installation guide for off-line

7/30/2019 Installation Guide for Off-line

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Off-line PMI System

Pressure Analyser

Installation Guide


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Installation Guide

Off-line PMI System

Pressure Analyser

Version 2.3

About this Guide

This Installation Guide applies to MAN Diesels O-line PMI System. It providesinstallation and commissioning personnel with technical advice and instructions

on installing, adjusting and checking the system to make it ready or use by the

technical personnel responsible or the daily operation o the system.

The scope o supply o the O-line PMI System hardware varies according to

the actual engine design specication and whether the system is delivered or a

new engine or a retrot project. The components o typical O-line PMI System

congurations are outlined in chapter 1.2 The Basic System.

For instructions on mounting and connecting a crankshat pickup or triggering

the system, consult the separate Mounting Guide belonging to the particular

pickup which is to be used with the system.

For guidance on the use o the system or cylinder pressure measurements on

diesel engines, a common Users Guide is provided with the system.

The supply, distribution and use o the PMI System and Data media, including

System Documentation, are subject to your acceptance o the Standard Condi-

tions o Licence which are supplied in the Sotware Package containing the PMI

System.

Taking the PMI System in use will indicate your acceptance of these condi-

tions.

Windows is a trademark o the Microsot Corporation, U.S.A.Trademarks

Conditions of Use


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MAN B&W Diesel A/STeglholmsgade 41

DK- 450 Copenhagen SV

Denmark

Telephone +45 33 85 11 00

Telefax +45 33 85 10 30

[email protected]

www.mandiesel.com

Copyright MAN Diesel A/S. Reg. No. 39 66 13 14

Reproduction permitted provided source is given

Subject to modication in the interest of technical progress3520-0006-00ppr May 2007


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Table

ofContents

1. Before You Begin

1.1 About this Guide ............................................................................................8

General Overview ............................................................................................8

PMI On-line Help ...........................................................................................8

Text Conventions .............................................................................................8

1.2 The Basic System ...........................................................................................9

2. Hardware Installation

2.1 General ........................................................................................................ 14

2.2 Intermediate/Freq. Divider & Junction Boxes ............................................. 16

2. Converter Box ............................................................................................. 16

2.4 Cable and Power Checks ............................................................................ 17

2.5 Engine Address & Pickup TDC Checks ...................................................... 19

3. Commissioning the System

.1 Installing the PMI Sotware ......................................................................... 22

.2 Checking Engine Registration .................................................................... 22

. Setting Up Communication ......................................................................... 24

.4 Trigger and TDC Test .................................................................................. 26

.5 System Reerence Measurements .............................................................. 28

0-Diagram Measurements ........................................................................ 28

E-Load Measurements .............................................................................. 29

.6 Checking & Editing Reerence Measurements ........................................... 0

.7 Technical Assistance ................................................................................... 4

Index

Contents


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Chapter1BeforeYouBegin

Chapter 1

Before You Begin

Welcome to MAN Diesels, O-line PMI System. It is designed to provide engi-

neers and service sta on board ship and at power plants with a computerised

tool or cylinder pressure measurements and analysis on MAN B&W two and

our stroke diesel engines.

It consists o a pressure transducer, a PMI Controller and a trigger system with

crankshat pickup which can be operated using an IBM compatible PC onwhich the PMI System sotware is installed. The system is supplied with the

necessary hardware and sotware, and is designed to automatically calculate,

display and log measurement results.

In this Chapter

About this Guide ................................................................................................... 8

General Overview ........................................................................................... 8

PMI On-line Help .......................................................................................... 8

Text Conventions ............................................................................................ 8

The Basic System ................................................................................................. 9


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Chapter1BeforeYou

Begin

1.1 About this Guide

1.1.1 General Overview

This Installation Guide provides inormation about the initial preparations and

procedures necessary or installing the hardware and sotware o the PMI Sys-

tem on board ship and at power plants, as well as or commissioning the sys-

tem.

