised for

200.0°C extern for type B=extern 2Setp in the Input menu.

1T-Lowp 0.0s Low pass filter time See also Explanatory note on

999.9s for setpoint switching switching filter (5.3.2)

1Alarm- -99.0°C Alarm limit=Setp.-amount 1Alarm- Lower alarm limit (ActVal < Setp)

0.0°C Alarm OFF See also Explanatory note on

220.0°C Alarm limit= 1Alarm- limit value alarm (5.3.3)

1Alarm+ -99.0°C Alarm limit=Setp.+amount 1Alarm+ Upper alarm limit (ActVal > Setp)


220.0°C Alarm limit= 1Alarm+ limit value alarm (5.3.3)

Parameter The following parameters for the 2nd controller are displayed only when

2nd Controller 2 controllers are selected in the Profile menu.

I 2SpTypA fixed Setp. type A = fixed value See also Functional extension

extern = external input Setpoint programme (Appendix)

2Setp A 0.0°C Setpoint A for type A=fixed Setpoint here e.g. 0-200°C; see also

200.0°C extern for type A=extern Explan. note on setpoints (5.3.1)

I 2SpTypB fixed Setp. type B = fixed value The second setpoint, B, is only

extern = external input active when an external switching

2Setp B 0.0°C Setpoint B for type B=fixed input has been parameterised for

200.0°C extern for type B=extern 2Setp in the Input menu.

2T-Lowp 0.0s Low pass filter time See also Explanatory note on

999.9s for setpoint switching switching filter (5.3.2)

2Alarm- -99.0°C Alarm limit=Setp.-amount 2Alarm- Lower alarm limit (ActVal < Setp)


220.0°C Alarm limit= 2Alarm- limit value alarm (5.3.3)

2Alarm+ -99.0°C Alarm limit=Setp.+amount 2Alarm+ Upper alarm limit (ActVal > Setp)


220.0°C Alarm limit= 2Alarm+ limit value alarm (5.3.3)

Negative values for the alarm parameters relate to system deviations

(relative to the setpoint); positive values for the alarm parameters relate

to fixed alarm limits; alarm parameter = 0 = limit monitoring OFF.?

Pleiger Elektronik

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5.3.1 Explanatory note on setpoints

The table for the Setpoint menu shows a permissible range from 0-200°C for setpoints �Setp A� and

�Setp B� of each controller. This range is valid for PT100 inputs in standard configuration. Additional

setpoint ranges can also be set, in each case adapted via the scaling factor to the employed measuring

sensors and the physical variables to be controlled.

These settings are carried out in the Input menu via parameters Scale-F, Scale-0 and Dim.

Several examples of other value ranges are shown in the following table.

See also Input menu (5.6)

5.3.2 Explanatory note on the switching filter

In order to avoid discontinuous transient conditions and overshoot

during setpoint switching, a switching low pass filter of the 2nd order

can be parameterised on the 362MC.

The time for the switching filter is set via the parameter Tf = T-Lowp.

5.3.3 Explanatory note on the limit value alarm

Alarm limits can be parameterised to monitor the actual values and

a permissible system deviation. These impose a lower alarm limit

and an upper alarm limit on the permissible control band. If the

actual value violates a fixed alarm limit for longer than 5s or a

relative alarm limit for longer than 60s, the alarm will be activated.

When an alarm is activated, the alarm relay is de-energised (Alarm ON)

(closed-circuit principle) and the current display is switched to the

error display. This display remains active until the alarm is

acknowledged via the Exit button. The alarm relay is energised

again (Alarm OFF) when the actual values is insite the control band.

For example:

Point 0: The 1st actual value attains the control band for the 1st time.

Alarm OFF; the alarm display function is started.

Point 1: The upper alarm limit is violated! The alarm is activated

(Alarm ON) and the error indication ActV++ is displayed.

Point 2: The upper alarm range is left again.

Alarm OFF; the alarm relay is energised.

Point 3: The lower alarm limit is violated. The alarm is activated

(Alarm ON) and the error indication ActV� is displayed.

Point 4: The lower alarm range is left again.

Alarm OFF; the alarm relay is energised.

Measuring sensor Measuring Parameters Comment

for example: range Scale-F Scale-0Dim Setp

PT100 0 to 500°C 500,0 0,0 °C 0 - 500,0 °C The required hardware

Pressure sensor -1 to 5 bar 6,0 -1,0 B -1,0 - 5,0 bar configuration for the

Displacement sensor 0 to 300 mm 300,0 0,0 mm 0 - 300,0 mm installed 362MC is to be

Rotation angle sensor 0 to 100% 100,0 0,0 % 0 - 100,0 % observed.

If no other error: Alarm relay energised = actual value within alarm limits;

Alarm relay not energised = limit value alarm;

see also Monitoring functions and error messages (6).?

Operational

display

Error

display

or

Alarm

acknowledge

alternate

each second

only

Operational display

Error display

:

W7I

Alarm ON

Alarm OFF

Alarm ON

Pleiger Elektronik

GmbH & Co. KG


5.4 Controller profile menu

On the 362MC, all the necessary settings for a controller are grouped together in

so-called profiles. Each profile thus contains all the parameters for a specific application.

The parameter memory of the 362MC contains 50 memory locations for different profiles, enabling

previously tested commissioning values to be stored as profiles for a large number of applications. The

commissioning procedure is then started by selecting the appropriate profile for the control task

concerned.

To this end, one of the controllers are first of all selected in the Profile menu via the parameter �DsplCtr�,

this controller´s profile is selected via �Prof-No� and its parameters are subsequently displayed and

altered in the following menus. Selection and entry points are marked accordingly on the display of the

362MC. The tables belonging to this description state which parameters are stored in which control menu.

5.4.1 Entering parameters for two controllers

It is to be noted here that

- only the parameters of one profile and thus of one controller are displayed;

- the two controllers must always be assigned different profiles via �Prof-No�.

During commissioning, the display should thus be set specifically to the controller which is to be put into

operation; e.g. from DsplCtr = 1 of 2 for the 1st controller to DsplCtr = 2 of 2 for the 2nd controller and

vice-versa. It is not necessary to enter the profile no. assigned to the controller under �Prof-No� again

for this purpose.

5.4.2 Entering parameters for one controller only

When the 362MC is used for one controller only, �DsplCtr� should be switched to �1 only�.

This precludes any switching. The parameters for the 2nd controller will no longer be displayed.


max)

DsplCtr only 1 Display controller = only controller 1 activ Entry point marked è

1 of 2 Display controller = displ. controller 1 of 2 Entry point marked è

2 of 2 Display controller = displ. controller 2 of 2 Entry point marked ¬

The parameters which are stored

I Prof-No 1 Select controller profile for operation in a controller profile and are thus

50 Value = profile no. 1 to no. 50 available for subsequent selection

are indicated as follows

I Save as 1 Save current controller profile as � for controller 1 and

50 value = profile no. 1 to no. 50 � for controller 2.

Controller

profile menu

?

?

If you save the selected profile to an available �Prof-No� via the �Save as� function

before commissioning, the parameters which have been altered in the course of

commissioning will be stored for you in this new profile. If possible, do not alter the

profile memory locations containing the factory presets (see Appendix), so as to

ensure that you will be able to access these profiles if necessary.

We urgently recommend you to alter the parameters marked with the I symbol

in the tables belonging to this description in �Manual� mode only. This will avoid

unintentional activation of the actuator.

With regard to the entry of parameters for the 2nd controller, the selection and entry

point is displayed as * to indicate controller 2 instead

of -> to indicate controller 1.

?

Pleiger Elektronik

GmbH & Co. KG


5.5 Controller parameters menu

This menu includes all the control-related parameters of the 362MC. In this menu the

controller type �CtrlTyp� is defined, the parameter set �ParSet� to be displayed and

possibly altered is selected and the structure of the controller �Struct� is set.

The parameters are then displayed directly in the same menu and, where appropriate, altered. The

menu thus ensures a complete overview of all values relating to the controller each time it is activated.

Controller

parameter menu

See also Functional extensions - Disturbance compensation or Setpoint programme (Appendix)

in the Parameter Value (min Meaning Comment

profile each controller max)

�� CtrlTyp 2PntPW 2-Point controller with feedback See also Explanatory note on

I 3PntPW 3-Point controller with feedback controller types (5.5.1)

2Point 2-Point controller without feedback

3Point 3-Point controller without feedback

Step 3-Point step controller

Cont Continuous controller

CscStep Cascade step controller

Werte ParSet 1 Parameter set selection The values of both parameter sets for

�� 2 No. 1 or 2 of the controller concerned each controller are stored in the profile.

Parameter (1)/(2) The selected parameter set of the

(each set) selected controller is displayed.

�� Struct P Structure = P action only See also Explanatory note on

PI = PI action controller structure (5.5.2)

PD = PD action D component is always relative to

PID = PID action the system deviation and damped;

PD2 = PD action D2 component is always relative to

PID2 = PID action the controlled variable and damped.

�� Kr -999.0 P gain See also Explanatory note on

999.0 controller structure (5.5.2)

�� Tn 10s Reset time for I component See also Explanatory note on

10000s controller structure (5.5.2)

�� Tv 0.1s Derivative action time for D component See also Explanatory note on

1000.0s controller structure (5.5.2)

�� Vd 1.0 max. D gain for D component See also Explanatory note on

1000.0 controller structure (5.5.2)

�� T drive 5.0s Actuator operating time for step controller See also Explanatory note on

1000.0s controller output parameters (5.5.3)

�� Ts min 0.1s min. switching duration for switching output See also Explanatory note on

100.0s controller output parameters (5.5.3)

�� T cycl 0.1s min. cycle time for 2-Point and 3-Point See also Explanatory note on

100.0s controller with feedback controller output parameters (5.5.3)

�� Deadbd -1.0% Deadband for switching and continuous See also Explanatory note on

5.0% controller controller output parameters (5.5.3)

�� Hyst 0.0% Hysteresis for 2-Point and 3-Point See also Explanatory note on

10.0% controller controller output parameters (5.5.3)

�� Ymin -100% min. controller output See also Explanatory note on

100% controller output parameters (5.5.3)

�� Ymax -100% max. controller output See also Explanatory note on

100% controller output parameters (5.5.3)

�� Kw 0.0 Setpoint gain See also Explanatory note on

10.0 controller output parameters (5.5.3)

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5.5.1 Explanatory note on controller types

The controller type �CtrlTyp� can be defined separately for each of the 362MC´s two controllers.

2-Point controller = switching controller with 2 switching output states, relay+ ON and relay+ OFF.

The 2-Point controller with feedback �2PntPW� operates internally as a continuous controller with

down-line pulse-width modulator and switching output. Its output corresponds to the ratio of ON period

to OFF period of relay+ of assigned relay set 1 or 2.

In the case of the 2-Point controller without feedback �2Point� the pulse-width modulator is replaced by

a threshold switch with hysteresis.

3-Point controller = switching controller with 3 switching output states, relay+ ON, relay+ and relay OFF

and relay- ON. The 3-Point controller with feedback �3PntPW� operates internally as a continuous

controller with two down-line pulse-width modulators and two switching outputs. Its output corresponds

to the ratio of ON period to OFF period of relay+ if the controller output is positive and relay- if negative,

both relay+ and relay- being from assigned relay set 1 or 2.

In the case of the 3-Point controller without feedback �3Point� the pulse-width modulator is replaced by

a threshold switch with hysteresis.

The two switching outputs can be parameterised separately, whereby the controller and output+ use the

complete 1st parameter set (1) and output- uses only the separate loop gain, Kr, and the parameters for

the switching outputs of the 2nd parameter set (2). See table:

Controller 362MC Typ: 2PntPW Actuator Controlled system

W xd Y X

PID

Controller 362MC Typ: 2Point Actuator Controlled system

W xd Y X

PID

PID

Controller 362MC Typ: 3PntPW Actuator Controlled system

W xd Y X

PID

Controller 362MC Typ: 3Point Actuator Controlled system

W xd Y X

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This enables adaption of the 3-Point controller to two different actuators for outputs + and -. External pa-

rameter switching is not applicable here.

3-Point step controller = step controller for I-actuators with 3PntPW output

In conjunction with the down-line integrating actuator, the internal controller �Step� simulates a continu-

ous controller and has a 3-Point output with feedback. It is thus only suitable for use in combination with

integrating actuators, such as motor actuators.

(The operational characteristics of �Step� correspond to those of Pleiger controller 362-D)

Continuous controller = controller with continuous output.

The controller output of the continuous controller �Cont� is supplied to the assigned analogue output.

The required hardware configuration of the 362MC is to be observed.

(The operational characteristics of �Cont� correspond to those of Pleiger controller 361-D).

Cascade step controller = internal interconnection of 2 controllers to create the cascade controller

�CscStep�. Controller output Y1 of the primary controller, with setpoint W and actual value X, is injected

into the secondary controller as setpoint V. In addition to the controlled setpoint V, the secondary 3-Point

step controller also receives secondary actual value U to form output Y2.

With setpoint gain KW2 of the secondary controller can be employed, for example, to bypass the primary

controller during commissioning (Kr1=0 switches PID off, Kw

2 results in W=V).

PID IPID

Kw2

Controller 362MC Typ: CscStep

Actuator Controlled system

+ Part A Part B

W xd Y1

V Y2

U X

- -

Parameter with

3-Point controller for with parameter

1st Parameter set 3-Point- CtrlTyp, Struct, Kr, Tn, Tv, Vd, Deadbd, Hyst, Ymin,Ymax, Kw (1)

switching output +

2nd Parameter set switching output - Kr, Deadbd, Hyst, Ymin,Ymax (2)

PID

Controller 362MC Typ: Step Actuator Controlled system

W xd Y X

I

Controller 362MC Typ: Cont Actuator Controlled system

W xd Y X

PID

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When the cascade step controller �CscStep� is selected, the primary continuous controller always uses

the 1st parameter set (1) and the secondary 3-Point step controller uses the 2nd parameter set (

2).

5.5.2 Explanatory note on controller structure

The parameterisable structures for the presented controller types are shown in the following table. On

selecting a controller type, the display always shows only the structures which are parameterisable in

accordance with this table!

P controller (proportional-action controller)

In the case of the P controller, a value of the controller output Y is

directly proportionally assigned to each value of the system deviation

xd. The assigned value is set via the gain factor Kr (P gain).

Xp is frequently used instead of Kr. Xp=100 / Kr

PI controller (proportional-plus-integral action controller)

In the case of the PI controller, the value of controller output Y is set

proportional to the system deviation xd (P component), and the

I component, which corresponds to the time integral of the system

deviation, is added to this value. The I component is set via reset time

Tn, which corresponds to the time in which the I component effects a

change in the controller output of a magnitude corresponding to the

P component.

PD controller (proportional-plus-differential action controller)

In the case of the PD controller, a D-component corresponding to the

time differential of the system deviation is added to the controller

output component (P component) which is proportional to system

deviation xd. The D component is set via derivative action time Tv,

which specifies how much earlier the step response of a PD controller

corresponds to a value which is attained by a P controller. A low pass

with the time constant T=Tv / Vd is employed to limit the bandwidth of

the differential element.

PD2 controller (proportional-plus-differential action controller)

This functions in the same manner as the PD controller, whereby the

D2 component corresponds not to the time differential of system

deviation xd but to the time differential of controlled variable X.

PID controller (PI controller with added D component)

PID2 controller (PI controller with added D2 component)

Regarding the D component, see also:

Special function - Trend compensation in the appendix.

CtrlTyp 2PntPW 3PntPW Step Cont CscStep ç when controller

or or prim. contrl. sec. contrl. of type

2Point 3Point (Cont) (1) (Step) (

2)

Struct P P P P ç these structures

PI PI PI PI PI PI are possible

PD PD PD PD PID PID PID PID PID PID PD2 PD2 PD2 PD2 PID2 PID2 PID2 PID2 PID2 PID2

<

W

.U

7Q

PI-Structure

<

W

.U

7Y�9G

PD-Structure

<

W

.U

7Q

7Y�9G

PID-Structure

<

W

.U

P-Structure

Pleiger Elektronik

GmbH & Co. KG


<V

[G

7]

7V

7V

7]

=R

=R

3PntPW

<V

[G

+\

=R

+\

=R

3Point<V

[G

+\=R

2Point

<V

[G

7]

7V

=R

2PntPW

<

W

.U

7Q

PI-Step-Structure

CtrlTyp 2PntPW 2Point Step Cont CscStep ç when controller

or or prim. contrl. sec. contrl. of type

3PntPW 3Point (Cont) (1) (Step) (

2)

Para- T drive T drive ç these parameters

meter Ts min Ts min Ts min are to be defined

T cycl Deadbd Deadbd Deadbd Deadbd Deadbd Deadbd

Hyst Ymin Ymin Ymin Ymin Ymax Ymax Ymax Ymax Kw Kw Kw Kw Kw Kw

Struct P PI PD PID ç when structure is

PD2 PID2

Parameter Kr Kr Kr Kr ç these parameters

Tn Tn are to be defined

Tv Tv Vd Vd

PI step controller (proportional-plus-integral action step controller)

PID step controller (PI step controller with added D component)

In the case of the PI and PID step controller, the value of controller

output Y

can only be generated in conjunction with the I component

of the actuator.

As with the other PI and PID controllers, the P, I and D components are

set via parameters Kr, Tn and TV/Vd. Operating time T drive of the

actuator controls the stepping function of the 3-Point output with feedback.

The display shows only the parameters contained in the following table, corresponding to the structure

defined in �Struct�.

The other control parameters are also displayed only when they are to be defined, checked or altered for

the selected controller type. Parameters which are not relevant are not shown. See table:

5.5.3 Explanatory note on controller output parameters

T drive

Operating time of the actuator for step

controllers which applies from feedback signal

OPEN to CLOSED in continuous drive mode.

Ts min and T cycl

Minimum pulse width Ts and minimum cycle

time Tz for pulse-width modulated outputs, for

purpose of adjustment to actuator and controlled

system.

Deadbd

Deadband Zo as zero drive range for pulse-

width modulated outputs and as threshold value

for OFF command of 2-Point and 3- Point

outputs without feedback. See also Cont

Hyst

Hysteresis Hy for ON commands of 2-Point and

3-Point outputs without feedback.

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Ymin and Ymax

Controller output limits for continuous controllers, including

the internally series-connected continuous controllers.

Kw

Setpoint gain, serves to compensate steady-state

deviation on P controllers.

On other controllers Kw always = 1.

5.6 Input menu

In the Input menu, the physical inputs of the 362MC are assigned to the various internal

input variables. This assignment is to be defined separately for each profile and thus for

each of the two controllers of the 362MC. Double assignments are possible, such as

assignment of external input �E1� to switch to the 2nd setpoint �2.Setp� in the profiles of both controllers,

for example. The table below shows the possible assignments.

The function Calibrate resistance input and the parameters for scaling and dimension assignment are

also located in the Input menu.

<

[G

<PLQ

<PD[

=R

Cont

?

*1 In special hardware-configuration the 1st PT100 input can be supplied as 0(4)-20mA input !

Input

menu

in the Parameter meaning Parameter Value (min Value meaning


�� Main (primary) actual value ActValX NC No input assigned

I Secondary actual value (cascade) ActValU PT100-1 1st PT100 input (or 0(4)-20mA) see*1

Trend compensation Trend PT100-2 2nd PT100 input

Disturbance compensation Disturb Lin 0.. 3rd linear input as 0-20mA, 0-(5)10V,

External setpoint ExtSetp Lin 4.. or 4-20mA

Position feedback FeedBk Lin ..4 or 20-4mA

Resist 4th resistance input

Value Function: Calibration of the R scale Rmax Store R as Rmax for scaling

�� resistance input; see Explanatory kalibr User factory setting for 0-200R

note on calibration (5.6.1) Rmin Store R as Rmin for scaling

�� Switch to 2nd setpoint 2.Setp NC No input assigned

I Switch to 2nd parameter set 2.Param E1 External input 1

Relay PLUS continuous ON Rel+On E2 External input 2

Relay PLUS continuous OFF Rel+Off E3 External input 3

Relay MINUS continuous ON Rel-On E4 External input 4

Relay MINUS continuous OFF Rel-Off E5 External input 5

Manual Internal state: Manual mode

E6 External input 6

�� Scaling factor Scale-F -1000.0

I 1000.0 See also Explanatory note on

�� Scale zero point Scale-0 -1000.0 scaling (5.6.2)

I 1000.0

�� Dimension Dim °C Dimension = degrees Celsius

No dimension

(Facility for assigning a physical mm Dimension = millimetre

unit of measurement to the % = per cent

scaled display value.) hP = hectopascal

See also Explanatory note on B = bar

scaling (5.6.2) °F = degrees Fahrenheit

free d

efin

ab

lefo

r each

para

mete

rfr

ee d

efin

ab

lefo

r each

para

mete

r

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GmbH & Co. KG


The following table presents an example of assignment of the physical inputs of the 362MC which would

correspond to the functions of a 362-D.

5.6.1 Explanatory note on calibration

Via the Calibrate resistance input function, the 362MC supports the adjustment of its 4th analogue input

to the actual values of a connected resistor feedback sensor which is necessary during commissioning,

for example, in order to compensate fitting tolerances.

The following procedure is recommendable here:

1. Start the calibration process

Set parameter �R scale� to value �kalibr�; the factory setting for a resistor feedback sensor of

0 to 200R is employed for the display.

2. Calibration zero point

Move actuator to CLOSED position (e.g. in Manual mode) until the actuator is completely closed!

Set parameter �R scale� to value �Rmin�; the current value of the resistor feedback sensor will be

stored as 0%=zero point.

3. Calibration end position

Move actuator to OPEN position (e.g. in Manual mode) until the actuator is completely OPEN!

Set parameter �R scale� to value �Rmax�; the current value of the resistor feedback sensor will be

stored as 100%=end position.

Each entered value will be stored only when the following procedure is observed: select �R scale�,

select parameter entry with Prgm button and press Prgm to save the value.

5.6.2 Explanatory note on scaling

The parameters Scale-F = scale factor and Scale-0 = scale zero point are employed to scale physical

variables, such as those setpoints and parameter entries, within the 362MC´s internal value range from

0 to 1. When internal values with physical scaling are required for display purposes, the values

concerned are scaled back with the same parameters.

Parameter Value Meaning

ActValX PT100-1 Main actual value is 1st PT100 input

ActValU NC No input assigned

Trend PT100-2 Trend compensation with 2nd PT100 input

Disturb NC No input assigned

FeedBk Resist Position feedback via 4th resistance input

ExtSetp NC No input assigned

2.Setp NC No input assigned

2.Param NC No input assigned

Rel+On E1 Relay PLUS continuous ON via external input 1

Rel+Off E2 Relay PLUS continuous OFF via external input 2

Rel-On E3 Relay MINUS continuous ON via external input 3

Rel-Off E4 Relay MINUS continuous OFF via external input 4

Scale-F

Scale-0

Scale-F

Scale-0

scaling Controller 362MC back scaling

internal

Entrys Displays

(e.g. Setpoints) (e.g. Parameters)

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Example

If a pressure transmitter with a physical measuring range from -1 bar to

+5 bar in accordance with the characteristic shown opposite is connected

at the input of the 362MC, scaling will be effected

in bar as follows: Scale-0 = -1 Scale-F = 6 Dim = B

in % as follows: Scale-0 = 0 Scale-F = 100 Dim = %

See also Explanatory note on setpoints (5.3.1)

5.7 Output menu

In the output menu, the internal output variables of the 362MC are assigned to the physical

outputs. This assignment is to be defined separately for each profile and thus for each of

the two controllers of the 362MC. Double assignments are not expedient and are thus not

permissible for entry. The following table shows the assignments for controller output and actual-value

output. The hardware configuration of the 362MC is to be observed in each case!

Attention: Avoid double assignment in case of changing the controller profile!

The following example contains the assignment of the 362MC´s physical outputs which would correspond to the

functions of a 361-D or 362-D:

Output

menu

In order to use the 2nd relay set or the linear outputs of the 362MC,

hardware extensions are required.?

OutputY Relais1 362MC output assignment for 362-D function

OutputX NCOutputY 1Lin 0> 362MC output assignment for 361-D function

OutputX NC



�� OutputY NC No output assigned

1Relais 1st relay set (Rel+ and Rel-) 2nd relay set only when

2Relais 2nd relay set (Rel+ and Rel-) hardware extension installed

1Lin 0> 1st linear output 0-20mA (0-5/10V) 1st and 2nd linear output only when

1Lin 4> 1st linear output 4-20mA hardware extension installed

1Lin 0< 1st linear output 20-0mA (5/10-0V) > standard direction (Ymin=0%)

1Lin 4< 1st linear output 20-4mA 0-20mA, 4-20mA, 0-10V, 0-5V

2Lin 0> 2nd linear output 0-20mA (0-5/10V) < reversed direction (Ymin=0%)

2Lin 4> 2nd linear output 4-20mA 20-0mA, 20-4mA, 10-0V, 5-0V

2Lin 0< 2nd linear output 20-0mA (5/10-0V) Bidirectional output with 0>

2Lin 4< 2nd linear output 20-4mA (Ymin=-100%), ±20mA, ±10V, ±5V

�� OutputX NC No output assigned

1Lin 0> 1st linear output 0-20mA (0-5/10V) 1st and 2nd linear output only when

1Lin 4> 1st linear output 4-20mA hardware extension installed

1Lin 0< 1st linear output 20-0mA (5/10-0V) > standard direction (Ymin=0%)

1Lin 4< 1st linear output 20-4mA 0-20mA, 4-20mA, 0-10V, 0-5V

2Lin 0> 2nd linear output 0-20mA (0-5/10V) < reversed direction (Ymin=0%)

2Lin 4> 2nd linear output 4-20mA 20-0mA, 20-4mA, 10-0V, 5-0V

2Lin 0< 2nd linear output 20-0mA (5/10-0V) Bidirectional output with 0>

2Lin 4< 2nd linear output 20-4mA (Ymin=-100%), ±20mA, ±10V, ±5V

?

In standard configuration, the PT100 inputs of the 362MC are calibrated for 0-200°C.

In this case the scaling is always Scale-0 = 0, Scale-F = 200, Dim = °C.?

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5.8 Display menu

The process variables which are to be shown in the two lines of the LCD display as the

operational display are selected in the Display menu. See also Display (2.1).

Pressing the Prgm button will switch the system to a second display level foras long as the

button remains depressed, thus enabling 4 process variables to be assigned. The operating language

�Lang� can also be selected in this menu. All text displays are then shown in the selected language.

The contrast adjustment function for the LCD display can also be selected in this menu.

5.8.1 Explanatory note on controller inputs/outputs

The two control diagrams illustrate the significance of the display parameters for

the controller inputs and outputs. The last letter appears on the display as an

upper case letter for controller 1 and as a lower case letter for controller 2.

Display

menu

362MC

Setp W Out+Y Feed Y

Out%Y

ActV X

Dist Z

Tren D

Switching

output

or

Linear

output

Controller Actuator Controlled

system


general max)

Line 1 1Setp W Setpoint - controller 1

Line 2 1Setp V Setpoint secondary - controller 1 See also Explanatory note on

2nd L1 1ActV X Actual value - controller 1 controller inputs/outputs

2nd L2 1ActV U Actual value secondary - controller 1

1Dist Z Disturbance input - controller 1

1Tren D Trend input - controller 1

1Out+Y Switching control output - controller 1 Display with symbol <<, || or >>

1Feed+Y Position feedback in % - controller 1 Additional to switching output symbols

1Out%Y Continuous control output in % - controller 1 Display in xx.x%

2Setp w Setpoint - controller 2

2Setp v Setpoint secondary - controller 2 See also Explanatory note on

2ActV x Actual value - controller 2 controller inputs/outputs

2ActV u Actual value secondary - controller 2

2Dist z Disturbance input - controller 2

2Tren d Trend input - controller 2

2Out+y Switching control output - controller 2 Display with symbol <<, || or >>

2Feed+y Position feedback in % - controller 2 Additional to switching output symbols

2Out%y Continuous control output in % - controller 2 Display in xx.x%

Lang deutsch Language selection for all

english display texts

LCDcntr 1 Contrast setting for the

255 LCD display

362MC

Setp W Out+Y Feed Y

Out%Y

ActV U

ActV X

Switching

output

or

Linear

output

Controller

(secondary)Actuator

Part A Part B

Controller

(primary)

Controlled system

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6 Monitoring functions and error messages

Numerous monitoring functions are integrated in the 362MC. These functions are executed during the

programme start or in the background during normal running of the programme, and monitor the

controller for correct, error-free functioning. When errors are established in a monitoring function, a

corresponding error message appears in text form on the LCD display.

In order to highlight the error message, the error is displayed in flashing mode (flashing cycle approx.

1 second), in alternation with the operational display. Should the established error be a serious error

which might impair the controller´s functions, an alarm will be activated and the control programme

will be stopped.

Upon activation of an alarm, the alarm relay is de-energised (closed-circuit principle).

See also Explanatory note on limit value alarm (5.3.3)

6.1 System monitoring functions

Basic system monitoring functions are executed each time the supply voltage is switched on and prior

to starting the standard controller programme. The appurtenant error messages are shown in the table

below. See also Explanatory notes

6.1.1 Explanatory note on Param error

When the parameters are loaded from the parameter memory, a check sum is generated as a 16-bit

CRC and compared against the stored check sum. If the two check sums are not identical, the error

signal will be output. This error may occur when the parameters are loaded during the programme start

or during commissioning, when loading profiles, for example. The controller programme cannot be

started.

When this error applies, the 362MC loads the factory presets as a precautionary measure. Please

check urgently, in the following order:

- the profiles of both controllers - incorrect profiles will be reloaded after entering the correct profile no.;

- the parameters in each profile and each parameter set - errors are corrected by entering the correct data;

- repeat the check by resetting the controller.

6.1.2 Explanatory note on ROM error and RAM error

When the programme is started, the check sum of the ROM programme memory is generated and

compared against the stored check sum. The main memory is also tested by writing test patterns and

check-reading. Should errors occur, it will not be possible to start the controller programme.

Repeat the test by resetting the controller. If the error occurs again, the controller is to be replaced.

Display Contrl. Monitoring function Additional measures

indication Stop

ERROR Yes Check on contents of parameter memory Controller programme will not be started! It is

Param by 16-BIT CRC with generator polynominal urgently necessary to check all parameters !

Check the system again via Reset.

ERROR Yes Check on contents of programme memory Controller programme will not be started!

ROM by 16-BIT CRC with generator polynominal Error indicates external EMC disturbance

or component defect.

ERROR Yes Check on main memory Re-check system via Reset.

RAM by writing test pattern and check-reading In case of error after Reset - replace controller.

See also Explanatory note on Reset (6.1.3)

ERROR The programme run monitoring function has Controller programme is started! Error indicates

Watchdog initiated a programme restart; the system monitoring external EMC disturbance. Acknowledge error

function does not identify any errors during the start! with EXIT; check for any accumulations.

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6.1.3 Explanatory note on the Reset function for the controller

Param, ROM and RAM errors can only be acknowledged by resetting the controller, after which the

system monitoring process is repeated.

6.1.4 Explanatory note on Watchdog error

The 362MC incorporates a programme run monitoring function. The correctly running controller

programme regularly resets a watchdog timer. Should deviations occur during execution of the

programme, e.g. as a result of major external EMC disturbances, this resetting pulse will not be

transmitted for the timer. The watchdog timer will then initiate a programme restart. During the restart,

the cause Watchdog error is displayed. The controller programme is not stopped. This error is to be

acknowledged by pressing the EXIT button, in the same manner as other error messages.

6.2 Sensor monitoring functions

The 362MC continuously checks the measured-value inputs for interruptions, short-circuits or other

deviations from the measuring range in the background during normal running of the controller

programme. As a general principle, only those errors are monitored which could actually disturb

operations on the basis of the currently parameterised functions.

Unused inputs and inputs are only employed for display purpose are not monitored.

The following table provides an overview of the various error messages.

An error which does not recur immediately after being acknowledged indicates

a major EMC disturbance. Make a note of such errors. Should the error recur

frequently, the cause of the error is to be eradicated.

Errors at important inputs will lead to the controller programme being stopped and

initiation of an alarm, as safe and reliable operation of the controlled system is not

longer ensured. Please do not acknowledge the error message until the cause of

the error has been eradicated.

?

?

Programme start after reset

These error messages show any multiple

errors corresponding to the errors which

were displayed briefly during the system

monitoring process.

Controller reset

These buttons are to be

pressed simultaneously.

Display: Monitoring function Additional measures

ERROR

1.PT >1 The 1st PT100 input has a measured value If the input to which the error message

> measuring range (standard > 200°C). relates is in use as

1.PT <0 The 1st PT100 input has a measured value an actual-value input,

< measuring range (standard < 0°C). a setpoint input,

2.PT >1 The 2nd PT100 input has a measured value a trend input or

> measuring range (standard > 200°C). a disturbance input,

2.PT <0 The 2nd PT100 input has a measured value the controller programme will be stopped and

< measuring range (standard < 0°C). an alarm will be triggered. The sensor and the

Lin >1 The linear input has a measured value connection cabling are to be checked;

> measuring range (standard > 20mA). an wire breakage, short-circuiting or sensor

Lin <0 The linear input has a measured value defects are the most common causes of these

> measuring range (standard < 0(4)mA). errors. Beyond this, the measuring input of the

Resist>1 The resistance input has a measured value controller may be defective.

> calibrated range (> Rmax). This is to be checked with a PT100 simulator

Resist<0 The resistance input has a measured value or current source, for example.

< calibrated range (< Rmin). After error acknowledge, the test is repeated.

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7 Service interface

The 362MC possesses a service interface which is accessible on the front of the controller. This inter-

face provides for more user-friendly operation and diagnosis of the controller. To this end, a PC and the

362MC service programme

�McDiag� are required.

The interface connector is accessible

on the installed controller after

removing the front frame and raising

the bottom labelling window.

7.1 Sevice programme McDiag

The service programme �McDiag� which has been developed for the 362MC controller can be run with

Windows 95/98 or NT4.0. The installation and operating instructions are provided on the data carrier.

Several operator interfaces of the programme McDiag are shown below by way of example.

A service package comprising McDiag data carrier and 362MC service interface cable is available for

the interface.

Fuse F2 Connector for service interface Front frame

Pleiger Elektronik

GmbH & Co. KG


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15

15

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65,5 +0,5

137 +

0,5

144

72

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140

8 Installation

The 362MC controller is delivered in a housing for installation in a control panel in accordance with

DIN 43700. The housing dimensions are 144 x 72 mm.

The required control panel cut-out is shown in the diagram. The

minimum overall installation depth including plug-in terminals is

140 mm. The space for the connecting cable which is to be

connected from the rear is to be added to this minimum dimension.

The housing is fixed by means

of fixing two clamps which are

offset relative to each other on

the top and bottom of the

housing.

When installing the controllers in

groups, a minimum spacing of

15 mm should be observed

between the cut-outs in the

control panel, as shown in the

diagram below.

The controller housing can also

be fitted in any sloping or

inclined surfaces.

Suitable wall-mounting boxes

are available for the local

installation of one or two

controllers.

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9 Connection

The connection points on the 362MC are grouped together on two screw-/plug terminals on the backside

of the controller. The voltage supply, the switching outputs, the alarm and the binary inputs are

connected via a 20-pole plug terminal; the linear inputs and the signals from supplementary modules are

connected via an 18-pole plug terminal.

9.1 Terminal assignments

The terminals are numbered from

no. 1 to no. 38 and identified by

symbols printed on the backside

of the controller.

The connection table below is

followed by several explanatory

notes on the controller connections.

Additional explanatory notes on the

connection of hardware extensions

are to be found under

Hardware extension (Appendix)

Connection table (362MC standard configuration) Terminal Signal name

1 L1 Voltage supply connection

2 N Standard 230V-AC (or 115V-AC)

3 SL Protective earth conductor or cabinet earth

4 N Output, 1st relay set

5 + (Open) Connection for 1st switching output

6 - (Closed)

7 N Output, 2nd relay set

8 + Connection for 2nd switching output

9 - (See Hardware extension in appendix)

10 Common

11 Make contact Alarm relay

12 Break contact

13 SL Protective earth conductor or cabinet earth

14 E1

15 E2

16 E3 Binary inputs

17 E4 for function switching

18 E5

19 E6

20 E (Common)

21 d

22 c Connection for extension module 2

23 b (See hardware extension in appendix)

24 a

25 d

26 c Connection for extension module 1

27 b (See hardware extension in appendix)

28 a

29 Linear input 4 (resistance)

30 Connection for resistor feedback sensor

31 - U/I Linear input 3 (current/voltage)

32 + Connection for measured-value transmitter

33 Linear input 2 (PT100)

34 (PT100-2) Connection for 2nd temperature sensor

35

36 Linear input 1 (PT100)

37 (PT100-1) Connection for 1st temperature sensor

38 (In special version for 0(4)-20mA)

�

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9.2 Connection of supply voltage

In standard configuration, the 362MC controller

is to be connected to a 230V AC voltage supply.

The controller is also available as a special

version for connection to a 115V AC power supply.

The infeed system is prepared for connection via

a three-core cable. The shield of the connection

cable and the protective earth conductor SL are

to be connected to the cabinet earth,

ensuring a substantial contact surface area.

The cable should be as short as possible and

have an adequate cross-section.

Should connection only be possible with a 2-core

cable, protective earth conductor terminal SL on

the controller is to be connected to cabinet earth.

Adequate earthing of the cabinet is imperative.

Fuse F1 for the internal system voltage supply is

accessible at the backside of the controller.

Fuse F2 for the power supply to the switching outputs is fitted under the front cover and can be replaced

from the front.

9.3 Connection of the switching outputs

In standard configuration, controller 362MC has one relay set, consisting of relay+ and relay-, as its

switching output. A 2nd relay set is available as a hardware extension. Two variants apply for connection

of the switching voltage.

9.3.1 Connection with AC switching output contacts The standard 362MC controller connects

the infeed supply voltage to the actuator

directly via the output relays. No additional

wiring is necessary. Fuse F2 is integrated

for separate protection. This fuse is

accessible under the front cover. The

amperage on the identification plate is to

be observed.

Example: AC actuator

9.3.2 Connection with floating switching output contacts A special version of the 362MC controller is

equipped with floating output contacts.

This enables control at voltages other than

the supply voltage, e.g. for DC actuators.

The maximum permissible contact load

as specified on the data sheet is to be

observed!

The control/switching voltage is to be

provided with external fusing!

Example: DC actuator

OP CL

+ -

362MC DC

actuator

Supply

voltage

Control

voltage

F1 F2

362MC

Supply voltage to

AC-Switching outputs

Supply voltage for

the internal system Connection with

3-Core cable

+Shield

F1 F2

362MC

Supply voltage to

AC-Switching outputs

Supply voltage for

the internal system Connection with

2-Core cable

+Shield

M1~

362MC AC

actuator

Supply

voltage

OP CL

+ -

F2

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GmbH & Co. KG


9.4 Connection of the alarm output

The alarm output of the 362MC is provided as a

changeover contact. The alarm relay is operated

according to the closed-circuit principle. When the

controller is functioning correctly, the relay coil is

energised. In the event of an error or power failure,

the coil voltage will be cut.

The alarm contact drops into its normal condition, as

illustrated on the symbol printed on the backside.

9.5 Connection of the binary inputs

The 362MC possesses 6 binary inputs, which can

be used for various functions and can be assigned

to functions as required via the parameters in the

Input menu.

In standard configuration, the inputs are to be

connected as floating contacts. The contact voltage

is provided by the controller.

As a special variant, the 362MC can be supplied

with an input circuit for DC contacts for a nominal

voltage of 24V DC. These inputs are to be

connected to +24V and the reference potential 0(24)

is to be connected to terminal 20.

9.6 Connection of the resistor feedback sensor

The remote resistor feedback sensor is connected to

the 362MC at the 4th linear output, using a two-core

cable.

After mechanical adjustment of the sensor on the actuator,

calibration is carried out via parameter entry in the Input

menu.

See also Explanatory note on calibration (5.6.1)

9.7 Connection of a U/I measured-value transmitter

In the standard configuration of the 362MC, the 3rd linear

input serves as a current input for currents from 0-20mA

or 4-20mA. The current input is configured as a differential

amplifier input. The max. common-mode voltage is +2V.

The 362MC is also available in a special version with a

voltage input for 0-10V or 0-5V. The appropriate hardware

configuration is to be observed here.

See also Commissioning menu - Input (5.6)

362MC

K1 K2

internal

Contact

voltage

K1 K2

0(24)

+24V

external

Contact

voltage

362MC

362MC

362MCCurrent inputI= 0-20mA

4-20mA

362MCVoltage inputU= 0-10V

0-5V

Signal

voltage

to alarm monitoring

system

362MC

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9.8 Connection of the PT100 sensor

In the standard configuration of the 362MC, the 1st

and 2nd linear inputs serve as PT100 inputs.

Connection is effected via a three-wire connection,

whereby the compensation for the line resistance

of 3 wires is based on 3 wires of the same cross-

section and the same length.

As the examples opposite show, it is also possible

to connect a 4-wire PT100 sensor in 3-wire

configuration without any problems whatsoever.

If a 4-wire system is already installed, such as is

employed on the 362-D for example, the 4th wire

is not to be connected.

When using a 2-wire PT100 sensor, e.g. for trend

compensation, connection is to be carried out as

shown in the example opposite.

The line resistance is not compensated in this

case; the absolute measured value is

consequently corrupted in many installations.

Installation via a 2-wire connection is sufficient for use as a differential trend input. Should you desire a

more accurate indication or wish to use the sensor as a main sensor, however, external compensation is

possible with a resistor between terminal 36 and 37. The resistance value for RL must correspond to the

resistance of one connecting wire.

9.9 Connection of a I -value transmitter at the 1st linear input

In the special configuration of the 362MC, the 1st

linear input serves as a current input for currents

from 0-20mA or 4-20mA. The current input is

configured as a differential amplifier input.

The max. common-mode voltage is +2V.

9.10 Connecting cable

Shielded, twisted-pair cabling is to be used for the linear outputs (see Hardware extension), the

communication interface (see Hardware extension) and inputs 3 and 4 which are described here

(resistance and U/I). The cable cross-section must be at least 0.22mm².

Shielded cabling with a minimum cable cross-section of 0.5mm² is to be used for the binary inputs and

linear inputs 1 and 2 (PT100).

It is recommended that shielded cabling be used for the switching outputs.

All linear inputs are electrically interconnected and connected to protective earth.?

362MCT

362MCT

362MC

T

RL

362MC1st linear input

as current inputI= 0-20mA

4-20mA

362M

CThe shields of all connection cables are to be

connected to control cabinet earth, ensuring a

substantial contact surface area. The cabling

should be as short as possible and have an

adequate cross-section.

?

Pleiger Elektronik

GmbH & Co. KG


10 Technical data

Voltage supply Standard OptionalInput voltage 230V AC ±10% 115V AC ±10%

Frequency 50 - 60Hz ±5%

Stromaufnahme max. 100mA max. 200mA (+switching current)

Permissible ambient temperatureOperating temperature 0 - +60°C

Storage temperature -20 - +85°C

Protection typeHousing and terminals IP00

Frontside IP30

HousingType Housing for installation in Wall-mounting housing

Dimensions 144x72 mm acc.DIN 43700 Dimension sheet available

installation depth 140 mm on request

Control panel cut-out 137+0.5 mm x 65.5+0.5 mm

Weight approx. 1200 g

Linear inputs (only 1st input)

1st and 2nd input (PT100 inputs) Pt100 0(4) - 20mA

Measuring range 0 - 200°C 0 - 500°C 0-100%

Resolution 0.2°C 0.5°C 20µA

Measuring accuracy ±0.5%

3rd input (current/voltage input)

Measuring range 0(4) - 20mA 0 - 5V, 0 - 10V

Resolution 20µA 5 / 10mV


Internal resistance 250 Ohm

4th input (resistance input)

Measuring range 0 - 200 Ohm

Resolution 0.2 Ohm


Binary inputsType 6 x optocoupler inputs

for floating contacts for 24V DC nominal inputs

(electrically isolated switching (switching voltage external)

voltage supplied)

Operating threshold 12V ±4V

Switching current 1mA ±0.5mA

Switching outputsType 1 x relay set (expandable by 2nd relay set)

each with relay +(OPEN) and -(CLOSED)

Switching voltage = supply voltage floating contacts

(internal connected) (external supply and fusing)

Max. contact current 1A at 230V-AC max. 8A and max. 250V

2A at 115V-AC purely resistive load only

Type 1 x alarm relay with floating changeover contact

Linear outputs (hardware extension)Type 2 x current output 2 x voltage output

Output range 0(4) - 20mA, ±20mA 0 - 10V, ±10V

Resolution 40µA 20mV

Accuracy ±0.5%

Load impedance max. 400 Ohm min. 1 kOhm

Communication interface (hardware extension)Type RS485 isolated RS422 isolated

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Figure shows all possible displayed parameters; displayed parameters dependent on parameterised function!

Appendix A1: Overview of menu structure for standard functions

Manual mode

Output1Output2

1SpTypA1Setp A1SpTypB1Setp B1T-Lowp1Alarm-1Alarm+2SpTypA2Setp A2SpTypB2Setp B2T-Lowp2Alarm-2Alarm+

DsplCtrProf-NoSave as

CtrlTypParSetStruct

KrTnTvVd

T driveTs minT cyclDeadbd

HystYminYmaxKw

ActValXActValU

TrendDisturbExtSetpFeedBk

R scale2.Setp

2.ParamRel+On

Rel+OffRel-On

Rel-OffScale-0Scale-F

Dim

OutputYOutputX

Line 1Line 22nd L12nd L2

LangLCDcntr

PW-lockPW-chng

Output1Output2

1Setp A1Setp B1Alarm-1Alarm+2Setp A2Setp B2Alarm-2Alarm+

PW-inp

alternate

each second

Operational display

Manual mode

Manual mode

withoutMenu extensions

for commissioning

(Password lock

ON)

ActValXActValU

TrendDisturbExtSetpFeedBk

R scale2.Setp

2.ParamRel+On

Rel+OffRel-On

Rel-OffScale-0Scale-F

Dim

1SpTypA1Setp A1SpTypB1Setp B1T-Lowp1Alarm-1Alarm+2SpTypA2Setp A2SpTypB2Setp B2T-Lowp2Alarm-2Alarm+

DsplCtrProf-NoSave as

CtrlTypParSetStruct

KrTnTvVd

T driveTs minT cyclDeadbd

HystYminYmaxKw

OutputYOutputX

Line 1Line 22nd L12nd L2

LangLCDcntr

1Setp A1Setp B1Alarm-1Alarm+2Setp A2Setp B2Alarm-2Alarm+

PW-lockPW-chng

PW-inpOperational display

Automatic mode

Automatic mode

withMenu extensions

for commissioning

(after Password

input)

Automatic mode

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Appendix A2: Parameters from A to Z for standard functions

These parameter names always appear in the 1st line of the LCD display.

Parameter

1Alarm-1Alarm+1Setp A1Setp B1SpTypA1SpTypB1T-Lowp2.Param2.Setp

2Alarm-2Alarm+2nd L12nd L2

2Setp A2Setp B2SpTypA2SpTypB2T-LowpActValUActValXCtrlTypDeadbd

DimDisturbDsplCtrExtSetpFeedBk

HystKrKw

LangLCDcntrLine 1Line 2

Output1Output2OutputXOutputYParSet

Prof-NoPW-chngPW-inp

PW-lockR scaleRel+OffRel+On

Rel-OffRel-On

Save asScale-0Scale-FStructT cycl

T driveTn

TrendTs min

TvVd

YmaxYmin

Meaning

Lower alarm limit, 1st controllerUpper alarm limit, 1st controller1st setpoint, 1st controller2nd setpoint, 1st controllerSetpoint type, 1st controller, 1st setp.Setpoint type, 1st controller, 2nd setp.Filter time, 1st controllerChangeover to 2nd parameter setChangeover to 2nd setpointLower alarm limit, 2nd controllerUpper alarm limit, 2nd controller2nd display line 12nd display line 21st setpoint, 2nd controller2nd setpoint, 2nd controllerSetpoint type, 2nd controller, 1st setp.Setpoint type, 2nd controller, 2nd setp.Filter time, 2nd controllerSecondary actual valuePrimary actual valueController typeDeadbandDimensionDisturbance compensationDisplay selection Controller no.External setpointPosition feedbackHysteresisP gainSetpoint gainLanguage changeoverContrast setting, LCD displayDisplay line 1Display line 2Actuating output, 1st controllerActuating output, 2nd controllerActual-value outputController outputSelect parameter setSelect controller profile no.Change passwordPassword entryActivate password lockCalibration - resistance inputRelay Plus continuous OFFRelay Plus continuous ONRelay Minus continuous OFFRelay Minus continuous ONSave controller profile no.Scale zero pointScale factorController structureMin. switching cycleActuator operating timeReset timeTrend compensationMin. switching durationDerivative action timeMax. D gainMax. Controller outputMin. Controller output

in menu Point

Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Input 5.6Input 5.6Setpt 5.3Setpt 5.3Display 5.8Display 5.8Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Setpt 5.3Input 5.6Input 5.6CtrlPar 5.5CtrlPar 5.5Input 5.6Input 5.6Profile 5.4Input 5.6Input 5.6CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5Display 5.8Display 5.8Display 5.8Display 5.8Manual 4Manual 4Output 5.7Output 5.7CtrlPar 5.5Profile 5.4Passwrd 5.2Passwrd 5.1Passwrd 5.2Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Profile 5.4Input 5.6Input 5.6CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5Input 5.6CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5

Pleiger Elektronik

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Appendix A3: Value assignments from A to Z for standard functions

These value assignments are always shown in the 2nd line of the LCD display.

Value

%°C°F

1 of 21ActV U1ActV X1Dist Z1Feed+Y1Lin 0<1Lin 0>1Lin 4<1Lin 4>1Out%Y1Out+Y

1Relais1Setp V1Setp W1Tren D2 of 2

2ActV u2ActV x2Dist z2Feed+y2Lin 0<2Lin 0>2Lin 4<2Lin 4>2Out%y2Out+y2PntPW2Point

2Relais2Setp v2Setp w2Tren d3PntPW3Point

BCont

CscStepdeutsch

E1E2E3E4E5E6

englishexternfixed

hPkalibr

Lin 0..Lin 4..Lin ..4Manual

mmNCNC

Off

in menu Point

Input 5.6Input 5.6Input 5.6Input 5.6Profile 5.4Display 5.8Display 5.8Display 5.8Display 5.8Output 5.7Output 5.7Output 5.7Output 5.7Display 5.8Display 5.8Output 5.7Display 5.8Display 5.8Display 5.8Profile 5.4Display 5.8Display 5.8Display 5.8Display 5.8Output 5.7Output 5.7Output 5.7Output 5.7Display 5.8Display 5.8CtrlPar 5.5CtrlPar 5.5Output 5.7Display 5.8Display 5.8Display 5.8CtrlPar 5.5CtrlPar 5.5Input 5.6CtrlPar 5.5CtrlPar 5.5Display 5.8Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Display 5.8Setpt 5.3Setpt 5.3Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6Output 5.7Passwrd 5.1

Meaning

No dimensionDimension per centDimension degrees CelsiusDimension degrees FahrenheitDisplay, controller 1 of 2Actual value, secondary controller 1Actual value, controller 1Disturbance, controller 1Position feedback in %, controller 11st linear output 20-0mA (5/10-0V)1st linear output 0-20mA (0-5/10V)1st linear output 20-4mA1st linear output 4-20mAContinuous output in %, controller 1Switching output, controller 11st relay set (Rel+ and Rel-)Setpoint, secondary controller 1Setpoint, controller 1Trend input, controller 1Display, controller 2 of 2Actual value, secondary controllerActual value, controller 2Disturbance, controller 2Position feedback in %, controller 22nd linear output 20-0mA (5/10-0V)2nd linear output 0-20mA (0-5/10V)2nd linear output 20-4mA2nd linear output 4-20mAContinuous output in %, controller 2Switching output, controller 22-Point controller with feedback2-Point controller without feedback2nd relay set (Rel+ and Rel-)Setpoint, secondary controller 2Setpoint, controller 2Trend input, controller 23-Point controller with feedback3-Point controller without feedbackDimension barContinuous controllerCascade step controllerDisplay texts in GermanExternal input 1External input 2External input 3External input 4External input 5External input 6Display texts in EnglishSetpoint type external setpointSetpoint type fixed setpointDimension hectopascalUse factory preset for 0-200R3rd linear input as 0-...mA/V3rd linear input as 4-20mA3rd linear input as 20-4mAInternal state: Manual modeDimension millimetreNo input assignedNo output assignedStatus - password lock is OFF

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Appendix A3: ContinuedThese value assignments are always shown in the 2nd line of the LCD display.

Appendix A4: Error displays and messages from A to Z

These items of information are shown in the 1st or 2nd line of the LCD display.

Appendix A5: Symbols employed in this manual

These symbols always have the same meaning throughout the manual.

Meaning

Values stored in profile of controller 1Values stored in profile of controller 2Value X in 1st parameter set of a controllerValue X in 2nd parameter set of a controllerPlease alter values in Manual mode only!Particularly important information

Symbol

?

�� X1

X2

I

Display

�-

|| << >>

0�-1.ActV�

1.ActV++1.PT <01.PT >12.ActV�

2.ActV++2.PT <02.PT >1

362MCERROR

Lin <0Lin >1

PAR ERRParam

RAMRAM ERR

Resist<0Resist>1

ROMROM ERR

Vx.xxWatchdog

in menu Point

Manual 4

Manual 4Manual 4Manual 4Passwrd 5.1

5.3.35.3.36.26.25.3.35.3.36.26.22.266.26.26.1.36.16.16.1.36.26.26.16.1.32.26.1

Meaning

Adjustment - 1st switching output(via emergency operating buttons only)Adjustment - switching output =0Adj. - switching output CLOSED=-Adj. - switching output OPEN=+Start password entry (4-digit)Error, 1st actual value above upper alarm limitError, 1st actual value below lower alarm limitError, 1st PT100 below measuring rangeError, 1st PT100 above measuring rangeError, 2nd actual value above upper alarm limitError, 2nd actual value below lower alarm limitError, 2nd PT100 below measuring rangeError, 2nd PT100 above measuring rangeController type, display during startError indication, for error in 1st lineError, linear input below measuring rangeError, linear output above measuring rangeParameter error during resetError, parameter monitoringError, RAM monitoringRAM error during resetError, R input below measuring rangeError, R input above measuring rangeError, ROM monitoringROM error during resetSoftware status x.xx, display during startError, watchdog monitoring

Value

Ononly 1

PPD

PD2PI

PIDPID2

PT100-1PT100-2Resist

RmaxRminStep

in menu Point

Passwrd 5.1Profile 5.4CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5CtrlPar 5.5Input 5.6Input 5.6Input 5.6Input 5.6Input 5.6CtrlPar 5.5

Meaning

Assignment - password lock ONDisplay controller 1 onlyController structure PController structure PDController structure PD with D2Controller structure PIController structure PIDController structure PID with D21st linear input as PT100 (0(4)-20mA)2nd linear input as PT1004th linear input as resistanceSave R as Rmax for scalingSave R as Rmin for scaling3-Point step controller

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Appendix B1: Hardware extension - 2nd relay set

The hardware of the 362MC can be extendet at the factory via the addition of a 2nd set of switching

output relays, comprising one relay+ and one relay-.

Terminal assignments

Connection is carried out via terminals

7-9 marked Relay 2, as specified in

the connection table opposite.

Connection and wiring

Two connection modes apply for the switching voltage, as already described for the 1st relay set under

Connection of switching outputs (9.3).

In standard configuration, the infeed supply

voltage is also connected directly to the

actuator via these output relays.

No additional wiring is necessary, therefore.

As in the case of the 1st relay set, the

incorporated F2 fuse is employed for

separate protection

In the special version, the 2nd relay set is

also available with floating output contacts.

This again enables control with voltages

other than the supply voltage, e.g. for DC

actuators.

The maximum permissible contact load

as specified on the data sheet is to be

observed!

The control/switching voltage is to be

provided with external fusing!

The use of shielded cabling is recommended.

See also Connection of switching outputs (9.3) and Connecting cable (9.10).

Parameterisation

The outputs are parameterised as controller output according to their respective tasks in the Output

commissioning menu. In the course of parameterisation, the output is assigned to the desired controller.

See also Output menu (5.7).

Connection table (362MC hardware extension)

(excerpt) - 2nd relay set - Terminal Signal name

7 N Output, 2nd relay set

8 + (Open) Connection for 2nd switching output

9 - (Closed)

M1~

362MC AC

actuator

OP CL

+ -

F2

N

(Terminal No. 2)

L1

(Terminal No. 1)

OP CL

+ -

362MC DC

actuator

external

Control

voltage

When the extendet version with a 2nd relay set is installed, the F2 fuse unit is rated

for the max. switching capacity of both relay sets together, and is fitted with a 2AT fuse

for the standard 230V AC version or a 4AT fuse for the special 115V AC version.

?

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Appendix B2: Hardware extension - Linear outputs

A module incorporating 2 linear outputs is available as a hardware extension for the 362MC which can

be installed at the factory. The module incorporates the respective D/A converters and the isolated

output stages, which in standard configuration are provided as current outputs. Voltage outputs are also

available as a special variant.


Connection is carried out by means of

terminals 21-24, which are marked

Module 2, in accordance with the

table opposite. The extension is

available only with 2 x current output

or 2 x voltage output.


The diagrams opposite show the connection

configuration. Connection is carried out with

shielded, twisted-pair cabling with a min. wire

cross-section of 0.22mm².

Parameterisation

The outputs are parameterised in the Output

commissioning menu as controller output or

outputs for external actual-value indication,

according to their respective tasks. The output

range 0-20mA / 4-20mA or, with opposite

effective direction 20-0mA / 20-4mA, is

assigned by the user as required. The same

applies to the voltage outputs. The outputs

are defined as unipolar or bipolar outputs via

appropriate parameterisation of the controller

output limiting parameters, Ymin and Ymax.

The following table shows several examples of

definitions for the output range. See also Controller parameters menu (5.5) and Output menu (5.7).

362MC

+

-

+

-R

I

2 x Voltage outputU= 0-10 V

±10 VR

I min. 1k U

1

U2

RI

2 x Current outputI= 0-20mA

4-20mA

±20mAR

L max. 400R

362MC

RL

+

-

+

-

I1

I2R

L


(excerpt) - linear outputs - Terminal Signal name

21 d + linear output 1 0(4)-20mA, ±20mA

22 c - (in special version 0-10 V, ±10 V)

23 b + linear output 2 0(4)-20mA, ±20mA

24 a - (in special version 0-10 V, ±10 V)

Output Parameters output Comment

assignment Ymin Ymax type range

1Lin 0> 0% 100% current 0-20mA

2Lin 4> 0% 100% current 4-20mA

1Lin 0< 0% 100% voltage 10-0 V reversed effective direction

2Lin 0> 0% 50% voltage 0-5 V

1Lin 4< 0% 100% current 20-4mA reversed effective direction

2Lin 0> -100% 100% current ±20mA

The shields of all connection cables are to be

connected to control cabinet earth, ensuring a

substantial contact surface area. The cabling

should be as short as possible and have an

adequate cross-section.

?

362M

C

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Overview of communication protocols

A description of the transmission procedures and the protocol assignments is available on request.

Appendix B3: Hardware extension - RS485/RS422 communication interface

A module incorporating a communication interface is available for the 362MC, for installation at the

factory. The interface is isolated, and in the standard version it is wired up as an RS485 interface

(2-wire). A special variant with RS422 interface (4-wire) is available. The communication interface

enables the transmission of process data and setpoints from the two controllers of the 362MC.


Connection is carried out by means of

terminals 25-28, which are marked

Module 1, in accordance with the

table opposite.


The diagrams below show the

connection configuration. Connection

is carried out with shielded, twisted-pair cabling with a min. wire cross-section of 0.22mm². 120 ohm is

recommended as the terminating impedance for the RS485 interface.

Parameterisation

The transmission speed �Baudr� and the

user address �Slave no� of the controller

are set via two additional parameters in

the Profile commissioning menu:


(excerpt) - RS485/RS422 communication interface - Terminal Signal name

25 d +Rx/Tx > transmitted and received data, RS485

26 c - Rx/Tx (in RS422 version Rx = received data)

27 b +Rx/Tx < transmitted and received data, RS485

28 a - Rx/Tx (in RS422 version Tx = transmitted data)

+Rx

-Rx

+Tx

-Tx 362M

CS

lave

Maste

r

RS

422

è

ç

Example: RS422-Interface

362MCSlave n

362MCSlave 2

362MCSlave 1

RS

485

Maste

rçèExample: RS485-Interface

120R

Data direction: 362MC -> Master

- confirmation setpoint message, controller 1

- confirmation setpoint message, controller 2

- process data and status, controller 1

- process data and status, controller 2

Data direction: Master -> 362MC

- setpoints and alarm limits, controller 1

- setpoints and alarm limits, controller 2

- request process data and status, controller 1

- request process data and status, controller 2

Parameter Value

Baudr 2400, 4800, 9600, 19200

SlaveNo 1...127

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Appendix C1: Special function - Trend compensation

The standard software of the 362MC incorporates a special function for the enhanced control of systems

with large dead times. This special trend compensation function, a traditional feature of Pleiger

controllers, enables the differential activation of a second measuring sensor.

Differential adjustment of this measured value, applied to the controller, enables early adjustment of the

controller output, before the primary measuring sensor is able to detect the trend of the controlled

system as a system deviation - this detection being delayed as a result of the large dead time. The

expected trend of the controller output is thus compensated in advance.

Selection

The special trend compensation function is selected via the �Trend� parameter in the Input

commissioning menu (5.6).

When the value �NC� is assigned to the Trend parameter, the special trend compensation function is

passive.

D component (without trend compensation)

The normal D component of the standard controller

without trend compensation is generated in

accordance with the diagrams shown here when

controller structure with D or D2 component is

selected in the �Struct� controller parameter.

When an input, such as the 2nd measured value input �PT100-2� is assigned to the �Trend� parameter,

however, the special trend compensation function is active.

The D component of the controller with trend compensation is generated in accordance with the

diagrams shown as follows when controller structure with D or D2 component is selected in the �Struct�

controller parameter.

ActV X

Switching

output

or

Linear

output

Setp W dx

-

Out+Y

Out%YI-

controller

P-

controller

D-

controller

Actuator Controlled

systemFeed Y

362MC without trend compensation

(Structure with D) in input menu:

ActValX = PT100-1

Tend = NC

Switching

output

or

Linear

output

Setp W dx

-

I-

controller

P-

controller

D2-

controller

362MC

(Structure with D2)

ActV X

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D2-Anteil bei Tendenzaufschaltung

Parameterisation

As in the case of the standard controller, the D component for the controller with activated trend

compensation is also set via the control parameters Tv and Vd.

See also Controller parameters menu (5.5)

Example

The circuit diagram below shows a typical example of the use of the special trend compensation

function. Here, an inlet temperature sensor (TIN

) has been added to the outlet temperature control (TOUT

)

of a main engine. The effects of the dead time between the outlet temperature sensor and the mixing

valve are reduced substantially by means of the special trend compensation function

(parameter Trend = PT100-2).

Cooler

Main engine

MTOUT

PT100

Tend D

3-Point

step controller

TIN

PT100

PT100-1 PT100-2

TTTT

ActV X

Out+Y

1Relay

362MC

Setp W

-

362MC with trend compensation

(Structure with D2) in input menu:

ActValX = PT100-1

Tend = PT100-2

Tend D

ActV X

Switching

output

or

Linear

output

Setp W dx

-

Out+Y

Out%YI-

controller

P-

controller

Actuator Controlled

systemFeed Y

D2-

controller

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Appendix C2: Functional extension - Disturbance compensation

The standard functions of the 362MC software can be extendet by additional software, which is to be

installed at the factory. Necessary internal hardware extensions, such as extensions to memory areas,

etc. are installed at the same time.

The functional extension disturbance compensation involves applying a disturbance which affects the

controlled system directly to the controller, so as to compensate the expected effects of this disturbance

on the control process in advance.

The disturbance is weighted via a definable characteristic, delayed via a 1st order low pass and added to

the output of the controller. In a special variant for 3-Point step controllers, disturbance compensation is

effected via addition to the controller setpoint (see Compensation).

Selection

The special disturbance compensation function is selected in controllers which are equipped with the

functional extension by assigning an input, e.g. the 3rd linear input �Lin 4..� (with 4-20mA measuring

range), to the �Disturb� parameter in the Input commissioning menu, instead of assigning the value

�NC� (= special function passive). See also Input menu (5.6).

Parameterisation

For the purposes of the disturbance compensation function, the �CtrlPar� commissioning menu

(controller parameters) is extended automatically to include the entry options shown in the table below.

See also Controller parameters menu (5.5)

Compensation

The special disturbance compensation function is not equally applicable or expedient for all

parameterisable controller types. The following notes on application of the disturbance signal thus relate

to the controller types of the 362MC which are selectable under �CtrlTyp� in the Controller parameters

menu.

CtrlTyp = 2-Point and 3-Point

Disturbance compensation is not expedient for these switching controllers without feedback,

and is thus not installed in the 362MC. Selecting this function when these controllers are active

will have no effect on the controller output or the setpoint.



Parameter (1) following parameter Kw The 1st parameter set of the controller is

1st parameter set used for disturbance compensation

�� Tz 0.1s Filter time for 1st order low pass Delays the compensation function.

1000.0s for disturbance compensation See Compensation delay

�� Kz 0% -100.0% Characteristic for disturbance weighting Weighting of the disturbance

100.0% Compensation at 0%-disturbance value compensation function is effected

�� Kz 25% -100.0% via the characteristic which can be

100.0% Compensation at 25%-disturbance value parameterised here.

�� Kz 50% -100.0% The characteristic is defined via the

100.0% Compensation at 50%-disturbance value interpolation points, Kz. The values

�� Kz 75% -100.0% between the points are determined

100.0% Compensation at 75%-disturbance value via linear interpolation.

�� Kz100% -100.0% 100.0% Compensation at 100%-disturbance value See also Characteristic

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CtrlTyp = 2PntPW, 3PntPW and Cont

Depending on the type of controlled system, disturbance compensation may be expedient when

operating switching controllers with feedback and the continuous controller. After being

weighted via the characteristic and delayed by the low pass, the disturbance is added to internal

controller output Y of the continuous PID controller. It thus has a direct effect on the pulse-

width modulated switching output (PW) or the linear output of the controller.

CtrlTyp = CscStep

Disturbance compensation is highly expedient in many applications when using the cascade

step controller. A measured value �Dist Z� from the system controlled by the secondary

controller may serve as the disturbance variable, for example. After being weighted via the

characteristic and delayed by means of the low pass, this disturbance is added to the

internal controller output Y = setpoint �Setp V� of the secondary controller. It thus has a direct

effect on the control process of the secondary controller.

In the case of the cascade step controller, the primary continuous PID controller always

uses the 1st parameter set (1) and the secondary 3-Point step controller always uses

the 2nd parameter set (2).

External changeover to the 2nd parameter set is thus not possible.

?

When the disturbance compensation function acts on a setpoint (Setp V), as is the

case with the cascade step controller, the % compensation is also proportional to

the scaling of the control range. When a scale from 0-200°C applies, a 1.0%

weighting for the disturbance compensation function (Z) will thus correspond to a

setpoint increase of 2.0°C.

?

Setp W dx Y Out+Y Feed Y ActV X

- + Out%Y

Example for controller type CtrlTyp = 2PntPW, 3PntPW and Cont

PID

disturbance

compensation

Actuator362MC

Dist Z

Controlled

system

Switching

output PW

or

Linear

outputZ

Setp W dx Y Setp V Out+Y Feed Y ActV U ActV X

- + -

Example for controller type CtrlTyp = CscStep

PID

disturbance

compensation

Actuator

362MC

Dist Z

PID

Switching

output PW I

Part A Part B

Controlled system

Z

Kw2

+

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CtrlTyp = Step , CscStep

Disturbance compensation is not expedient with the 3-Point step controller, either, and is thus

not implemented in the 362MC. Selecting this function for controller type �Step� will have no

effect. A 3-Point step controller with setpoint compensation can be implemented via special

parameterisation of a �CscStep� controller, however. After being weighted via the characteristic

and delayed by the low pass, the disturbance is added to �Setp W� to generate �Setp V�.

In this way, the disturbance leads directly to an increase or reduction in the setpoint.

Condition: Parameter of 1st parameter set Kr1=0, Kw

1=1, other parameters not in use,

parameter of 2nd parameter set Kw2=1, other parameters to be set for step controller,

parameter in Input menu ActV X=NC, ActV U=PT100-1

Characteristic

The characteristic to weight the influence of the disturbance is defined via 5 interpolation points

distributed evenly over the value range. The values between the interpolation points are determined via

linear interpolation.

Example of the values of a characteristic: Graph of the characteristic:(arbitrary values used for purpose of illustration)

Kz 0% = 10.0%

Kz 25%= 40.0%

Kz 50%= 50.0%

Kz 75%= 70.0%

Kz100%= 50.0%

In accordance with this characteristic, the contoller

output is increased by +40% points at a disturbance

factor of 25%, for example, and by +70% points at a

disturbance factor of 75%.

If the controller output is limited by Ymin and Ymax,

these limits will continue to apply.

Compensation delay

Application of the disturbance to the controller

output is delayed by time Tz.

100 %

80 %

60 %

40 %

20 %

0 %

0 % 25 % 50 % 75 % 100 %

disturbance value

Weig

hti

ng

(ad

ded

to

co

ntr

oller

ou

tpu

t)

Setp W Y Setp V Out+Y Feed Y ActV U

+ -

Example for controller type CtrlTyp = CscStep (setpoint compensation)

(PID)

disturbance

compensation

Actuator

362MC

Dist Z

PID

Switching

outputPW I

Controlled

system

(Part A)Z

Kw2

+

Kr1=0

Kw1=1

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Example

The following circuit diagram shows a typical example of use of the special disturbance compensation

function. The outlet temperature (TOUT

) of a main engine is controlled using a cascade step controller

(CtrlTyp=CscStep), whereby the secondary control circuit reduces the turbo-charger´s disturbing effects

on the inlet temperature (TIN

). By means of the special disturbance compensation function (parameter

Disturb = Lin 4..), a measured value for engine output (TS) is weighted via the characteristic and

delayed by means of the low pass and then added to controller output Y of the primary controller. In this

way, the setpoint for the inlet temperature is adjusted before the disturbance is able to manifest itself in

the form of an altered outlet temperature.

Setp W

-

Y Setp V

+ -

Cooler

M

PT100-2

ActV U

Out+Y

1Relais

Continuous

PID controller

primary

PT100-1

ActV X

3-Point

step controller

secondary

Main engine

TOUT

PT100

TIN

PT100

TTTT

Turbo charger

engine output value

(4-20 mA)TS

Lin 4..

Dist Z

+

Z

362MCKw2

A possible characteristic for this application:

(arbitrary values used for purpose of illustration)

The values for Setp V apply for Setp W=80.0°C,

Kw2=1 and Setp W=ActV X (Y=0 compensated).

Kz TS Value Z Setp V

mA % °C °C

0% 4 0.0 0.0 80.0

25% 8 - 6.0 -12.0 68.0

50% 12 - 8.0 -16.0 64.0

75% 16 - 5.0 -10.0 70.0

100% 20 - 3.5 - 7.0 73.0

disturbance value

0 % 25 % 50 % 75 % 100 %

0 % 0°C

- 2 % - 4°C

- 4 % - 8°C

- 6 % - 12°C

- 8 % - 16°C

- 10 % - 20°C

Weig

hti

ng

(ad

ded

to

co

ntr

oller

ou

tpu

t)

Weig

hti

ng

(ad

ded

to

setp

oin

t)

Graph of the characteristic:

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Appendix C3: Functional extension - Setpoint programme

The standard functions of the 362MC software can be extendet by additional software in the form of the

Setpoint programme, which is to be installed at the factory. Necessary hardware extensions, such as ex-

tensions to memory areas, etc., are carried out at the same time.

The functional extension Setpoint programme which is described here enables the setpoint control of

ramps, whereby the setpoints, gradients and hold times are stored step by step in the setpoint pro-

grammes and can be recalled as a time-controlled automatic programme.

5 programmes containing 20 individual steps each are available for this purpose.

Selection

The special Setpoint programme function is selected in controllers which are equipped with the

functional extension by assigning a setpoint programme �SpPrgNo� (1 to 5) to the �SpTyp� parameters

in the extended Setpoint menu. This assignment is possible for both the 1st controller (1SpTypA) and

the 2nd controller (2SpTypA) of the 362MC. If a changeover input for changeover to the 2nd setpoint has

been assigned to one or both controllers, setpoint programmes can be assigned to the 2nd setpoints

(1SpTypB, 2SpTypB), too. See also Parametrisation and Display.

If setpoint type 1SpTypA=StpPrg1 is set for the 1st controller, for example, the entire sequence of

setpoint programme 1 will be started and the various time setpoints resulting from the programme will be

controlled by the 1st controller.

Programme structure

The basic structure of a setpoint programme is illustrated below by reference to an example. In this

example, a temperature is to be transformed via the setpoint programme into a fixed value for control.

The scaling for the controller has been set at Scale-0=0 and Scale-F=200 for PT100 input and the

dimension has been defined as Dim=°C. See also explanatory note on Scaling (5.6.2)

The following setpoint programme has been stored:

If the setpoint programme is now started, the process concerned will be continued smoothly from the last

setpoint, in the example at approx. 50°C, and the 1st step will be executed. In the example, the setpoint

is increased to 60°C in 10s. In the following 2nd step, the setpoint is increased to 80°C in 45s, i.e. at a

gradient of 0.44°C/s. In the 3rd step a hold time of 180s has been defined for the attained level of 80°C.

In the 4th step the setpoint is then increased from 80°C to 95°C in 60s, i.e. at a gradient of 0.25°C/s. As

no value has been programmed in the 5th step, the value of 95°C will be retained as a fixed value.

See also Programme functions.

Step 1 Setp1 60.0°CTime1 10s





100 °C

90 °C

80 °C

70 °C

60 °C

50 °C

0s 50s 100s 150s 200s 250s 300s 350s

Time

Setp

oin

t

Time1 Time2 Time3 Time4

Setp1

Setp2 Setp3

Setp4

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1st controller max)

I 1SpTypA fixed Setpoint type A = fixed value Extension for selection of Setpoint

extern = external input programme in addition to types fixed

StpPrg1 = setpoint and external

StpPrg2 programme The programme no. 1 to 5 to be

StpPrg3 programme no. 1 executed is selected directly here.

StpPrg4 to programme no. 5 The fixed-value entry 1SetpA is

StpPrg5 omitted when SetpPrg is selected.

I 1SpTypB fixed Setpoint type B = fixed value As in the case of 1SpTypA, a

extern = external input a setpoint programme can also be

StpPrg1 = setpoint assigned for the second setpoint B,

ò programme no. 1 if the changeover function is active.

StpPrg5 to programme no. 5 See Setpoint menu, 5.3

1T-Lowp Filter time for setpoint changeover

1Alarm- See 5.3 lower alarm limit See Setpoint menu, 5.3

1Alarm+ upper alarm limit

Parameter The following parameters for the 2nd controller are only displayed when

2nd controller 2 controllers have been selected in the Profile menu.

I 2SpTypA fixed Setpoint type A = fixed value As for the 1st controller, a setpoint

extern = external input programme can also be assigned to

StpPrg1 = setpoint to the 2nd controller.

ò programme no. 1 See 1SpTypA (above)

StpPrg5 to programme no. 5

I 2SpTypB fixed Setpoint type B = fixed value

extern = external input

StpPrg1 = setpoint See 1SpTypB (above)

ò programme no. 1

StpPrg5 to programme no. 5

2T-Lowp Filter time for setpoint changeover

2Alarm- See 5.3 lower alarm limit See Setpoint menu, 5.3

2Alarm+ upper alarm limit

I* SpPrgNo 1 Programme selection for entry The selected setpoint programme is

5 Programme no. 1 to 5 is loaded in the Entry field.

Setp1 0.0°C 1st step Entries for the 20 steps of the loaded

200.0°C Setp1 - temperature per example setpoint programme.

Time1 -5s Time1 - 1-9999s; (time 0 or negative Setpoint here e.g. 0-200°C; see also

9999s see Programme functions) Explanatory note on setpoints

Setp2 See above 2nd step (5.3.1)

Time2 ò to See also Programme structure,

Setp20 See above 20th step Programme entry and

Time20 (last step) Programme functions

I* If a setpoint programme is selected via �SpPrgNo� in order to carry out changes to the

programming of the steps and if this programme has been activated under 1SpTypA, 1SpTypB,

2SpTypA or 2SpTypB, the changes should be carried out in manual mode only.

Parameterisation

The setpoint programme is activated and entries effected in the extended Setpoint menu:

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Programme entry

As shown in the table under �Parameterisation�, the number (1 to 5) of the programme to be created or

edited is first of all selected in the parameter �SpPrgNo�. The selected programme is then loaded into

the entry field. The individual steps, each defined by �Setp� (value) and �Time� (value) (1 to 20), are

then displayed and can be entered or edited.

Programme functions

In addition to starting, stopping and ending a setpoint programme, the following additional special

programme functions are also available:

Programme start: When a setpoint programme is activated it starts beginning at step 1.

The activation can either be triggered by an external switchover of the setpoint to

a setpoint programme or

by changing the type of the current setpoint to a setpoint programme StpPrg(1-5).

This selection should be carried out in Manual operating mode -

MANUAL = controller stop, after which the programme is started in Automatic

mode by pressing the Auto button.

Programme stop: If the controller is switched to Manual mode by pressing the Man and Exit buttons

(simultaneously), the setpoint programme will be stopped at the last time setpoint.

It will subsequently be resumed on pressing the Auto button for Automatic mode.

Programme end: When Time = 0s is programmed in a step, the setpoint programme will be ended

in the preceding step. The final setpoint programmed in this preceding step will

continue to be controlled as a fixed value.

Programme call: When Time = negative (-1 to -5) is programmed in a step, the corresponding

setpoint programme (1 to 5) will be called and started at step 1.

Programme loop: If the same setpoint programme is called within a programme call, e.g. in the final

programme call (Time = -(own StpPrg No), the setpoint programme will be

started again at step 1, thus creating a continuous programme loop.

Display

To display the state of the setpoint programme during execution a special display function is provided.

This function displays the number (1 to 5) and the current step (1 to 20) of the setpoint programme in a

single line.

The following figures show some examples how to use this function.

Example controller 1

1. Line: StpPrg1 in step 4

2. Line: current setpoint (1Setp W)

Example controller 2

1. Line: SwPrg3 in step 15

2. Line: controller output (2Feed+y)

In the 1st example the current setpoint of the pro-

gramme is displayed in the second line. This shows

the run of the setpoint between the different steps.

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Example

The functions of the setpoint programme are illustrated below by reference to a possible application for

the 362MC functional extension Setpoint programme in conjunction with changeover to a 2nd setpoint.

In this example, the speed of a motor is to be selectable in two speed ranges, fast and slow, via a

changeover selector. The transitions between the speeds, slow>fast and fast>slow, are to be effected

gently and in several steps during changeover.

To this end, the parameter 2Setp has been assigned to input E5 in the Input menu and a slow

changeover contact of the changeover selector has been connected to this binary input. The value

range has been selected in the Input menu as Scale-0=0, Scale-F=100 and Dim=%. In the Setpoint

menu, the value StpPrg1 (slow>fast) has been assigned to parameter 1SpTypA and the value StpPrg2

(fast>slow) has been assigned to 1SpTypB. The two setpoint programmes are defined as shown in the

following tables. The resultant functional sequence is shown in the diagram.

StpPrg1Setp1 50.0%Time1 40sSetp2 70.0%Time2 20sSetp3 85.0%Time3 10sSetp4 0.0%Time4 0s

StpPrg2Setp1 75.0%Time1 35s Setp2 55.0%Time2 18sSetp3 40.0%Time3 5sSetp4 0.0%Time4 0s

Setp

oin

t

E5=Changeover fast slow fast

90%

80%

70%

60%

50%

40%

30%0s 40s 80s 0s 40s 80s 0s 40s 80s

Time


general max)

Line 1 1Setp W Setpoint - controller 1

Line 2 1SpPrg Setpoint programme - controller 1

2nd L1 1Setp V Setpoint secondary - controller 1 See also Explanatory note on

2nd L2 1ActV X Actual value - controller 1 Display menu (5.8)1ActV U Actual value secondary - controller 1

1Dist Z Disturbance input - controller 1

1Tren D Trend input - controller 1

1Out+Y Switching control output - controller 1 Display with symbol <<, || or >>

1Feed+Y Position feedback in % - controller 1 Additional to switching output symbols

1Out%Y Continuous control output in % - controller 1 Display in xx.x%

2Setp w Setpoint - controller 2

2SpPrg Setpoint programme - controller 2

2Setp v Setpoint secondary - controller 2 See also Explanatory note on

2ActV x Actual value - controller 2 Display menu (5.8)2ActV u Actual value secondary - controller 2

2Dist z Disturbance input - controller 2

2Tren d Trend input - controller 2

2Out+y Switching control output - controller 2 Display with symbol <<, || or >>

2Feed+y Position feedback in % - controller 2 Additional to switching output symbols

2Out%y Continuous control output in % - controller 2 Display in xx.x%

Lang deutsch Language selection for all

english display texts

LCDcntr 1 Contrast setting for the

255 LCD display

Parameterisation of display function

If one setpoint type SpTyp is set to a StpPrg(1 to 5) the display function for setpoint programmes are

selectable in the extended Display menu (5.8). The extended display menu are shown in the following

table.

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Appendix D1: Steps for commissioning

The 362MC controller incorporates profile memories whose parameters have been pre-parameterised at

the factory for commissioning. This factory set-ups are based on decades of experience in controller

applications. Using the profile memories will place these experiences at your disposal and save your

commissioning time. The following procedure is to be observed:

ð set the controller to Manual mode (press Man and Exit buttons simultaneously);

ð select an appropriate profile for the control task concerned, activate the profile memory and

save to an available profile memory via the Save as function (see 5.4);

ð check the input and output assignments and correct if necessary (see 5.6 + 5.7);

ð check functions assigned to the LCD displays and adjust if necessary (see 5.8);

ð check correct acquisition of the measured values;

ð check the actuator for correct functioning in Manual mode (see 4);

ð switch the controller to Automatic mode (Auto button) and start up the controlled system

(adjusting the parameters, if appropriate).

Adjusting the parameters

In most applications only minor adaptations of the factory set-up is necessary. The most important

adaptations concern the controller parameters Kr and Tn. The aim is to make the controlled

system stable and reduce control deviations as fast as required and possible. We recommend the

following steps, starting with the factory set-up:

è1 To test the behaviour of the controlled system it

should be stimulated using a small change of the

setpoint W to W* (up or down).

Go on with è2 or è3.

è2 If the controlled system is not stable (swinging),

decrease P-gain Kr by steps and loop with step è1

and è2 until the system is stable and shows only a

little or no overshot.

After that go on with è4.

è3 If the controlled system is already stable (no swinging),

increase P-gain Kr by steps and loop with step è1

and è3 until the system shows a little or no overshot

and is still stable to.

After that go on with è4.

è4 If the control deviation decreases to slowly in the stable

system, decrease reset time Tn by steps and loop with

step è1 and è4 until the system so fast as required

and possible.

Pay attention to the stability of the system and if

required, go on again with è2.

ð at the end of the commissioning procedure, document the parameter changes,

e.g. in copies of the profile memory tables in Appendix D2.

Pleiger Elektronik

GmbH & Co. KG


?

Appendix D2: Profile memories and factory presets

The factory-preset profile memories are assigned to profile nos. 1 to 19. Profiles 20 to 50 can be used to

store the changes carried out in the course of commissioning.

The following table presents the factory presets for the general parameters and profile memory nos. 1

to 6, whose settings will facilitate the commissioning start-up procedure for several important control

tasks.

The contents of the profiles are as follows:

Profile no. 1 Basic temperature control with PT100 input, motor control valve and controller 1;

(e.g. control of the outlet temperature in the cooling circuit of a main engine).

Factory-preset for controller 1

Profile no. 2 Basic temperature control with PT100, motor control valve and controller 2;

(e.g. control of tank heating in conjunction with 1st controller + profile no. 1).

>Hardware extension - 2nd relay set - required<

Factory-preset for controller 2

Profile no. 3 Temperature control with 2 x PT100 input, motor control valve and controller 1 with

additional differential trend compensation of the 2nd PT100 measuring sensor;

(e.g. control of the outlet temperature of a cooling circuit in a main engine with trend

compensation for the inlet temperature).

See also Appendix C1

Profile no. 4 Temperature control with 2 x PT100 input, motor control valve and controller 1 as

cascade step controller with additional disturbance compensation for a 4-20mA signal

from a measured-value transmitter;

(e.g. primary control of outlet temperature in the cooling circuit of a main engine with

secondary control of inlet temperature, whereby a signal proportional to the machine

output is applied as the disturbance variable).

>Functional extension - Disturbance compensation - required<

See also Appendix C2

Profile no. 5 Differential pressure control with 4-20mA input, motor control valve and controller 1;

(e.g. control of throttle valve position down-line of a pump according to pressure

difference between inlet and outlet of the pump)

>hardware configuration - Linear input 1 as 0(4)-20mA input - required<

Profile no. 6 Temperature control with PT1pp input, pneumatic control valve and controller 1;

(e.g. control of outlet temperature in the cooling circuit of a main engine)

>hardware extension - Linear outputs - required<

Profile no. 1 for 1st controller and profile no. 2 for 2nd controller

are factory-preset.

Pleiger Elektronik

GmbH & Co. KG


Please use a copy of this sheet to document your settings and changes.

x = not active at this CtrlTyp and Struct preset

DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

selected as only 1

1

RS

485

/42

2 9600

1

Catchword:Basic temperature control

with controller 1

(or similar control set-ups)

OutputY

OutputX

1Relais

NC

ChangesFactory

presets�Profile

1st controller

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-1

NC

NC

NC

NC

Resist

kalibr

E6

NC

NC

NC

NC

NC

200.0

0

°C

ChangesFactory

presets

Rmin Rmax

�Profile

1st controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

Step

1

PID

17.0

220s

0.1s

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

PID

17.0

220

0.1

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

0.0s

0%

0%

0%

0%

0%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes�Profile

1st controller

x

x

x

x

x

x

x

x

x

x

x

x

x

x

1SpTypA

1Setp A

1SpTypB

1Setp B

1T-Lowp

1Alarm-

1Alarm+

fixed

60.0°C

fixed

60.0°C

0.0s

0.0°C

0.0°C

for

1st co

ntr

oll

er

Factory

presetsChangesgeneral

Parameter

Line 1

Line 2

2nd L1

2nd L2

Lang

1Setp W

1Feed+Y

1Tren D

1ActV X

deutsch

Factory


Parameter

Pleiger Elektronik

GmbH & Co. KG




DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

by selection as 2 of 2

2

RS

485

/42

2 Factory presets and

changes see 1st controller

Catchword:Basic temperature control

with controller 2


Hardware extension

2nd Relay set required

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-2

NC

NC

NC

NC

NC

kalibr

NC

NC

NC

NC

NC

NC

200.0

0

°C

ChangesFactory

presets

Rmin Rmax

�Profile

2nd controller

OutputY

OutputX

2Relais

NC

ChangesFactory

presets�Profile

2nd controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

Step

1

PID

17.0

220s

0.1s

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

PID

17.0

220

0.1

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

0.0s

0%

0%

0%

0%

0%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes

x

x

x

x

x

x

x

x

x

x

x

x

x

x

�Profile

2nd controller

2SpTypA

2Setp A

2SpTypB

2Setp B

2T-Lowp

2Alarm-

2Alarm+

fixed

60.0°C

fixed

60.0°C

0.0s

0.0°C

0.0°Cfo

r 2nd c

on

tro

ller

Factory


Parameter

general

Parameter

Factory presets and

changes see 1st controller

Pleiger Elektronik

GmbH & Co. KG




DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

selected as only 1

3

RS

485

/42

2 9600

1

Catchword:Temperature control with controller 1

and trend compensation

OutputY

OutputX

1Relais

NC

ChangesFactory

presets�Profile

1st controller

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-1

NC

PT100-2

NC

NC

Resist

kalibr

E6

NC

NC

NC

NC

NC

200.0

0

°C

ChangesFactory

presets

Rmin Rmax

�Profile

1st controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

Step

1

PID

17.0

220s

0.1s

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

PID

17.0

220

0.1

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

0.0s

0%

0%

0%

0%

0%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes

x

x

x

x

x

x

x

x

x

x

x

x

x

x

�Profile

1st controller

Line 1

Line 2

2nd L1

2nd L2

Lang

1Setp W

1Feed+Y

1Tren D

1ActV X

deutsch

Factory


Parameter

1SpTypA

1Setp A

1SpTypB

1Setp B

1T-Lowp

1Alarm-

1Alarm+

fixed

60.0°C

fixed

60.0°C

0.0s

0.0°C

0.0°C

for

1st co

ntr

oll

er

Factory


Parameter

Pleiger Elektronik

GmbH & Co. KG




DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

selected as only 1

4

RS

485

/42

2 9600

1


and disturbance compensation

Functional extension

Disturbance compensation required

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-1

PT100-2

NC

Lin 4..

NC

Widerst

kalibr

E6

NC

NC

NC

NC

NC

200.0

0

°C

ChangesFactory

presets

Rmin Rmax

x

�Profile

1st controller

OutputY

OutputX

1Relais

NC

ChangesFactory

presets�Profile

1st controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

CscStep

1

PI

0.0

220s

0.1s

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

PID

17.0

220

0.1

1.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

0.0s

3%

4%

5%

6%

6%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes

x

x

x

x

x

x

x

x

x

x

�Profile

1st controller

Line 1

Line 2

2nd L1

2nd L2

Lang

1Setp W

1Feed+Y

1Setp V

1ActV U

deutsch

Factory

proposalChangesgeneral

Parameter

1SpTypA

1Setp A

1SpTypB

1Setp B

1T-Lowp

1Alarm-

1Alarm+

fixed

60.0°C

fixed

60.0°C

0.0s

0.0°C

0.0°Cfo

r 1st co

ntr

oll

er

Factory


Parameter

Pleiger Elektronik

GmbH & Co. KG




DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

selected as only 1

5

RS

485

/42

2 9600

1

Catchword:Diff. pessure control with controller 1


Hardware modification

1st Linear input as 0(4)-20mA input

required

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-1

NC

NC

NC

NC

NC

kalibr

E6

NC

E4

NC

NC

NC

100.0

0

%

ChangesFactory

presets

Rmin Rmax

�Profile

1st controller

OutputY

OutputX

1Relais

NC

ChangesFactory

presets�Profile

1st controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

Step

1

PI

10.0

350s

0.1s

1.0

90.0s

1.0s

10.0s

2.5%

1.0%

0%

100%

1

PI

10.0

350

0.1

1.0

90.0s

1.0s

10.0s

2.5%

1.0%

0%

100%

1

0.0s

0%

0%

0%

0%

0%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

�Profile

1st controller

1SpTypA

1Setp A

1SpTypB

1Setp B

1T-Lowp

1Alarm-

1Alarm+

fixed

50.0%

fixed

60.0%

0.0s

0.0%

0.0%

for

1st co

ntr

oll

er

Factory


Parameter

Line 1

Line 2

2nd L1

2nd L2

Lang

1Setp W

1Out+Y

1Setp W

1ActV X

deutsch

Factory


Parameter

Pleiger Elektronik

GmbH & Co. KG




DsplCtr

Prof-No

Baudr

SlaveNr

Factory

presetsChanges

(Save as)

selected as only 1

6

RS

485

/42

2 9600

1


and pneumatic contol valve


Hardware extension

Linear outputs required

ActValX

ActValU

Trend

Disturb

ExtSetp

FeedBk

R scale

2.Setp

2.Param

Rel+On

Rel+Off

Rel-On

Rel-Off

Scale-F

Scale-0

Dim

PT100-1

NC

NC

NC

NC

NC

kalibr

E6

NC

NC

NC

NC

NC

200.0

0

°C

ChangesFactory

presets

Rmin Rmax

�Profile

1st controller

OutputY

OutputX

1Lin 4>

NC

ChangesFactory

presets�Profile

1st controller

CtrlTyp

ParSet

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Struct

Kr

Tn

Tv

Vd

T drive

Ts min

T cycl

Deadbd

Hyst

Ymin

Ymax

Kw

Tz

Kz 0%

Kz 25%

Kz 50%

Kz 75%

Kz100%

Cont

1

PID2

17.0

220s

0.1s

5.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

PID2

17.0

220

0.1

5.0

90.0s

1.0s

10.0s

0.0%

1.0%

0%

100%

1

0.0s

0%

0%

0%

0%

0%

1st p

ara

me

ter

se

t2nd p

ara

me

ters

se

t

Factory

presets

Dis

turb

an

ce

co

mp

en

sa

tio

n

Changes

x

x

x

x

x

x

x

x

x

x

x

x

x

x

�Profile

1st controller

Line 1

Line 2

2nd L1

2nd L2

Lang

1Setp W

1Out%Y

1Tren D

1ActV X

deutsch

Factory


Parameter

1SpTypA

1Setp A

1SpTypB

1Setp B

1T-Lowp

1Alarm-

1Alarm+

fixed

60.0°C

fixed

60.0°C

0.0s

0.0°C

0.0°Cfo

r 1st co

ntr

oll

er

Factory


Parameter

Pleiger Elektronik

GmbH & Co. KG


Appendix D3: Programme entries table for setpoint programmesFunctional extension Setpoint programme required (factory preset > all values = 0)


SpPrgNo

Setp1

Time1

Setp2

Time2

Setp3

Time3

Setp4

Time4

Setp5

Time5

Setp6

Time6

Setp7

Time7

Setp8

Time8

Setp9

Time9

Setp10

Time10

Setp11

Time11

Setp12

Time12

Setp13

Time13

Setp14

Time14

Setp15

Time15

Setp16

Time16

Setp17

Time17

Setp18

Time18

Setp19

Time19

Setp20

Time20

Only

if

Functional exte

nsio

n S

etp

oin

t pro

gra

mm

e insta

lled

1 2 3 4 5

Pleiger Elektronik

GmbH & Co. KG


Note

Controller 362MC

special configurations

and extensions

(additional configurations

on request)

Service interfaceRS 232

Alarm relais1 x change contact

floating

1st relay set withU

E = 230/115 V-AC

connected contacts

Special version1st relay set withfloating contacts

without2nd relay set

Hardware extension2nd relay set with U

E =

230/115V-AC-contacts

Hardware extension2nd relay set with U

E =

floating contacts

withoutLinear outputs

Hardware extensionLinear outputs2 x 0(4)-20mA

Hardware extensionLinear outputs

2 x 0-10V

6 x Binary inputsas logical inputs for

floating contacts

4th Linear inputresistance input

Measuring range 0-200R

Special version3rd Linear input 0-10V

Measuring range 0-100%

3rd Linear input0(4)-20mA


2nd Linear inputPT100

Measuring range 0-200°C

Special version1st Linear input 0(4)-20mA


Special version1st Linear input PT100


1st Linear inputPT100


withoutcommunication interface

Hardware extension

communication interface

RS 485

Hardware extension

communication interface

RS 422

Special versionPower supplyU

E = 115 V-AC

Power supplyU

E = 230 V-AC


Disturbance compensation


Setpoint programme

Controller 362MC

Standard

configuration

Controller 362MC Delivery configurations

Special version6 x Binary inputs for

24 V-DC signals

Standard functionsfor 1 or 2 controllers

> 2-Point controller> 3-Point controller> 3-Point step controller> Cascade step controller> Continuous controller

Special adjustmentLED-Display with 3½ digits

(Solution 0,1°C or 0,1%)

PLEIGER ELECTRONICS 362MC

Name Position

Company Telephone No.

Fax No.

No. of pieces Date for delivery Comment

If you need special versions or extensions in addition to the

standard, please mark the -squares obove.

Your FAX-Request for the offer to 0049- 23 24 / 3 98- 3 89

Pleiger ElektronikGmbH & Co. KG

Catchword: Basic temperature control with controller 1 (or similar control set-ups)

Factory Changes (also usual for change a 362-D, 0-200°C without

presets (Save as) trend compensation against a 362MC controller)

DsplCtr selected as only 1

Prof-No 1

Baudr 9600

SlaveNo 1 Factorygeneral Param. presets

Factory Changes 1SpTypA fixed

Profile 1stcontroller presets 1Setp A 60.0°C

CtrlTyp Step 1SpTypB fixed

ParSet 1 1Setp B 60.0°C

Struct PID 1T-Lowp 0.0s

Kr 10.0 1Alarm- 0.0°C

Tn 150s 1Alarm+ 0.0°C

Tv 0.1s FactoryVd 1.0 Profile 1stcontr. presets

T drive 90.0s ActValX PT100-1

Ts min 1.0s ActValU NC

T cycl 10.0s Trend NC

Deadbd 0.0% Disturb NC

Hyst 1.0% ExtSetp NC

Ymin 0% FeedBk Resist

Ymax 100% R scale kalibr Rmin Rmax

Kw 1 2.Setp E6

Struct PID 2.Param E5

Kr 10.0 Rel+On E4

Tn 150s Rel+Off E3

Tv 0.1s Rel-On E2

Vd 1.0 Rel-Off E1

T drive 90.0s Scale-F 200.0

Ts min 1.0s Scale-0 0

T cycl 10.0s Dim °C

Deadbd 0.0% FactoryHyst 1.0% Profile 1stcontr. presetsYmin 0% OutputY 1Relais

Ymax 100% OutputX NC

Kw 1 Factorygeneral Param. presets

Tz 0.0s Line 1 1Setp W

Kz 0% 0% Line 2 1Feed+Y

Kz 25% 0% 2nd L1 1Tren D

Kz 50% 0% 2nd L2 1ActV X

Kz 75% 0% Lang deutsch

Kz100% 0% = not active at this CtrlTyp and Struct preset


Changes

Changes

Changes

RS

485

/4

22

Changes

Dis

turb

ance

com

pen

sati

on

for

1st c

on

tro

ller

2nd p

aram

eter

s se

t1st

par

amet

er s

et

Profiles for 362MC Version 2.11e Edition: 3/02 Subject to modifications Page: 1

JXLJUK1

PL 0.00.6-98.14.00-06_en

JXLJUK1

80.0 °C

Electrical Equipment-

C5.05.05.10.15.04

M25

en / 18.11.2004 FD028774 1/1

�

Electrical Equipment

-

c new 28.4.04 West. Datum 26.02.2004

b new 15.04.04 Ket. Bearb. Westphal d new 15.05.04 Ket. Gepr. Ketelsen

Zust. Änderung Datum Name Norm DIN/IEC

Caterpillar Motoren GmbH & Co. KG c

Urspr. Ers. f. Ers. d.

Kabelliste CABLE LIST

Ktr. 271 356-359

5.1 9-A-1071-89

=

+ Blatt/page: 2 von/of: 2

* internal wiring

Motor 1 / ENGINE 1 Motor 2 / ENGINE 2 Motor 3 / ENGINE 3

CABLE TYPE YARD CABLE TYPE YARD CABLE TYPE YARD CABLE TYPE W1 (L)M2XH 4 x 2,5 mm 138 – 101 138 – 201 138 – 301 W2 (L)M2XH 3 x 6 mm 138 – 130 138 – 230 138 – 330 W3 (L)M2XCH 3 x 2,5 mm 138 – 103 138 – 203 138 – 303 W4 FM2XCH 7 x 2 x 0,75 mm 138 – 104 138 – 204 138 – 304 W5 (L)M2XCH 3 x 1,5 mm 138 – 105 138 – 205 138 – 305 W6 (L)M2XCH 3 x 2,5 mm 138 – 106 138 – 206 138 – 306 W7 FM2XCH 19 x 2 x 0,75 mm 138 – 107 138 – 207 138 – 307 W8 FM2XCH 4 x 2 x 0,75 mm 138 – 108 138 – 208 138 – 308 W9 (L)M2XCH 5 x 1,5 mm * 138 – 109 138 – 209 138 – 309 W10 (L)M2XH 3 x 6 mm 177 – 003 177 – 004 177 – 005 W11 (L)M2XCH 3 x 1,5 mm * 138 – 111 138 – 211 138 – 311 W12 (L)M2XCH 4 x 1,5 mm 138 – 112 138 – 212 138 – 312 W13 (L)M2XCH 4 x 1,5 mm 138 – 113 138 – 213 138 – 313 W14 FM2XCH 2 x 2 x 0,75 mm 138 – 114 138 – 214 138 – 314 W15 FM2XCH 2 x 2 x 0,75 mm 138 – 115 138 – 215 138 – 315 W16 FM2XCH 10 x 2 x 0,75 mm 138 – 116 138 – 216 138 – 316 W17 (L)M2XCH 7 x 1,5 mm 138 – 117 138 – 217 138 – 317 W18 FM2XCH 2 x 2 x 0,75 mm 138 – 118 138 – 218 138 – 318 W19 (L)M2XCH 3 x 1,5 mm 138 – 119 138 – 219 138 – 319 W20 FM2XCH 10 x 2 x 0,75 mm 138 – 120 138 – 220 138 – 320 W21 FM2XCH 2 x 2 x 0,75 mm * 138 – 121 138 – 221 138 – 321 W22 (L)M2XCH 3 x 1,5 mm 138 – 122 138 – 222 138 – 322 W23 (L)M2XCH 3 x 1,5 mm 138 – 123 138 – 223 138 – 323 W24 (L)M2XCH 3 x 1,5 mm 138 – 124 138 – 224 138 – 324 W25 FM2XCH 2 x 2 x 0,75 mm 138 – 132 138 – 232 138 – 332 W26 (L)M2XCH 4 x 1,5 mm 138 – 131 138 – 231 138 – 331 W27 (L)M2XCH 3 x 1,5 mm 138 – 127 138 – 227 138 – 327 W28 FM2XCH 10 x 2 x 0,75 mm 138 – 128 138 – 228 138 – 328

• IF LENGTHS OF SUPPLY CABLE EXCEED 60 m, THE VOLTAGE DROP SHOULD BE CONSIDERED.

• SIGNAL CABLES ARE NOT TO BE LAID IN PARALLEL TO ANY OTHER POWER CABLES CONDUCTING HIGH VOLTAGE (I.E. LARGE MOTORS) OR RADIO COMMUNICATION CABLES. CABLES FOR

REMOTE CONTROL SIGNALS CAN INDUCE CURRENT FROM THEIR IMMEDIATE ENVIRONMENT SUFFICIENT TO DISTURB OR EVEN DAMAGE THE ELECTRONIC CONTROL SYSTEM.

(L)M2XH (DIN 89158) => MSKCe

(L)FM2XCH (DIN 89159) => FMSKCe

Maintenance Unit-

C5.05.05.45.23.01

-

en / 16.05.2002 FD022856 1/1

�

Maintenance Unit

-

Bedienungsanleitung Operating instructions

Druckminderstation Pressure-reducing station l 335 320 200 0

8838900353_631A (11/00) 27

Table of contents

Table of contents 27

Safety information 28 Explanation of symbols 28 Occupational safety 29

Design and mode of operation 30 General 30 Block diagram 31

Startup 32 Ports and Installation 32 Assembly position 32

Maintenance and care 33 General 33 Replacing the sealing elements, dismantling 34 Dismantling the filters and the drain valves 34 Dismantling the pressure switch 36 and the adjusting screw Dismantling the pressure control valves 36 Dismantling the three/two-way valve 38 Dismantling the servo valves 40 Replacing the sealing elements, assembly 42 Setup and Tests 43 Spare parts package 44

Storage and transportation 45 General 45

Technical specifications 46 General 46 Circuit diagram 46 Dimensional drawing 47

After sales service and adresses 48 Any questions? 48

GB

8838900353_631A (11/00) 28

Safety information Explanation of symbols

Danger! This symbol is to be found with all information and warnings in these operating instructions regarding work safety, where there is potential danger to humans. Take notice of such warnings and act with particular caution in these cases.

Warning! This symbol is to be found in these operating conditions wherever it is necessary to ensure that guidelines, regulations and warnings are adhered to and that the work processes are carried out correctly, without damage to or destruction of the servo-actuator.

This way up! This symbol is found wherever components have to be transported, stored or mounted in a particular position. (to DIN 30 600)

Grease! This symbol is to be found wherever components, areas etc. need to be lubricated.

Secure by glue! This symbol is marking parts which must be secured by means of a liquid adhesive (according to DIN 30 600).

FettGrease

Warning!

8838900353_631A (11/00) 29

Safety information Occupational safety

Warning Do only pressurise the pressure-reducing station, if it has been mounted properly. Do not handle the pressure-reducing station, if it is pressurised. Always cut off the air supply before starting work.

Technical State The pressure-reducing station has been designed according to the latest state of the technology and safety standards for operation.

Proper Use The pressure-reducing station has the following purpose: Reduction of a high inlet pressure to a low outlet pressure. The ambient conditions as well as the operating pressure range specified in the technical data have to be observed. The compressed air supplied must be clean, dry and free of lubricant. Air quality:

Applications other than those stated are regarded as not appropriate. Improper use is at the customer's risk. The manufacturer is not liable for any resulting damage. This device may cause danger if it is used improperly, under inappropriate conditions or by unqualified personnel. Using the device appropriately does, of course, also mean observing the assembly, dismantling and maintenance instructions.

Guarantee The pressure-reducing station must by maintained and repaired by authorised, skilled personnel only. The user must only operate the pressure-reducing station in perfect condition. The user is obliged to report any changes of the device's condition that might reduce its safety. Unauthorised modifications and changes that might reduce the safety of the pressure-reducing station are not permitted. Before commissioning please read the operating instructions carefully.

Quality class acc. to:

PNEUROP-recommendation

6611/1984

DIN ISO8573-1

Solid mattersOil ratePressure dew point

431

532

8838900353_631A (11/00) 30

Design and mode of operation General

Purpose The pressure-reducing station has the following purposes:

• Filtering the pressurized air and condensing

• Reduction of a high inlet pressure to a low outlet pressure

• Monitoring of the reduces outlet pressure via pressure gauge and safety valve

• Ventilation of the compressed air tab “A”.

Design The pressure-reducing station consists of a housing that contains all necessary component. These are for the main part: compressed air filter with drain valve (1), pressure control valves (2), safety valve (3), pressure gauge (4), three/two-way valve, operated electro-magnetically (5) and pressure switch (6) with testing tab (7).

Mode of operation The pressurized air entering at point “P” (pmax = 30 bar) flows through the compressed air filter (1) and is cleaned from solid impurities. The resulting condensate is collected in the lower part of the housing and may be drained via the drain valve. The cleaned, pressurized air then reaches the pressure control valve (2). Here the reduction from the inlet pressure to a lower outlet pressure (3 bar...8,5 bar) takes place. The outlet pressure set at the pressure control valve is indicated at the pressure gauge (4). The safety valve (3) has to limit the operating pressure in the pressure-reducing station to a maximum of 8,5 bar in order to prevent damages to the connected devices. The compressed air continues to flow from the pressure control valve (2) to the electro-magnetically operated three/two-way valve (5). This valve can supply the tab “A” with compressed air. In addition to tab “A” tab “P1” also furnishes a constant compressed air supply. The pressure switch (6) is used for monitoring of the reduced outlet pressure. In case an upper or lower threshold limit of the pressure value has been exceeded, an electrical contact is closed or opened. The compressed air tab “14” can be used to supply compressed air to the testing tab (7) for the pressure switch, thus ensuring that the function of the pressure switch (6) can be continuously monitored during operations. In order to enable this feature, the adjusting screw of the testing tab has to be turned into the housing until it stops. If the compressed air supply at tab “P” is interrupted, the pressure-reducing station is vented by force; thus ensuring that no pressure is present at any of the subsequent devices. (cf. block diagram on page 31 and circuit diagram on page 46)

8838900353_631A (11/00) 31

Design and mode of operation

Block- diagram fig. 1

PP

1

A

141

2

3

4

567

8838900353_631A (11/00) 32

Startup Ports and Installation Assembly position

Ports and Installation The pressure-reducing station is fixed with 2 screws M10. The boring pattern can be taken from the dimensional drawing. Pneumatic connections are materialised by traded ports M14x1.5.

Assembly position For assembly purposes it has to be taken into account that the drain valve points downwards.

Warning! When disassembled dirt, humidity or foreign matter must not enter the compressed air ports. For this reason the ports must be closed by means of suitable transportation protecting plugs. The disassembled pressure-reducing station must be protected from environmental influences. Before assembly the transportation protecting plugs must be removed. In addition the device must be visually inspected for damages of any kind. fig. 2

Warning!

8838900353_631A (11/00) 33

Maintenance and care General

Maintenance and care instructions In order to guarantee a good performance of the pressure-reducing station, the following maintenance and care instructions have to be adhered to.

Drain valve The filters should be drained daily using the drain valve. In order to do so, the handles of the drain valve should be slightly moved sideways.

Warning! If the valves are under pressure, the condensate is very powerfully ejected. Do not move the handles with your hands but use suitable tools to move the handles sideways.

Cleaning of the filter cartridge The filter cartridges have to be cleaned regularly according to the state of contamination of the compressed air. For cleaning purposes cleaner's naphtha or dissolvents can be used. Dry the filter cartridge before returning it to its position. Follow fig.3 for the removal and reinsertion of the cartridges.

Danger! Conduct all works on the pressure-reducing station only in an un-pressurized state.

Warning! Check the seals at the fastening screw. Ensure that the cartridge is not installed at an angle.

Replacing the filter cartridges Extremely dirty filter cartridges should be replaced by new ones. The required parts are contained in the spare parts package 335 320 003 2.

Replacing the sealing elements All sealing elements of the pressure-reducing station have to be replaced after 8 years at the latest. A spare parts package 335 320 003 2 is available. It contains all spare parts that are necessary for the replacement of all sealing elements.

Greasing the sealing elements The sealing elements of the pressure-reducing station have to be greased lightly using the lubricant contained in the repair set before assembly, except if they are subject to special maintenance and care instructions. Before assembly, all sealing seats, faces etc. have to be cleaned.

FettGrease

Warning!

Warning!

8838900353_631A (11/00) 34

Maintenance and care

Dismantling

The following section describes the dismanteling and assembly of a pressure-reducing station 335 320 200 0 for the replacement of the sealing elements. All elements necessary for a complete scheduled overhaul are contained in the spare parts package 335 320 003 2. In case of such an overhaul, the following instructions for the dismanteling/mounting have to be adhered to.

Replacing the sealing elements, dismantling

Warning! Conduct all works in a de-pressurized state. Shut off the compressed air supply and vent the device. Interrupt the electric power supply.

Dismantling the filters and the drain valves (fig. 3)

• Loosen fastening screw T1 and remove sealing ring 1, filter 2 and O-ring 3

• Remove valve screw T2 and sealing ring 4

• Remove circlip 7 and spring 6 as well as valve 5 from the valve screw T2.

Warning!

8838900353_631A (11/00) 35

Maintenance and care fig.3

XY

T1M = 150Nm

1

2

3

AB

C

ABC

A

X

T2

M = 60Nm

4

7

6

5

A

Y

26

T11

8838900353_631A (11/00) 36


Dismantling

Dismantling the pressure switch and the adjusting screw (fig. 4) • Disassemble pressure switch T3. Loosen screw T4 (2x)

• Remove O-ring 11

• Disassemble circlip 12 and remove washer T5

• Remove adjusting screw T6 from the housing. Remove O-rings 8, 9 and 10

• Remove ventilation 13.

Dismantling the pressure control valves (fig. 5)

• Loosen grub screw T7 and remove cap T8 from the housing

• Take spring T9 and piston T10. Remove O-ring 14

• Disassemble circlip 15 and pull valve 16 together with valve nut 17, bushing 18 and valve ring 19 from the drill hole. Remove spring 20

• Dismantle circlips 22, 24 and filters 23, 25

• Remove banjo bolt T11 from the housing and remove collar 26 (cf. fig. 3).

8838900353_631A (11/00) 37

Maintenance and care fig.4 fig.5

9.8

13.6

+0.

2

X

T7

T8

T9

T10

14

22

23

2425

15

16

17

18

19

20

21XB-B

T3 11

12

T5

T6

8

9

10

13

A-A

T4

8838900353_631A (11/00) 38


Dismantling

Dismantling the three/two-way valve (fig. 6)

• Dismantle servo valve T12. In order to do so, remove ventilation T13, the coil T14 and loosen the screw T15 (2x)

• Remove sealing 27

• Loosen screw T16 (2x) and remove the base plate T17

Warning! compression spring T18 is pre-stressed • Disassemble the following parts: compression spring T18, bushing

T19, piston T20, sleeve T21, ram T22, washer T23 (6x), washers 35, spacer T24 (2x), sealing ring 28 (4x) as well as groove ring 29

• Disassemble circlips 24, 30 and filters 25, 31.

Warning!

8838900353_631A (11/00) 39

Maintenance and care fig.6

D-D 27

T18

T19

35

T23T24

28

X

28

T20

T21

T22

35

T23T24

28

29

Y

28

X

Y

T12

T15

T16

T17

25

24

3031

C-C

D D

T13 1.2 NmM =A+0.2

T14

8838900353_631A (11/00) 40


Dismantling

Dismantling the servo valves (fig. 7) • Loosen countersunk screw T25 (2x) and remove base plate T26

• Remove O-ring 32

• Pull anchor system 33 from the housing T27

• Press taper pin T28 from the housing T27 and remove handle T29

• Remove O-ring 34.

8838900353_631A (11/00) 41

Maintenance and care fig. 7

T25

T27T28

T26

T29

34

32

33

8838900353_631A (11/00) 42


Assembly

Replacing the sealing elements, assembly Reassemble the device in reverse sequence. Take care not to damage the sealing elements during assembling. All sealing elements must prior to assembling be slightly lubricated with the grease from the spare parts kit. Before this all sealing surfaces are to be cleaned.

Assembly of the filter and the drain valve (fig. 3)

• Replace sealing ring1, filter 2 and O-ring 3. Tightening torque for fastening screw T1: MA = 150 Nm

• Replace sealing ring 4, valve 5, spring 6 and circlip 7. Tightening torque for valve screw T2: MA = 60 Nm

• Replace collar 26.

Assembly of the pressure switch and the adjusting screw (fig. 4)

• Replace O-rings 8, 9, 10, 11, circlip 12 and ventilation 13.

Assembly of pressure control valve (fig. 5)

• Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring 19, spring 20, O-rings 21 and 14.

Warning! Keep clearance 13.6+0,2 mm for valve nut 17. Secure valve head with substance for locking screws (e.g.. Loctite 241).

Warning! Ensure correct assembly position of valve ring 19!

• Replace circlips 22, 24 and filters 23, 25.

Assembly of the three/two-way valve (fig. 6)

• Replace sealing 27, sealing ring 28 (4x) and groove ring 29

• Replace circlips 24, 30 and filters 25, 31.

Warning! Bushing T19 and sleeve T21 must overhang the upper housing edge by 0.4 ±0.1mm. Attach washers 35 accordingly.

Assembly of the servo valves (fig. 7)

• Replace anchor system 33 as well as O-rings 32 and 34.

FettGrease

Warning!

Warning!

8838900353_631A (11/00) 43


Setup and Test

Setup and Tests of the pressure-reducing station After the dismantling/mounting of the pressure-reducing station, it is required to set up the operating pressure of the pressure control valves again. In order to do so, the grub screw T7 has to be loosened and the cap T8 has to be screwed from the housing with the exception of the last five turns. Set tab P to a pressure of 30 bar. By turning the cap T8 the operating pressure at the pressure control valve can be adjusted, then tighten the grub screw T7.

Warning! Turn cap T8 only in pressureless state. Check the three/two-way valve for correct performance by working it. Finally the complete pressure-reducing station has to be tested for tightness.

Warning!

8838900353_631A (11/00) 44


Spare parts package

335 320 003 2

Spare parts package: Order number 335 320 003 2 Item Description Dimension Qty.

010203040506070809101112131415161718192021222324252627282930313233343536

sealing ringfiltero-ring

valveconical springcirclip

ventilation

valvevalve nutbushingvalve ringconical spring

filter

filtercollar

groove ring

filter

anchor system

washerlubricant

sealing ring

o-ringo-ringo-ringo-ringcirclip

o-ringcirclip

o-ringcirclip

circlip

sealing ringsealing ring

circlip

o-ring

o-ring

36 x 42 x 2

23,2 x 2,422 x 27 x 1,5

0,8 x 12,7 x 26,515 x 16 x 1,55 x 1,24 x 1,2

6,75 x 1,7820 x 1

32,9 x 3,514 x 1

1 x 11,2 x 18,15,28 x 1,78

22 x 0,520 x 2,38,3 x 0,5

8 x 28 x 3 x 4

12,8 x 21,2 x 430 x 1,230 x 28 x 1

4 x 113 x 21,9 x 0,2

11111111111111111111111221141111116

20 g

8838900353_631A (11/00) 45

Storage and transportation General

During storage and transportation the pressure-reducing station must in principle be protected against mechanical damage and weather influences. Contacts with aggressive media must be avoided. Compressed air ports must be closed in a way to prevent entry of dirt, humidity and foreign matter. The ambient temperature during storage and transportation must neither drop below -35°C nor exceed +80°C.

Storage

Warning! Consider that sealing elements are subjected to ageing also during storage. The storage period must be taken into account for deter-mining the replacement intervals appropriately.

Transportation

Danger! In principle the provisions for the prevention of accidents must be observed. Above all the device must during transportation be secured against getting out of place resp. falling down.

Warning!

8838900353_631A (11/00) 46

Technical specifications

General Catalogue number: 335 320 200 0

Circuit diagram fig. 8

P

A

P1

14

1

2

3

4

5

6

7

Technical DataPermissible Mediuminlet pressureoutlet pressurepressure reducing valvesafety valvepressure switchthreaded tabsthermal application range

compressed airmax. 30 barmin. 3 bar / max. 8,5 baradjusted to 7,5 bar

8,5 bar 6,0 bar, decreasing

M14 x 1,5273 K … 343 K

adjusted toadjusted to

8838900353_631A (11/00) 47

Technical specifications

Dimensional drawing fig. 9 threaded tabs: M14 x 1.5; 12 deep

20

20

15112

14424

200

90

178

256

11

18

11

6

32

65

17.5

32

70

109

45

56

48

After sales service and adresses any Questions?

Are there any questions left? If anything is still not clear after reading these operating instructions, please let us know. Your suggestions for improvements are always welcome. If you require any further information, please contact the sales staff in our Marine Technique Division directly or the address below. Rexroth Mecman GmbH Bartweg 13

D – 30 453 Hannover

Dep. M-V (Sales department):

Tel. +49 - 511 - 21 36 - 251 Fax. +49 - 511 - 21 36 - 165 Dep. M-K (After sales service):

Tel. +49 - 511 - 21 36 - 670 Fax. +49 - 511 - 21 36 - 165 Email:

[email protected]

Subjekt to alteration. This edition supersedes all previous ones. Printed in Germany No part of this edition may be reproduced without our prior permission. Order no. 883 890 035 3 Version A (11/00)

Electrical EquipmentEngine Monitoring Devices Terminal Box

C5.05.05.70.06.45

-

en / 29.10.2004 FD021336 1/1

�

Electrical Equipment

Engine Monitoring Devices Ter-minal Box

RPM–SWITCH–UNIT

Equipment list

Unit Description CAT- No. Stock- No. Drawing - No.

CD6 / Mischke Seite: 1

Status: 28.10.2004 EG 1.00.7-36.29.00-45_en Caterpillar : Confidential Green

c

A1 Plug in card (without presetting)

263 360 140 9.01.7-91.21.00-16

Plug in card (presetting for engine M20)

193 300 029 9.01.7-91.21.00-16


193 375 001 9.01.7-91.21.00-16


193 466 036 9.01.7-91.21.00-16

Plug in card (presetting for engine VM32)

193 466 037 9.01.7-91.21.00-16


193 376 030 9.01.7-91.21.00-16

Plug in card (presetting for engine VM43)

193 376 030 9.01.7-91.21.00-16

A2 Plug in card

263 360 150 9.01.7-91.21.00-17

RPM Switch UnitDescription

C5.05.05.75.11.45

-

en / 10.01.2001 FD020042 1/1

�

RPM Switch Unit

Description

Engine Adjusting Valve-

C5.05.06.09.15.00

-

en / 25.02.2004 FD020148 1/1

�

Engine Adjusting Valve

-

Turbocharger - R5-3 -Data sheet (KBB)

C5.05.06.10.02.57

M25

en / 22.09.2004 FD028643 1/1

�

Turbocharger - R5-3 -

Data sheet (KBB)

OPERATINGandMOUNTING INSTRUCTIONforEXHAUST GAS TURBOCHARGER

Type R5-3

Works- No.

Variants- No.

226,227,228

001082.458-

Kompressorenbau Bannewitz GmbHWindbergstraße 4501728 BannewitzFederal Republic of Germany

Phone: +49 (351) 40 85 603 (Sales) +49 (351) 40 85 633 (Service) +49 (172) 35 16 045 (24 Hours Phone)Fax: +49 (351) 40 85 840

5 Edition ( 04/04)en th

Exhaust gas turbocharger R5-3

Type plate

Type / Works -No.

Variants - No.

max

Weight

Speed34500

685

rpm

kg

R5-3 226,227,228/

2.458- 00108

t 650max

Year of Manuf. 2004

Made in Germany

The data given in the operating instructions apply only to the exhaust gas turbochargers of the works number mentioned above. This number is also given on the type plate affixed to the compressor housing of the exhaust gas turbocharger.

In case you have questions regarding the exhaust gas turbocharger, it is important to give the correct - type- variant number- works number.

Only if these data are known the request can be handled properly and promptly.

Direct your requests to the following address:

Kompressorenbau Bannewitz GmbHWindbergstr. 4501728 BannewitzFederal Republic of Germany

Telefax: + 49 (351) 40 85 840Telephone: + 49 (351) 40 85 603 (Sales) + 49 (351) 40 85 633 (Service) + 49 (172) 35 16 045 (24 Hours Phone)

Cº

Page 2 of 53 5 Edition ( 04/04) enth

Turbocharger - R5-3 -Operating Instructions (KBB)

C5.05.06.10.11.24

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en / 22.10.2002 FD023465 1/1

�

Turbocharger - R5-3 -

Operating Instructions (KBB)


en 5 th

Edition (04/04) Page 3 of 53

Table of Contents

Chapter Title Page

1 SAFETY ......................................................................................... 5

1.1 Built-in safety systems .................................................................................5

1.2 Safety measures (to be taken by operator) .................................................5

2 GENERAL INFORMATION ABOUT DANGERS........................... 6

2.1 Danger zone...................................................................................................6

2.2 Operators and maintenance personnel .......................................................6

2.3 Use of spare parts and wearing parts..........................................................7

3 DESIGN AND SPECIFICATIONS.................................................. 8

3.1 Brief description............................................................................................8

3.2 Operating data ...............................................................................................9

3.3 Pipe connections.........................................................................................10

3.4 Test connections.........................................................................................11

3.5 Dimensions of important subassemblies..................................................12

4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER ............. 13

4.1 General requirements .................................................................................13

4.2 Console for the TC ......................................................................................13

4.3 Gas and air pipings .....................................................................................13

4.4 Loads of housings of the exhaust gas turbocharger ...............................14

4.5 Vibrations.....................................................................................................14

5 OPERATION................................................................................ 15

5.1 Preparation for operation ...........................................................................15

5.1.1 Lubricating oil supply .....................................................................................15

5.1.2 Cooling water.................................................................................................15

5.2 Engine operation .........................................................................................16

5.3 Putting out of operation..............................................................................16

5.4 Failures.........................................................................................................17

6 MAINTENANCE........................................................................... 18

6.1 General .........................................................................................................18

6.2 Maintenance work .......................................................................................18

6.3 Cleaning .......................................................................................................19

6.4 Maintenance schedule ................................................................................20

6.4.1 Maintenance for Marine Diesel Oil (MDO) application...................................20

6.4.2 Maintenance for Heavy Fuel Oil (HFO) application .......................................21

6.5 Troubleshooting table.................................................................................22


Page 4 of 53 5 th

Edition (04/04) en

Chapter Title Page

7 DISASSEMBLY AND ASSEMBLY ............................................. 23

7.1 Introduction ................................................................................................. 23

7.2 Checking the components ......................................................................... 23

7.3 Test results.................................................................................................. 25

7.4 Clearance sheet .......................................................................................... 27

7.5 Process of maintenance............................................................................. 28

7.5.1 Compressor washing .................................................................................... 28

7.5.2 Turbine washing............................................................................................ 29

7.5.3 Stoppage the exhaust gas turbocharger ....................................................... 31

7.5.4 Bearing check ............................................................................................... 32

7.5.5 Disassembly of the complete turbocharger ................................................... 33

7.5.6 Assembly of the complete turbocharger........................................................ 34

7.5.7 Assembly and disassembly of silencer or air-intake housing ........................ 35

7.5.8 Cleaning the silencer..................................................................................... 36

7.5.9 Assembly and disassembly of the compressor housing................................ 37

7.5.10 Assembly and disassembly of the bearing housing with rotor....................... 38

7.5.11 Disassembly of rotor complete...................................................................... 39

7.5.12 Installation of rotor complete ......................................................................... 41

7.5.13 Disassembly turbine outlet housing .............................................................. 44

8 SPARE PARTS AND TOOLS ..................................................... 45

8.1 General......................................................................................................... 45

8.2 Spare parts .................................................................................................. 46

8.2.1 Bearings........................................................................................................ 46

8.2.2 Gaskets......................................................................................................... 47

8.2.3 Locking elements .......................................................................................... 48

8.3 Tools ............................................................................................................ 49

9 SECTIONAL DRAWING.............................................................. 50

10 LIST OF COMPONENTS ............................................................ 51


en 5 th


1 SAFETY

The exhaust gas turbocharger has been designed on the basis of the following standards

and regulations:

• EC machinery directive (89/392/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC)

• EN 292 Parts 1 and 2: Safety of machines (fundamentals)

• EN 294 : Safety of machines; Safety distances to be kept to prevent the upper limbs from

reaching dangerous zones.

1.1 Built-in safety systems

• A safety system for the turbocharger is not necessary as its design and connection with

the engine to which it is attached require an inherent safety.

• Because of the high temperatures occurring, the turbine housing is provided with a protec-

tive cover.

• For general speed monitoring, i.e. without a turn-off function being included, a tachometer

can be mounted on the exhaust gas turbocharger.

Maintenance work must not be done during operation. See Chapter 7.5.1

and 7.5.2 "Maintenance" for maintenance jobs to be done while the en-

gine is running.

1.2 Safety measures (to be taken by operator)

• These operating instructions are part of the exhaust gas turbocharger and shall be always

accessible for the operators and maintenance personnel.

• The operating instructions should be read before mounting the turbocharger. Particular at-

tention should be paid to directions and information relating to dangers.

The user is required

• to instruct his operators and maintenance personnel on the safety equipment of the turbo-

charger

• makes them familiar with safe working methods

• supervises observance of the safety regulations.

The individual jobs in these instructions are described such that they can be understood by

skilled workers.

The necessary tools and testing/inspection means must be available to these workers.

The user must obtain permission to operate the unit from the local authorities and observe

the following:

• labour safety

• cleaning and maintenance of the machines

• product disposal

• environmental protection.


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2 GENERAL INFORMATION ABOUT DANGERS

2.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the en-

gine.

During turbocharger operation, the user must keep the danger zone free

of any objects so to ensure unhindered access to the unit.

Ear muffs should be worn as the sound level is high. Care should also

be taken when approaching the hot housings!

The exhaust gas turbocharger is mounted on the engine. It may not be interfered with when

the engine is running.

• Make sure the exhaust gas pipes on the turbine side cannot come loose during operation

since exhaust gas might escape at this point.

• As the exhaust gas turbocharger is an integral part of the engine, its operation is de-

scribed in connection with the engine. However, its maintenance is described separately.

2.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport, as-

sembly, installation, operation, setting, maintenance, cleaning and troubleshooting.

Adhere to the following accident prevention regulations:

- winches, hoisting and drawing gear (VBG 8)

- load take-up devices for hoisting operations (VBG 9a).

If these regulations are not observed, your life and limb may be endangered!

1. The turbocharger may only be maintained by duly qualified and authorised persons.

2. In operating the turbocharger, the responsibilities shall be clearly defined and must be ad-

hered to so as to prevent confusing competences with respect to the safety aspect.

3. The operating instructions shall be followed irrespective of what kind of work (operation,

maintenance, repair etc.) is concerned.

4. The cleaning, maintenance and repair work described in these instructions are easy to

understand by persons skilled in mechanical, cleaning and maintenance work.

The necessary tools and testing/inspection means must be available to these persons.

5. Operators are not allowed to interfere with the unit in a way that would affect machine

safety.


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6. It is also within the responsibility of the operator to see to it that no unauthorised person

works on the turbocharger.

7. The operator must inform the user without delay of any safety-affecting changes to the

turbocharger.

8. The user must not operate the turbocharger when it is not in proper condition.

2.3 Use of spare parts and wearing parts

It is emphasised that spare and wearing parts not supplied by us are not tested/ inspected

and approved by us. The use of such products may negatively affect the performance of your

turbocharger. We assume no liability for damage caused by the use of components and ac-

cessories not made by us.

For ordering spare parts and tools, please refer to the

• parts list

• sectional drawings

• spare parts list

• tools list.

The spare parts lists attached contain all spare parts for the turbocharger. DIN (standard)

parts may be bought from specialised dealers.

For the assembly, disassembly and commissioning of the turbocharger, refer to the respec-

tive sections in these operating instructions.

Before doing any maintenance, cleaning or repair work, turn the engine off and secure it against unintentional starting. See chapter 7.5.1 and 7.5.2 "Maintenance" for maintenance jobs to be done during engine op-eration.

Please observe the following accident prevention regulations: - winches, hoisting and drawing gear (VBG 8) - load take-up devices for hoisting operations (VBG 9a).

If these regulations are not observed, your life and limb may be endan-

gered!

See the inspection schedule (see Chapter 6.4) for the maintenance inter-

vals.


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3 DESIGN AND SPECIFICATIONS

3.1 Brief description

Exhaust gas turbocharger (TC): R5-3

Variant number : 2.458-. . . . .

Mass : 685 kg

The R5-3 TC is equipped with a single- stage radial flow turbine and a single- stage radial

flow compressor.

The turbine wheel is welded to the shaft, whereas the compressor impeller is shrunk to the

shaft. The complete rotor has a bearing consisting of two plain bearings in a water-cooled

bearing housing. The turbine and compressor housing is flanged to the bearing housing. The

turbine outet housing is mounted on the turbine inlet housing. You can use a silencer or an

intake housing on the entrance of the compressor housing.

The bearing lubrication is connected to the lubricating oil system of the engine.

The TC is not equipped with a special control device. The TC speed obtained depends on the

engine output.

The TC variant attached to the engine is thermodynamically adjusted and is binding for this

engine variant, i. e. if the TC has to be replaced, use the same TC variant.

Modifications and additional attachments to the TC are subject to a written consent of the TC

manufacturer.


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3.2 Operating data

Variants refer to type plate (Page 2)

Max. speed (rpm) refer to type plate (Page 2)

Max. exhaust gas temperature upstream of turbine (°C) refer to type plate (Page 2)

Types of lubricating oil: Engine oil with a kinematic viscosity

of at 50oC e.g. SAE 30, SAE 40

60...115 mm2

/s

Nominal oil filter fineness upstream of TC : max. 25 µm

Lubricating oil pressure upstream of TC : 300 ± 150 kPa

Admissible lubricating oil pressure for special operating con-ditions

At start-up : min. 50 kPa

From start-up to idle running : min. 50 kPa

At standstill (Prelubrication or relubrication/ Standby opera-tion)

see diagram down

Lubricating oil flow : 20 ... 30 l/min

Lubricating oil temperature at inlet : 40 ... 80 °C

Lubricating oil temperature at outlet : max. 100 °C

Cooling water pressure: max. 300 kPa

Cooling water temperature at inlet: 50 ... 85 °C

Max. temperature difference between inlet and outlet cooling water :

10 K

Cooling water flow : min. 1.5 m3/h

Counter - pressure downstream of turbine : max. 2.5 kPa(g)

Vacuum upstream of compressor : max. 1.5 kPa(g)

Sound power level (measured on silencer at 100 mm dis-tance from compressor housing):

108 dB at 30,000 rpm

POil

(kPa)

tOil (oC)

Admissible lubricating oil pressure for prelubrication or relubrication

(Standby operation)


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3.3 Pipe connections

Dimensions are specified in mm!

Exhaust gas Inlet single - nozzle housing (1x) Ø 190 mm

Inlet double - nozzle housing (2x) Ø 125 mm

Inlet triple - nozzle housing (3x) Ø 110 mm

Outlet 270 x 600 mm

Charge air Outlet Ø 175 mm

Lubricating oil Inlet at bearing housing M27x2

Outlet at bearing housing Pipe 45 x 2

Cooling water Inlet at bearing housing Pipe 35 x 2

Outlet at bearing housing Pipe 35 x 2

Compressor washing Air piping Pipe 12 x 1 St

Water piping Pipe 12 x 1,5 Cu

Turbine washing Water piping

Drainage

Pipe 12 x 2

Pipe 35 x 2

Further connection dimensions can be taken from the assembly drawing. This can be re-

quested from the TC manufacturer.

The piping for the pipe connections listed is not included in the scope

of supply of Kompressorenbau Bannewitz GmbH.

Pipes have to be laid free of stress in any case.


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3.4 Test connections

On request, the TC can be equipped with a speed measuring device consisting of magnetic

screw (9001) and an inductive speed sensor (9002).

The magnetic screw (9001) is screwed into the shaft centring hole. The inductive speed sen-

sor (9002) is screwed into the silencer/ air intake housing to the limit and then unscrewed by

one turn (distance 1 - 1,5 mm). The inductive speed sensor (9002) is secured with the lock

nut (A).

Legend

2500 Compressor housing

2517 V-profile clamp

2800 Silencer

2900 Intake housing

9001 Magnetic screw

9002 Inductive speed sensor

A Lock nut


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3.5 Dimensions of important subassemblies

Exhaust gas turbocharger, cpl. 685 kg

Silencer 75 kg

Air-intake housing 30 kg

Compressor housing, cpl. 123 kg

Turbine inlet housing, cpl. 120 kg

Turbine outlet housing, cpl. 153 kg

Bearing housing, cpl. 124 kg

Rotor cpl. 30 kg

Shaft 20 kg

Compressor impeller 8 kg

Foot, complete 50 kg


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4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER

4.1 General requirements

The TC is to be connected to the engine without deflection or torsion. Thermal expansions

and relative motions are to be compensated by flexible or movable elements in the pipings.

4.2 Console for the TC

The console is to be designed resistant to deflec-

tion and torsion in order to prevent any additional

forces from acting on the fastening bolts. Use bolts

of property classes 10.9 or 12.9 according to

ISO898-1. If the foot is not in horizontal position

(angle of inclination > 25°), it is to be supported

additionally (refer to figure).

4.3 Gas and air pipings

Gas and air pipes must not be supported at the exhaust gas turbocharger housings, but only

on the engine. They are to be fastened in a way avoiding free oscillations.

Thermal expansions are to be absorbed by expansion joints (compensators) to be arranged

as closed to the exhaust gas turbocharger as possible.

Compensators are to be prestressed in cold condition in order to ensure an optimum relief

during the operation.

Thick flexible gaskets must not be used instead of compensators or sliding seals.

Soft compensators are to be installed in the piping downstream of the air outlet, upstream of

the gas inlet as well as upstream of the air-intake housing.

Exhaust gas outlet of an exhaust gas turbocharger is connected via diffuser and compensa-

tor to the exhaust gas piping. This exhaust gas piping has to be fixed to the building or ship

directly downstream of the compensator (refer to figure). The remaining forces acting on the

turbine housing are composed of the weight of the diffuser and of the compensator pressure.

Legend

1 - fastening point in

building or ship

2 - compensator

3 - diffuser

23 - diffuser housing


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4.4 Loads of housings of the exhaust gas turbocharger

The air and gas piping may transfer inadmissible high forces and moments onto the TC

caused by deformation or thermal expansion.

This may caused distortion at TC housing components perhaps resulting in damages at the

TC; e. g. elimination of mounting clearances resulting in a rotor contact with the housings,

damaged bearings, TC failure.

The pipings attached may apply the following forces and moments to the TC

Maximum admissible forces and moments

F1 1000 N

M1 500 Nm

M2 400 Nm

While dimensioning the compensator and the diffuser, make sure to se-

lect their masses and the rigidity of the compensator in order to prevent

the forces mentioned from being exceeded in cold as well as warm oper-

ating conditions as well as during start-up and stopping.

Recommended compensator rigidity : < 300 N/mm

Mass of diffuser firmly screwed to TC including half of the mass of the compensator

(max. admissible) : 120 kg

4.5 Vibrations

Maximum admissible vibration load at engine for 2 - 300 Hz :

Effective vibration speed at TC 30 mm/s

at silencer 50 mm/s

Amplitude 1 mm

Effective acceleration 15 m/s2

(measured at TC at shaft level longitudinal and transverse to the Rotor)


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5 OPERATION

5.1 Preparation for operation

5.1.1 Lubricating oil supply

The lubricating oil supply of the TC plain bearing is taken from the engine oil circuit. The lubri-

cating oil flow depends on the oil temperature, the oil pressure and the TC speed.

A nominal oil filter fineness of 25 µm is specified for the lubricating oil upstream of the TC. If

the lubricating oil filter of the engine does not meet this requirement, a correspondingly

switchable filter is to be inserted upstream of the TC. This lubricating oil filter has to permit a

lubricating oil flow of not less than 35 l/min.

The lubricating oil supply have an open width of not less than 15 mm and the lubricating oil

return line shall have an open width of not less than 40 mm. The lubricating oil return line is

to be designed as short inclined piping.

Prior to putting into operation, ensure that the bearings of the TC are supplied with oil in any

case.

The lubricating oil pressures required for special operating conditions are listed under chap-

ter 3.2. Ensure and check the free return flow of the lubricating oil.

The following has to be checked :

• Lubricating oil temperature upstream of TC

• Lubricating oil pressure upstream of TC

During installation, make sure to provide sufficient space for maintenance and repair work.

• Ensure the lubricating oil supply of the plain bearings (refer to chapter

3.2).

• Lubrication has to be started prior to start-up processes.

• The engine has to be stopped immediately when the oil pressure falls

below the minimum value.

• Pay special attention to prevent leakage's in the oil supply and return

pipes to prevent oil from flowing under the sheathing of hot, gas-

carrying housings in order to prevent the formation of hazardous oil va-

pours (and fire risks).

5.1.2 Cooling water

The cooling of the bearing housing is taken from the engine cooling water circuit (Connection

dimension see chapter 3.3). Prior to putting into operation or maintenance, ensure that the

connections of cooling circuit are tightly.

Ensure the cooling-water flow adjust, that you have not more then 10 K between the entrance

of cooling-water and outlet (see chapter 3.2).


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5.2 Engine operation

The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started to-

gether with the engine. The TC speed is adjusted depending on the operating conditions of

the engine.

The charge air pressure required for the engine is fixed by adjusting the turbine nozzle ring

and the compressor diffuser during the TC approval.

If the corresponding meters are available, enter the following measured values into the en-

gine log during engine operation (at least once every 24 operating hours) :

• Speed of exhaust gas turbocharger

• Exhaust gas temperature upstream of turbine or downstream of cylinder

• Charge air temperature downstream of compressor or downstream of charge air cooler

• Charge air pressure downstream of compressor

• Lubricating oil temperature upstream of TC

• Lubricating oil pressure upstream of TC

• At the same time, perform the following checks at regular intervals:

• Tightness of the exhaust gas, charge air, cooling water and oil pipings

• Smooth running of the exhaust gas turbocharger

The charge air pressure is utilised as parameter for the exhaust gas turbocharger speed.

Unsteady operation (vibration of TC) indicates an unbalance of rotating parts possibly result-

ing in the damaged rotor or bearing (refer to chapter 6.5).

5.3 Putting out of operation

After the engine has been stopped, the exhaust gas turbocharger continues to run for some

time. The run out period depends on the installation.

If the rotor comes to an immediate standstill, this can be caused by one of the following rea-

sons:

• damaged bearings

• contact of compressor or turbine blades by thermal distortion (refer to chapter 4.3 and

4.4.)

• clamed foreign matters

Measures for extended period without operation

Drain the cooling water from the cooling water compartments. Preserve cooling water com-

partments, oil compartments and all machined surfaces of the exhaust gas turbocharger by

slushing oil.

Protect the exhaust gas turbocharger against continuous vibration possibly damaging the

bearing during standstill.

Remove the preservation of the exhaust gas turbocharger prior to restoring it.

Perform an inspection according to the maintenance schedule, chapter 6.4.

Instruction for extended preservation and removing the preservation are available on request.


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5.4 Failures

Failures can be detected by abnormal measured values (exhaust gas temperature, charge

air pressure, speed), heavy noise or leakage's of lubricating oil and cooling water pipes.

In case of irregularities, reduce the engine load or stop the engine.

Since even minor failures may cause heavy consequential damages, determine the cause of

failure and eliminate it immediately (refer to chapter 6.5).

Stoppage the exhaust gas turbocharger

If the exhaust gas turbocharger has to be stopped due to a defect and if the engine has to

run in emergency operation, perform the work according to the chapter 7.5.3.

During stopping the exhaust gas turbocharger, limit the engine power in

order to prevent the exhaust gas temperature from exceeding admissible

values downstream of outlet valves. Pay attention to the operating in-

struction of the engine manufacturer.


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6 MAINTENANCE

6.1 General

Maintenance and monitoring work is summarised in the maintenance schedule, chapter 6.4.

Proper maintenance work enables failures to be detected in time. The maintenance work

also indicates necessary overhauls as well as work to be scheduled during yard or harbour

times on interruptions.

The operating hours specified in the maintenance schedule are to be considered as aver-

ages. They can be extended or shortened according to existing operating conditions as well

as to be adjusted to the maintenance intervals of the engine.

It is important to eliminate even minor, apparently insignificant defect immediately and to de-

termine and eliminate their causes in order to prevent consequential damages at engine or

exhaust gas turbocharger.

If the engine is not equipped with an automatic monitoring system with data recording, entries

into the engine log are required at least once every 24 operating hours. Thereby, you can de-

tect deviations in time.

6.2 Maintenance work

In order to keep the exhaust gas turbocharger in the safe conditions, perform the inspection

and check of various subassemblies and components according to maintenance schedule,

chapter 6.4.

The chapter 7.5 include detailed instructions on the work sequence for maintenance and

overhaul work.

Make sure to observe the following accident prevention regulations:

• winches, hoisting and towing equipment (VBG 8)

• load take-ups in hoisting gear operation (VBG 9a)

If bolts or nuts cannot be loosened immediately, do not apply excessive forces in order to

avoid damages of threads causing retouching work. Apply diesel fuel and wait for half an

hour. In this way, "Seizing" of threads can be avoided in most cases.

For bolted connections under heavy thermal load, bolts and nuts are made of high-

temperature material. Make sure that you do not confuse these bolts and nuts with commer-

cial ones during assembly work. In order to prevent burning and to facilitate subsequent dis-

assembly, apply a suitable bolt paste (e.g. molybdenum sulphide paste, graphite) prior to as-

sembly. Contamination's have to be removed from the threads previously.

During assembly, all bolted connection equipped with locking elements (lock nut, locking

plate) have to be properly locked.

For a basic overhaul or repairs effecting essential parts of the exhaust

gas turbocharger, it is recommended to document their condition. The

"Test results" form can be used as sample (refer to chapter 7.3).


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6.3 Cleaning

Cleaning the silencer

• refer to chapter 7.5.8

Cleaning the compressor

• Cleaning during operation: refer to chapter 7.5.1

• Mechanical Cleaning: refer to chapter 7.5.7 and 7.5.9

Remove the silencer and compressor housing. (The compressor impeller remains of the

shaft.). Deposits are removed by diesel fuel or another admissible liquid cleansing agent.

• Pay attention to accident prevention regulations ! • While washing, make sure to prevent the cleansing agent from pene-

trating into the charge air piping or into the interior of the turbo-charger.

Cleaning the turbine

• cleaning during operation : refer to chapter 7.5.2

(for heavy fuel oil operation only)

Cleaning the cooling water compartments

The contamination of cooling water compartments in the bearing support depends on the

cooling water care and the cooling water at mixture in the engine circuit. It is recommended

to clean engine cooling compartments and cooling compartments of the bearing support si-

multaneously.

Heavy deposits in the cooling water compartments of the exhaust gas

turbocharger result in a reduced life of the housing and of the bearing.


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6.4 Maintenance schedule

6.4.1 Maintenance for Marine Diesel Oil (MDO) application

The operating hours given in the table below are guidelines which can be

reduced for adjustment to the maintenance intervals of the engine.

Item Chapter Maintenance work Maintenance interval

(operating hours)

1. Check for abnormal noise 24

2. 7.5.1 Compressor washing during operation, actuate

compressor washing system

24 - 48

3. 7.5.8

Clean air filter at silencer approx. 250

or on demand

4. Check fastening bolts at the feet, tighten all

housing bolts and piping joints

once after commis-

sioning, then every

1,000 hours

5. 7.5.4 -

7.5.13

Inspection I

• disassembly

• cleaning

• checking of rotor and bearings

• checking of housings

• assembly

max. 10,000

6. 7.5.4 -

7.5.13

Inspection II

• like inspection I

• replacement of the bearings

max. 20,000

7. 7.5.4 -

7.5.13

Inspection III

• like inspection II

• replacement of the rotor

max. 40,000


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6.4.2 Maintenance for Heavy Fuel Oil (HFO) application

The operating hours given in the table below are guidelines which can be

reduced for adjustment to the maintenance intervals of the engine.

Ite

m

Chapter Maintenance work Maintenance

interval

(operating

hours) 1. Check for abnormal noise 24

2. 7.5.1 Compressor washing during operation, actuate

compressor washing system

24 - 48

3. 7.5.2 Turbine washing during operation, actuate tur-

bine washing system

Cleaning with water

approx. 300

depending on HFO

quality

4. 7.5.8

Clean air filter at silencer approx. 250

or on demand

5. Check fastening bolts at the feet, tighten all hous-

ing bolts and piping joints

once after commis-

sioning, then every

1,000 hours

6. 7.5.4 -

7.5.13

Inspection I

• disassembly

• cleaning

• checking rotor and bearings

• checking housings

• assembly

max. 10,000

7. 7.5.4 -

7.5.13

Inspection II

• as inspection I

• replacement of bearings

max. 20,000

8. 7.5.4 -

7.5.13

Inspection III

• as inspection II

• replacement of rotor

max. 40,000

The nozzle ring is subject to an increased wear for heavy fuel oil opera-tion. Therefore it is a wear part.

The lifetime of the nozzle ring is approximately 12,000 hours, but it de-pends on HFO quality and operating conditions.

After exceeding the lifetime the nozzle ring should be replaced in case of fundamental change of performance data as charge air pressure and ex-haust temperature.


Page 22 of 53 5 th

Edition (04/04) en

6.5 Troubleshooting table

Fa

ult

Causes Chapter T

em

p. u

pstr

ea

m o

f tu

rbin

e a

bo

ve

ad

m. m

ax. va

lue

Ch

arg

e a

ir p

ressu

re a

nd

/or

sp

ee

d to

o lo

w

Ch

arg

e a

ir p

ressu

re a

nd

/or

sp

ee

d to

o h

igh

He

avy n

ois

e

De

laye

d s

tart

, sh

ort

co

astin

g

Lu

bri

ca

tin

g o

il le

aka

ge

Lu

bri

ca

tin

g o

il p

ressu

re to

o lo

w

Tu

rbo

ch

arg

er

pu

mp

s

Tu

rbo

ch

arg

er

vib

rate

s

Silencer or air filter contaminated 7.5.8

Compressor contaminated 7.5.9

Charge air cooler contaminated Engine

Leaking exhaust gas piping Engine

Exhaust gas counter pressure too high

downstream of turbine

Engine

Turbine wheel or compressor impeller

damaged (unbalanced) 7.5.10

7.5.11

Defective bearing 7.5.4,

7.5.11

Rotor in contact with housing 7.5.11

Foreign matter in turbine or compressor

(unbalanced) 7.5.9,

7.5.10

Turbine contaminated 7.5.2

Turbine nozzle ring contaminated 7.5.2

Failure of fuel injection at engine Engine

Leaking charge air piping Engine

High air intake temperature Engine

Inlet or outlet valves of the engine con-

taminated

Engine

Low air intake temperature Engine

Lubricating oil filter contaminated Engine

Lubricating oil pressure gauge defective Engine

Lubricating oil inlet temperature too high Engine

Excessive pressure in oil return Engine

Sealing air ineffective

Gaskets damaged, connections leaking

Plain compression rings damaged 7.5.11


en 5 th


7 DISASSEMBLY AND ASSEMBLY

7.1 Introduction

The chapter 7.5 shall enable the user to perform certain repair and maintenance work by

himself.

Work sheets are sorted according to the sequence required to disassemble the exhaust gas

turbocharger. The instructions on the work sheet always refer to the working sequence men-

tioned in the heading.

In case of complicated repair and overhaul work, it is required to prepare an exact working

sequence by compiling the respective work sheets.

It is assumed that the staff is familiar with the work and that the tools required are ready at

hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding

hoists have to be available.

If change are caused by damages at certain components or if the exhaust gas turbocharger

is in a poor maintenance condition, the working time required may be extended.

Make sure to observe the following accident prevention regulations:


• load take-ups in hoisting gear operation (VBG 9a)

7.2 Checking the components

The check list shown below can be used as instructions for the check of the condition of the

exhaust gas turbocharger and its major components. As a rule, the user is able to eliminate

minor damages. Major damages effecting rigidity, balance and smooth running of rotation

components should be eliminated by the manufacturer or an authorised workshop. If dam-

aged parts are returned for repair, ensure a good protection against transportation damages.

After having disassembled the exhaust gas turbocharger, perform the following checks at

cleaned parts. The condition is to be recorded in the "Test results" form, chapter 7.3.

The valuation is made by means of the "Clearance sheet", chapter 7.4.


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Rotor

• Are the turbine blades damaged or did they touch the housing ?

• Are contact traces visible at the housing ?

• Are contact traces visible at the rotor ?

• Does the shaft run smoothly ?

• How is the condition of bearings ?

• Are the plain compression rings heavily worn ?

If retouching work is performed or if rotor parts are replaced, rebalanc-

ing has to be executed ! (for admissible residual unbalance, refer to

clearance sheet, chapter 7.4)

Wear occurs at the plain compression rings in axial direction during run-

ning-in, which his intended and could be max. 0.5 mm.

Compressor impeller

• Can you detect sliding traces or cracks at the compressor impeller ?

• Are the bore and the axial surface OK ?

Bearing

• Is the axial clearance of the rotor inadmissible high ?

• Are the bores of bearings irregularly worn ?

• Is there heavy wear at the bearing faces at thrust bearing plates, compressor or turbine

bearing ?

For evaluation of bearings, refer to chapter 7.5.4 .

Turbine nozzle ring

• Are the guide vanes twisted ?

• Is foreign matter clamped into the ducts ?

• Can you detect traces of foreign matter ?

Housing

• Are the housings heavily contaminated by oil, dust or soot ?

• Is there any leakage at housings ? (Main items: connection flanges, joints, oil and water

connections)

• Are all bolts and nuts tight ?

After extended standstill periods, boiler scale may occur in cooling water

compartments. It is to be removed by suitable solvents.


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7.3 Test results

Exhaust gas turbocharger : Works No. :

Variant No. :

Type of engine : Engine No. :

Customer name :

Address :

(Location, ship's name)

Latest inspection/ overhaul at : by :

Inspected/ overhauled at : by :

Number of operating hours since commissioning :

since latest inspection/ overhaul :

Results of inspection of components

Rotor/ Shaft

Turbine blades O no

damaged O yes

O blade parts missing

O traces of foreign matter

Contamination/ O no

deficits of O slight Plain compression O no

rotor blades O heavy rings damaged O yes

O uni-lateral

O uniform Radial deviation of rotor

(acc. to Clearance sheet) ............. mm

Blades tarnished O no Blade cracks O no

O yes O yes

Location : ..............

Gap between turbine impeller and housing Gap between compressor impeller and housing

(acc. to Clearance sheet) Clear. S12 : ........ mm (acc. to Clearance sheet) Clear. S1 : .......... mm

Clear. S14 : ........ mm Clear. S2 : .......... mm

Sliding traces O no Rotor rebalanced O no

at shaft O yes O yes

Bearing seats O no Condition prior O good

damaged O yes to rebalancing O poor

Compressor impeller

Sliding traces O no Blade cracks O no

O yes O yes

Location : ............... Location : ...............

Contamination O clean Quality of O good

O contaminated Bore O average

O oily O poor

Turbine nozzle ring

Guide vanes O good O Part turn out

O twisted O Traces of foreign matter

O scaled


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Bearing housing

O clean Sealing air bores O clean

O coked O narrowed

O corroded O clogged

Compressor diffuser

Guide vanes O little Damage O no

contamination O heavy O yes

Location : ...............

Compressor bearing

O used Stop surface of radial bearing

O replaced B(rad) : ................ mm

Reason ................

Marks O no

O yes Location : ............... Depth : ................. mm

Thrust bearing

O used Stop surface of thrust bearing

O replaced B(ax) : ................. mm

Reason ................

Marks O no

O yes Location : ................ Depth : ................... mm

Turbine bearing

O used Stop surface

O replaced B(rad) : ................ mm

Reason ................

Marks O no

O yes Location : ............... Depth : ................. mm

Silencer

Contamination O oil Condition of O good

O dust felt layer O poor

O soot

Filter mat O yes

cleaned O no

Other defects/ component/ type :


en 5 th


7.4 Clearance sheet

Clearance/ Value

(mm)

New condition Limit

Clear. Parts designation Parts No. min max clear.

max.

*)

S1 Compressor impeller- compressor housing

(radial)

1002/ 2500 0.5 0.6 1.0

S2 Compressor impeller- compressor housing

(axial)

1002/ 2500 0.6 0.7 0.9

S6 Rotor- compressor bearing (radial/ d7-d6) **) 1000/ 3200 0.10 0.13

S8 Rotor- turbine bearing (radial/ d11-d10) **) 1000/ 3100 0.11 0.14

S12 Turbine imp.- turbine housing (radial) 1000/ 2100 0.5 0.6 0.8

S13 Turbine imp.- radiation protection 1000/ 2009 0.6 0.9 1.1

S14 Turbine imp.- turbine housing (axial) 1000/ 2100 0.5 0.7 0.9

S15 Rotor- compressor bearing (axial) 1000/ 3200 0.10 0.2

S18 Compression ring- bearing cover turbine 1009/ 2004 0.20 0.35 0.5

S19 Compression ring- bearing cover compressor 1008/ 2003 0.20 0.35 0.5

*) by stepping over according work or spare part used

**) Measuring of bearing bore help a plug gauge( three points)

Admissible residual unbalance of rotor: 16 gmm per bearing

Admissible radial deviation of rotor: 0.020 mm (point E)

Admissible tightening torque of rotor nut: 360 (+5) Nm

Rotor pushed to the left for measuring the clearance S2, S15


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7.5 Process of maintenance

7.5.1 Compressor washing

(Every 25 - 50 operating hours)

Legend

1 Ball

valve

2 Water

tank

3 Water

piping

4 Air pip-

ing

5 Pipe

union

6 Design

with Silencer

7 Design with air intake housing

8 Pipe union

Work sequence:

1. Operate engine close to full load.

2. Open water tank (2), fill with clean water (no seawater), close water tank.

3. Open valve (1), wait for approx. 20 sec., close valve (1). The compressed air flows

through the air piping (4) via valve (1) into the water tank. The water is pressed through

the water piping (3) into the injection pipe, atomised by the air taken in and hits the com-

pressor blade with high speed.

• Perform cleaning with warm engine close to full load operation only.

• Continue to operate the engine for at least 10 minutes after cleaning.

• Do not wash before a pause of operation. Corrosion attach!

• Washing is ineffective in case of hardened deposits, thus perform

washing at regular intervals.


en 5 th


7.5.2 Turbine washing

Heavy fuel oil operation results in contamination and deposits on nozzle

ring and turbine wheel reducing the efficiency. Due to these deposits the

charge air pressure will be increased.

The washing intervals depend on the fuel quality and operating condi-

tions. That's why they must be adjusted based on the experience gained

during engine operation if necessary later on. The washing interval could

be adjusted from 50 to 600 hours.

The increase of charge air pressure could be used for adjusting the wash-

ing interval, which could adjusted within 50 to 600 hours.

Read and take down the charge air pressure and exhaust gas tempera-

tures at a reference point (at 75 % or 100 % of the output) before and after

washing to check the washing effect.

Legend (Example, could vary depending on engine installation)

1 Sanitary fresh water 5 Stop valve 9 Valve

2 Regulating valve 6 Wash-water piping 10 Escape funnel or sight glass

3 Fresh-water piping 7 Injector 11 Turbine outlet housing

4 Removable flexible tube 8 Connection for drain

2100 Turbine inlet housing


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Edition (04/04) en

Work sequence:

1. Connect the flexible tube (4) to fresh-water piping (3).

2. Reduce the engine output to approx. 15 % of its rating until the temperature after cylinder

has come down to its specified value. (see table)

3. Wait for approx. 10 minutes!

4. Open the valve (9) of the drain (8) (if present).

5. Open valve (2) and adjust the water pressure (see table).

6. Open stop valve (5) for approx. 30 seconds and close again.

7. Wait for approx. 3 minutes so that the injected water can evaporate.

8. Repeat steps 6. and 7. twice or three times.

9. Close the stop valve (5), valve (2) and the valve (9) of the drain.

10. Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes, increase

engine load slowly!

11. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations

which did not occur before.

12. Remove the flexible tube (4).

Operating values for turbine washing

Engine

output

Exhaust gas tem-

perature after cyl-

inder

Exhaust gas tempera-

ture

before / after the tur-

bine

Water pressure

(gauge)

Total

washing pe-

riod

max. 15% 300 – 330 °C 400 – 420 / <330 °C 150 – 200 kPa 3-4x 30 sec

• Hot exhaust gas can escape from the drain - Risk of burning!

• Continue to operate the engine for at least 30 minutes after cleaning.

• Do not wash before a stop of operation. Corrosion risk!

• Washing is ineffective in case of hardened deposits, thus perform washing at regular intervals.

• Pay attention also to instruction of the engine’s operating manual!


en 5 th


7.5.3 Stoppage the exhaust gas turbocharger

In case of damages at the TC especially at the rotor or at the bearings it

is recommended to put out of operation to avoid any further damages.

Pay attention to the operating instruction of the engine manufacturer.

During locking the exhaust gas turbocharger, limit the engine power in

order to prevent the exhaust gas temperature from exceeding admissible

values downstream of outlet valves.

Related chapter 7.5.7, 7.5.9, 7.5.10

Legend

2100 Turbine inlet housing, cpl.

2105 Hexagon-head nut

2106 Spring washer

Tools required

1 Open-jawed spanner A/F 18/19

1 Sealing disk (9709)

Initial condition: The turbocharger is

mounted on the engine.

Mass of the silencer approx. 70 kg

Mass of the air intake bend approx. 30 kg

Mass of the compressor housing approx. 120 kg

Mass of bearing housing with rotor approx. 140 kg

Work sequence:

1. Disassembly of the silencer (2800) /Intake housing complete (2900) according to chapter

7.5.7.

2. Loosen the charge air pipe at the compressor housing (2500).

3. Loosen water and air pipes for compressor washing.

4. Disassembly of the compressor housing (2500) according to the chapter 7.5.9.

5. Drain lubricating oil and cooling water, loosen the connections.

6. Disassembly of the bearing housing (2000) with rotor according to the chapter 7.5.10.

Use hoisting gear!

Be careful for dismounting work to avoid damage to the turbine blades.

7. Mount the sealing disk (9709) on the turbine housing (2100) and tighten with hexagonal

nuts.


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7.5.4 Bearing check

Related chapter 7.5.7 to 7.5.11

Radial bearing (3100/3200)

Thrust bearings (3200)

Initial condition: Compressor bearing (3200) and turbine bearing (3100) removed. (For

clearances, refer to chapter 7.4.)

Work sequence 1: Load-carrying sector of radial bearings

1. Clean bearings carefully!

2. Determine stop face width B(rad)!

3. Visual inspection!

Replace bearing, if :

• The load-carrying sector width B(rad) of the radial bearing has

reached 12 mm.

• Heavy dirt marks can be seen.

Determine the causes !

Work sequence 2: Load-carrying sector of axial bearings

1. Carefully clean the stop faces at both sides of theaxial bearings.

2. Determine the bearing stop face width B(ax).

3. Determine axial clearance S15.

4. Visual inspection!

Replace bearings, if :

• B(ax) is larger than 2/3 of the sliding face.

• The sliding faces reveal heavy dirt marks.

If material is deposited on the bearing faces of the shaft, a repair is re-

quired in an authorised workshop.

New bearing

Legend

D Bearing diameter R Radius at wedge face B(ax) Load-carrying sector width of thrust bearing B(rad) Load-carrying sector width of radial bearing

Tools required

1 Micrometer screw

1 Caliper gauge

Bearing after

longer

operation

Load-

carrying

sector

Wedge-shaped

sector

Sliding surface

Sliding surface


en 5 th


7.5.5 Disassembly of the complete turbocharger

Legend

2000 Bearing housing, cpl.


2201 Foot, compressor

2202 Foot, turbine

2300 Turbine outlet housing

2500 Compressor housing, cpl.

2800 Silencer

2900 Intake housing complete

Tools required

1 Socket spanner A/F 13



1 Open-jawed spanner A/F 22


1 Hoist / 2 Ropes

Mass of exhaust gas turbocharger is approx. 750 kg

Make sure to observe the following accident prevention regulations :


• load take-ups in hoisting gear operation (VBG9a)

Pay attention the pipings and sheathings!

General

Under normal conditions, the complete exhaust gas turbocharger has to be removed from the

engine for an inspection only. It is sufficient to dismantle individual subassemblies for main-

tenance and checks. While removing the exhaust gas turbocharger, pay attention to space

conditions in the engine room.

Work sequence:

1. Loosen sheathings from turbine housing (2100).

2. Loosen exhaust gas pipings from compressor inlet and outlet housings (2100/2300). Pay

attention of gaskets.

3. Loosen the pipings from compressor housing (2500), remove them, if required.

4. Drain lubricating oil and cooling water from TC, loosen cooling water inlet and outlet and

lubricating oil inlet and outlet.

5. Loosen water and air pipes for compressor washing.

6. Hang a rope in the eye bolt on the side of the bearing housing (2000) with shakles

7. Place a rope on the outlet housings (2300) and hoist.

8. Loosen and remove the bolts on the feets (2201/2202).

9. Lift TC and put down on a wooden plate. Save for tipping!


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7.5.6 Assembly of the complete turbocharger

Legend

2000 Bearing housing, cpl.


2201 Foot, compressor

2202 Foot, turbine


2500 Compressor housing, cpl.

2800 Silencer

2900 Intake housing complete

Tools required

1 Socket spanner A/F 13





1 Hoist / 2 Ropes

Molybdenum sulphide lubricant

Mass of exhaust gas turbocharger is approx. 750 kg

Make sure to observe the following accident prevention regulations :


• load take-ups in hoisting gear operation (VBG9a)

Pay attention the pipings and sheathings!

Work sequence :

1. Lift complete TC (refer to chapter 7.5.5) with 2 ropes by hoist and put it onto the engine

console. Pay attention to pipe connection !

2. Insert and tighten bolts at the foot.

3. Connect exhaust gas pipes to turbine inlet and outlet housing (2100/2300).

4. Attach sheathing.

5. Connect charge air piping.

6. Connect cooling water inlet and outlet as well as lubricating oil inlet and outlet.

7. Connect water and air pipes for compressor washing.

8. Tighten bolts at foot of TC and all connection pipes.

After having installed the TC, check that the assembly is free of stresses

and forces. Retouch pipings, if required.

9. Supply lubricating oil and cooling water to TC and check all flanged connections for leak-

age's.

Use proper gaskets for pipe joints only. Apply molybdenum sulphide lu-

bricant to connecting bolts of exhaust gas pipes prior to installation.


en 5 th


7.5.7 Assembly and disassembly of silencer or air-intake housing

Legend



2800 Silencer

2900 Air-intake housing

9001 Magnetic screw

9002 Inductive speed sensor

A Lock nut

Tools required


1 rope

2 shackles

Mass of silencer approx. 70 kg

Mass of air-intake housing approx. 30 kg

Work sequence 1 : Disassembly of silencer/ air-intake housing

1. Loosen the cabel of the inductive speed sensor (9002)

2. Hang the silencer (2800) with a rope and two shackles on the hoist or the rope around the

intake housing (2900)

3. Loosen hexagon nuts of the V-profile clamp (2517), remove from one side the hexagon

nuts.

4. Remove the tension tape from the flange.

5. Pull-off silencer/ air-intake housing in axial direction from compressor housing (2500) and

put it onto a wooden base.

Work sequence 2: Assembly of silencer/ air-intake housing

1. Hang the silencer (2800) with a rope and two shackles on the hoist or the rope around the

intake housing (2900)

2. Slide on silencer/ air-intake housing in axial direction onto the compressor housing.

3. Round the V-profile clamp (2517) around the flange, assembly hexagon nuts and ttighten

with 25-30 Nm.

4. The inductive speed sensor (9002) is screwed to the limit and then unscrewed by one turn

(distance 1 - 1,5 mm). After disassembly inductive speed sensor (9002) is secured with

the lock nut (A). Connect the cabel.


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Edition (04/04) en

7.5.8 Cleaning the silencer

(Every 250 operating hours)

Related chapter 7.5.7

Legend:

2800 Silencer

2813 Filter mat

2815 Tension tape

2816 Punched plate

A Possible connection for maintenance

indicator

B Felt coat

General

In most of the cases, merely the filter mats have to be cleaned. For this purpose, the silencer

may stay at the exhaust gas turbocharger.

The given maintenance interval of 250 running hours is just a mean guide value, since the

accumulation of dirt in the filters and the pressure drop resulting therefrom are largely de-

pendent on the environment. For operation under extreme conditions, it is recommended to

add a maintenance indicator (water gauge) signalling the right moment for cleaning.

This indicator shall be adjusted so as to give the cleaning signal when a vacuum of

app. 100 mm w.g. is reached at point A intended for mounting (e.g. a MANN maintenance in-

dicator for air filters, max. 200 mm w.g. = 20 mbar).

Work sequence : Cleaning the filter mats and felt coat

1. Open the tension tapes(2815) and pull the filter mat (2813) over the silencer (2800)

against the flange. The punched plate (2816) stays by the silencer

2. Lay filter mat (2813) into clean liquid (diesel fuel, perchlorethylene) for approx. 10 hours.

Subsequently, rinse in the liquid and externally clean by a soft brush, stub out and dry the

filter mat.

3. Take off the punched plate (2816) means of loosen from three bolt (M6). (Only after

heavy soiling of the felt coat.(B)).

4. Clean the dry contaminated felt coat with a brush or oily contamination with diesel fuel

wipe up. Do not use water!

5. Install filter punched plate (2816) and dryed filter mat (2813) in reverse order. Before

screw the punched plate press it at the sides of egde.

Pay attention to applicable accident prevention regulations (handling of

hazardous, volatile, combustible solvents) and fire protection regula-

tions (DIN 14096). Cleaning by a P3-solution or trichlorethylene is prohib-

ited. If other solvents are used, check the compatibility with the filter ma-

terial.

In case of ship operation, pay attention to the regulations of classifica-

tion societies with regard to washing liquids.

If the felt coatings of the silencer are heavily contaminated, they have to

be replaced. For this purpose, disassemble the silencer according to

chapter 7.5.7. The silencer has to be overhauled by an authorised work-

shop.


en 5 th


7.5.9 Assembly and disassembly of the compressor housing

Related chapter 7.5.7

Legend

1002 Compressor impeller

2000 Bearing housing

2014 Hexagon-head bolt

2015 Spring washer

2201 Foot, turbine


2512 O-Ring


5001 Compressor diffuser

5002 Silicon cord

5003 Cylindrical screw

5004 Stop bushing

Tools required




2 ropes /4 shackles

Mass of compressor

housing

approx. 120 kg

Work sequence 1: Disassembly of the compressor housing

1. Remove air and water piping for compressor washing.

2. Hang compressor housing (2500) with a rope and shackles on the hoist.

3. Mark the position of compressor housing. Loosen the V-profile clamp (2517) and take it

away.

4. Pull off the compressor housing (2500) and the compressor diffuser (5001). Do not tilt !

5. Remove compressor diffuser (5001).

Work sequence 2: Assembly of the compressor housing

1. Change silicone cord (5002) at the rear of the compressor diffuser (5001).

2. Insert compressor diffuser (5001) and tight it on with cylindrical screws (5003) and stop

bushings (5004).

3. Put on the o-ring (2512) on the bearing housing (2000).

4. Hang compressor housing (2500) with a rope and shackles on the hoist.

5. Carefully attach compressor housing (2500) in axial direction to the bearing housing. Pay

attention to housing position !

6. Hang the V-profile clamp (2517) around and fasten the hexagon nuts bothside with 25 to

30 Nm). Check the clearance S1!

7. Connect water and air piping for compressor washing to compressor housing (2500).

Make sure not to damage the compressor impeller (1002) during disas-

sembly and assembly of the compressor housing.


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7.5.10 Assembly and disassembly of the bearing housing with rotor

Related chapter 7.5.7, 7.5.9

Legend

1000 Rotor cpl.

2000 Bearing housing cpl.

2100 Turbine inlet housing cpl.

2104 Stud bolt

2105 Hexagon nut

2106 Spring washer

2201 Foot, turbine side

2300 Turbine outlet housing cpl.

Tools required


1 Hoist

1 Rope with Shackle

2 Eye bolts

Initial condition: Compressor housing, silencer and all pipings are removed.

Mass of bearing housing with rotor approx. 110 kg

Mass of turbine inlet housing approx. 120 kg

Mass of turbine outlet housing approx. 153 kg

Work sequence 1: Disassembly of bearing housing with rotor

1. Assemble two blank flange with eye bolt on side of the bearing housing.

2. Join the bearing housing (2000) on the hoist.

3. Loosen the hexagon nuts M10 (2105) of the spring washers (2106).

4. Loosen the screws from the foot (2201) from the motor support.

5. Forcing-off uniformly the bearing housing (2000) with forcing screw. Are the connection with carbon glued, net with diesel fuel and wait a minute.

6. Move careful the bearing housing (2000) out of the turbine housing (2100) in axial direc-tion. Put it on a wooden plate.

Be careful for mounting and dismounting work to avoid damage to the

turbine blades.

Work sequence 2 : Assembly of bearing housing with rotor

1. Clean the connecting flange between bearing housing and turbine housing from combus-tion residues by fine abrasive cloth. Subsequently apply molybdenum sulphide lubricant to flange.

2. Fasten bearing housing by the rope to the hoist and lift it to the turbine housing.

3. Carefully insert the bearing housing under consideration of the housing position into the turbine housing; tighten bolts.

4. Tighten the screws from the foot (2201) to the motor support.

5. Check rotor for contact by slightly rotating it !


en 5 th


7.5.11 Disassembly of rotor complete

Related chapter 7.5.5 to 7.5.10

For the disassembly of the rotor mount the bearing housing on a rack or

clamp it in a vice (with soft-material jaws).

Mass of bearing housing with rotor approx. 150 kg.

Mass of rotor cpl. 30 kg

Legend Tools required

1000 Rotor cpl. 1001 Shaft 1 Socket spanner A/F10

1002 Compressor impeller 1003 Spacer 1 Open-jawed spanner A/F10

1004 Thrust ring 1005 Rotor nut 1 Open-jawed spanner A/F13

1007 Conical spring washer 1007 Feather key 1 Open-jawed spanner A/F18/19

1008 Plain compression

ring, turbine


ring, compresssor

1 Open-jawed spanner A/F24

2003 Bearing cover, comp. 2004 Bearing cover, turb. 1 Locking device (9705)

2005 Gasket, turbine 2007 Gasket, compr. 1 Extractor for thrust ring (9707)

2009 Labyrinth cover 2011 Hexagon-head bolt 2 Eye bolts (9708)

2012 Locking plate 2013 Hexagon nut 1 Torque spanner 400 Nm

A/F36

2014 Hexagon-head bolt 2015 Curved spring washer

3101 Turbine bearing 3102 Stud bolt

3201 Compressor bearing 3203 Hexagon-head bolt

3204 Locking plate 4000 Turbine nozzle ring

cpl


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Edition (04/04) en

Work sequence 1: Disassembly of the compressor impeller (1002)

1. Mount on the locking device (9705) of rotor and connect on the flange of bearing housing.

Loosen rotor nut (1005) with torque spanner A/F 32.

2. Loosen the rotor nut (1005) and remove it with the spring washer (1006).

3. Heat the hub of the compressor impeller (1002).

Temperature 150 °C max.

• Use burner flame with excessive gas.

• Uniformly heat the impeller hub range.

• Protect shaft thread by pipe against heat.

4. Pull off the compressor impeller (1002) from the shaft.

The installation position of the compressor impeller is marked with re-

gard to the shaft.

Work sequence 2: Disassembly of the compressor bearing (3201)

1. Unlock and loosen the hexagon head bolts (2011) and remove the bearing cover of com-

pressor (2003). The plain compression rings of compressor are located in the bearing

cover (1009). Pay attention to the gasket (2005) !

2. After cooling the shaft (1001) pull off spacer (1003).

3. Unlock and loosen the hexagon head bolts (3203) and remove the compressor bearing

(3201) with the aid of forcing screws.

4. Move the extractor for thrust ring (9707) on the shaft (1001) and turn it in the thrust ring

(1004).

5. Pull thrust ring (1004) from the shaft (1001).

Work sequence 3: Disassembly of the turbine bearing (3101)

1. Pull shaft (1012) carefully out of bearing housing.

2. Remove turbine nozzle ring (4000) and the labyrinth cover (2009) after having loosened

the four hexagon nut (2013).

3. Screw off bearing cover of turbine (2004). Pay attention to the gasket (2007) !

4. Remove the turbine bearing (3101) from the bearing housing. Close openings at bearing

housing in order to prevent dirt from reaching the bearing compartment and the oil bores.

5. Remove the plain compression ring of the turbine (1008) from the shaft.

Now, the turbocharger is disassembled. Check, evaluate and clean parts

according to chapter 7.2 and 7.3.


en 5 th


7.5.12 Installation of rotor complete

Related chapter 7.5.5 - 7.5.11

For installing the rotor mount the bearing housing on a mounting rack.

Mass of bearing housing with rotor approx. 150 kg.

Mass of rotor complete 30 kg.

Legend Tools required

1000 Rotor cpl. 1001 Shaft 1 Socket spanner A/F10

1002 Compressor impeller 1003 Spacer 1 Open-jawed spanner A/F10

1004 Thrust ring 1005 Rotor nut 1 Open-jawed spanner A/F13

1007 Conical spring washer 1007 Teather key 1 Open-jawed spanner A/F18/19


ring, turbine


ring, compresssor

1 Open-jawed spanner A/F24

2003 Bearing cover, comp. 2004 Bearing cover, turb. 1 Locking device (9705)

2005 Gasket, turbine 2007 Gasket, compr. 2 Eye bolts (9708)

2009 Labyrinth cover 2011 Hexagon-head bolt 1 Torque spanner 400 Nm

A/F36

2012 Locking plate 2013 Hexagon nut 1 Feeler gauge

2014 Hexagon-head bolt 2015 Curved spring washer

3101 Turbine bearing 3102 Stud bolt

3201 Compressor bearing 3203 Hexagon nut

3204 Locking plate 4000 Turbine nozzle ring

cpl


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Edition (04/04) en

Prior to the assembly, check the cleanliness of the bearing housing, of

oil conducting ducts and of the sealing air piping. Pay attention to the

specifications of chapter 7.4 (Clearance sheet) during assembly.

Work sequence 1: Installation of the turbine bearing and shaft into the bearing housing

1. Insert turbine bearing (3101) with the flattened flange side at the bottom; tighten and lock.

Pay attention on the assembly position. The stud bolt (3102) goes upper

in the groove (twisting securing)!

Always assembly turbine bearing with stud bolt!

2. Insert and tighten turbine side bearing cover (2004) with original gasket (2007). If the gas-

ket was damaged during disassembly, insert a gasket of the same thickness, since oth-

erwise the clearance S18 is changed and has to be reset. The clearance is measured af-

ter installation of the compressor bearing.

3. Attach labyrinth cover (2009) onto the centring of the bearing housing.

4. Insert the plain compression ring of the turbine (1008) into the shaft groove.

5. Apply clean oil onto turbine bearing and slight the shaft carefully into the bearing. Be es-

pecially careful while introducing the plain compression rings into the bearing cover.

Work sequence 2: Installation of the compressor bearing and completing the rotor

1. Apply oil to the thrust ring (1004) and slide it according onto the shaft. Pay attention on the

assemly position.

2. Wet the compressor bearing (3200) with oil. Move it onto the shaft with its flat flange side

pointing downward and fasten it with hexagon-head bolts (3203) and locking plates

(3204).

3. Check clearance S18 : (if components are replaced)

Press shaft from the turbine side to the bearing housing. Put dial gauge onto the shaft end

and adjust it to zero. Loosen fastening bolts (3203) of the compressor bearing and force

compressor bearing (3201) by approx. 1 mm. Press shaft towards compressor side. The

shaft is moved by the clearance S18; correct by changing the thickness of the bearing

cover gasket (2007), if required.

4. Check clearance S13 : by means of feeler gauge.

5. Mount the locking device (9705) to the turbine wheel and fasten it to the flange of the

bearing housing.

6. Slide spacer (1003) onto the shaft up to the shoulder. Pay attention the assembly position!

7. Check clearance S19 : Determine the distance between external face of compressor

side bearing cover and the colour of the supported plain compression ring by a caliper

gauge. After having attached the bearing cover of the compressor (2003), measure the

distance between external face of bearing cover to the spacer by caliper gauge, while

pressing the shaft towards the compressor. The difference of the two dimensions is the

clearance S19. The correction is made by changing the thickness of the gasket at the

bearing cover (2005).

8. Install bearing cover, compressor (2003) and insert the plain compression rings, com-

pressor (1009) with staggered joints.


en 5 th


9. Heat compressor impeller (1002) (max. 150 °C) and slide it onto shaft.

The mounting marks at shaft (1001) and compressor impeller (1002) have

to match.

10. Grease slightly the thread by molybdenum lubricate. Mount spring washer (1012) and

rotor nut (1005).

11. When the compressor impeller has cooled down, tighten the rotor nut (1005) by torque

spanner with 50 Nm. Mark the position of rotor nut.

Lock rotor by means of locking device (9705). Use universal joint in any

case !

12 Tighten again the rotor nut (1005) with 360 Nm. The reached turning angle of the rotor

nut (1005) should be 75 to 90 degree otherwise dismantle rotor nut (1005) and spring

washer and repeat point 10 to 12.

13. Bolt turbine nozzle ring (4000) with labyrinth cover (2009) to bearing housing.

14. Check rotor for smooth running : Apply 40 cm3 oil into the oil guide bore in the bear-

ing housing and slowly turn rotor. The rotor has to be turned easily without sensible re-

sistance and has to make some rotations after having been pushed.

15. Check truth of rotor running : Apply dial gauge to shaft end at compressor side and

measure the radial run-out of the rotor while slowly turning the rotor. The radial run-out

is specified in the clearance sheet, chapter 7.4

Now the bearing housing with rotor is assembled and can be completed according to chapter

7.5.5 to 7.5.10.


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7.5.13 Disassembly turbine outlet housing

Legend

2101 Turbine inlet housing

2302 Outer diffuser


2304 Inner diffuser

2306 Countersunk screw

2307 Stud bolt

2308 Stud bolt

2309Hexagon nut

2310 Spring washer

2313 Hexagon-head bolt

2314 Spring lock washe

Tools required



1 Socket spanner A/F 18/19

1 Hoist with ropes

Initial condition: Exhaust gas manifold and drain pipe for turbine washing are diassembled

from the turbine outlet housing.

Work sequence :

1. Removed the sheathing.

2. Hang the turbine outlet housing (2303) with a rope on the hoist.

3. Loosen hexagon-head nut (2309) with the curved spring washer (2310).

4. Forcing-off uniformly the turbine outlet housing (2303) with forcing screws.

5. Move careful axial the turbine outlet housing (2303) from turbine inlet housing (2101) and

put it on a wooden plate.

6. Loosen the hexagon-head bolt (2313) and removal the inner diffuser (2304).

7. Loosen the 2 hexagon-head bolt (2306) and removal the outer diffuser (2302) from the

turbine outlet housing (2102).


en 5 th


8 SPARE PARTS AND TOOLS

8.1 General

The following specification required for the order :

1. address of orderer

2. type of turbocharger

3. variant number (refer to to type plate on Page 2)

4. works number (refer to type plate on Page 2)

5. part number and designation

6. shipment address

The optionally supplied spare parts books contain the selection of the most important ware

parts as well as a corresponding list.

A certain selection of tools can be ordered, too. These are tools required to maintain and re-

pair the exhaust gas turbocharger and not included in the basic equipment of every work-

shop.


Page 46 of 53 5 th

Edition (04/04) en

8.2 Spare parts

8.2.1 Bearings

Part

number

Quantity Designation

3100 1 Turbine bearing

3200 1 Compressor bearing


en 5 th


8.2.2 Gaskets

Part

number


1008 1 Plain compression ring, turbine

1009 1 Plain compression ring, compressor

2005 1x2 Gasket , compressor (S=0,5/0,2)

2007 1x2 Gasket , turbine (S=0,5/0,2)

2020, 2312 1 Gasket

2021 1 Gasket

2022 3 Gasket A27x32 DIN 7603

2511 2 Gasket A17x21 DIN 7603

2513 3 Gasket A10x14 DIN 7603

5002 1 Silicon cord


Page 48 of 53 5 th

Edition (04/04) en

8.2.3 Locking elements

Part number Quantity Designation

2012, 3204 18 Locking plate 6,4 DIN 463

2014 4 Locking plate 8,4 DIN 463

2106, 2310 24 Curved spring washer 12 DIN 137

2316, 2509 11 Curved spring washer 12 DIN 137

2314 3 Spring lock washer B12 DIN 127

2106

2310

2316

2509

2314

2012

2014

3204


en 5 th


8.3 Tools

Part number Quantity Designation

9705 1 Locking device

9706 1 Plug scew with gasket for oil supply

9707 1 Extractor for thrust ring coplete

9709 1 Cover plate, not in the toolbox, optional order


Page 50 of 53 5 th

Edition (04/04) en

9 SECTIONAL DRAWING


en 5 th


10 LIST OF COMPONENTS

Part

number


1000 1 Rotor, cpl.

1001 1 Shaft

1002 1 Compressor impeller

1005 1 Rotor nut

1003 1 Spacer

1004 1 Thrust ring

1006 1 Conical spring washer

1007 2 Feather key

1008 1 Plain compression ring, turbine

1009 1 Plain compression ring, compressor

2000 1 Bearing housing, complete

2001 1 Bearing housing

2003 1 Bearing cover, compressor

2004 1 Bearing cover, turbine

2005 1 Gasket , compressor 0,2 mm

2005 1 Gasket , compressor 0,2 mm

2007 1 Gasket , turbine 0,2 mm

2007 1 Gasket , turbine 0,5 mm

2009 1 Labyrinth cover

2011 12 Hexagon-head bolt

2012 12 Locking plate

2013 4 Hexagon-head screw


2015 7 Curved spring washer

2020 1 Gasket

2021 1 Gasket

2022 3 Gasket

2100 1 Turbine inlet housing, cpl.

2101 1 Turbine inlet housing

2104 12 Stud bolt

2105 12 Hexagon-head nut


2107 *) Screw plug

2108 *) Gasket

*) 1 x per gas intake casing


Page 52 of 53 5 th

Edition (04/04) en

Part Quantity Designation

2200 1 Foot, complete

2201 1 Foot, compressor

2202 1 Foot, turbine

2300 1 Turbine outlet housing, complete

2302 1 Outer diffuser

2303 1 Turbine outlet housing

2304 1 Inner diffuser

2306 2 Countersunk screw

2307 8 Stud bolt

2308 4 Stud bolt

2309 12 Hexagon nut


2312 1 Gasket


2314 3 Spring lock washer



2500 1 Compressor housing, complete

2501 1 Compressor housing

2510 2 Screw plug

2511 2 Gasket

2512 1 O-Ring

2513 3 Gasket

2514 2 Stud bolt

2515 2 Hexagon nut

2516 1 Cylindrical grooved pin

2517 2 V-profile clamp

2800 1 Silencer complete

2813 1 Filter mat 20x265x1950 mm

2815 2 Tension tape

2816 1 Punched plate


en 5 th


Part Quantity Designation

2900 1 Intake housing complete

3100 1 Turbine bearing complete

3101 1 Turbine bearing

3102 1 Zylinderstift

3200 1 Compressor bearing complete

3201 1 Compressor bearing


3204 6 Locking plate

4000 1 Turbine nozzle ring complete

4001 1 Turbine nozzle ring

5000 1 Compressor diffuser complete

5001 1 Compressor diffuser

5002 1 Silicon cord

5003 2 Cylindrical screw

5004 2 Stop bushing

8000 1 Sheathing

8001 1 Sheathing , turbine inlet housing

8002 1 Sheathing , turbine outlet housing

9000 Compenents parts

9001 1 Magnetic screw

9002 1 Inductive speed sensor

9003 1 Speed indicator

Charge Air Cooler-

C5.05.06.30.17.21

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en / 14.12.2000 FD020020 1/1

�

Charge Air Cooler

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engine operating instructions type m25maytau.ut.edu.vn/userfiles/files/mak-m25.part3.pdf · manual...

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