The guide includes the ollowing chapters:

Chapter 1 Before You BeginThis is the chapter which you are now reading. It provides brie details about

the contents o this Guide and how to obtain on-line help with the Application

Sotware o the system. In addition, a short description o the PMI System and

its main components is included, explaining what you need to know about thesystem beore installing it.

Chapter 2 Hardware InstallationProvides instructions and advice on how to mount, connect and adjust the

hardware o the PMI System. For inormation about the pickup device which is

to be used or triggering the system, consult the separate Mounting Guide or

the device.

Chapter 3 Commisioning the SystemExplains how to install the PMI sotware on your PC and start the system. Also,

details are given about how to make reerence measurements or setting up the

PMI System.

Wiring diagrams and drawings o the system hardware are supplied in a sepa-

rate older which is included with this and the other documentation provided.

For inormation and instructions about operation and use o the system or cyl-

inder pressure measurements, please consult the separate Users Guide which

is provided.

1.1.2 PMI On-line Help

To help you in hands on use o the PMI System, its application sotware in-

cludes on-line help inormation. This is available directly on your PC whenever

using it together with the PMI System. It is activated by pressing the unctionkey F1 on the keyboard.

1.1.3 Text Conventions

Settings & Values:The values and settings shown in the displays and stated in accompanying text

throughout the guide, are included as examples only.

Menus & Menu Commands:Reerences to specic commands that are given in menus and dialogue boxes

are indicated in single quotes, e.g. Open Engine in the File menu.

Commands depicted with a leader, i.e. Options ..., open a selection dialogue


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which oers a number o options to choose rom, while those without a leader,

i.e. Print, immediately initiate the particular action designated.

1.2 The Basic System

A schematic o the O-line PMI System is shown in Fig. 1-1.

Junction Box

PMI Controller Pressure Transducer

Crankshaft Angle Encoderor Position Pickup

Power Supply

Intermediate orFrequency Divider

Box

TwoStrokeDiesel Engine

LEDIndicator

Personal Computerwith PMI System

Application Software

Engine ControlRoom

Converter Box

Fig. 1-1 Schematic of the Off-line PMI System (not to scale)

The o-line version o the system employs a high-perormance piezo-electric

transducer o well proven design which is mounted on the cylinder head cover

rom which the cylinder pressure is measured.

To obtain a pressure indication which accurately describes the change in cylin-

der pressure throughout each work cycle o an engine, the pressure detected

by the transducer must be synchronised with the motion o the engine. For this

purpose the PMI System is designed to be used with dierent types o crank-shat pickup, or example:

Angle Encoder: A sealed unit containing an optically encoded disc, coupled

to the crankshat o the engine.

LE-Pickup: A pair o Light Emitting Sensors which detect the light refected

rom a continuous strip o zebra tape bonded on the drive shat o the engine.

PD-Pickup: A pair o Proximity Detectors which are based on inductive pick-

ups. They detect the rotation o a TDC marker and the individual teeth o a

gear wheel or a specially designed trigger ring at the end o the crankshat.


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Chapter1BeforeYou

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Pickup Engine Type

& Layout

Mounting Maintenance

Angle

Encoder

Main & Aux. Engineswithout PTO

Engine crankshat viafexible coupling

Sealed unit requiringlittle or no maintenance

LE-Pickup

& Zebra Tape

Main & Aux. Engineswith / or without PTO

Zebra tape bondedto ree section o en-gine drive shat

Zebra tape must occa-sionally be cleaned

PD-Pickup Main & Aux. Engineswith / or without PTO

Operates rom gearwheel

Immune to mostdisturbances

Table 1-1 Crankshaft Pickups for use with the PMI System

Divider Box

24V DC

PDPickupBox

To Next Engine

Junction Box

Gear Wheel orTrigger Ring

IntermediateBox

Junction Box

PMIController

PressureTransducer

LEPickupBox

Zebra Tapeon Drive Shaft

IntermediateBox

Junction Box

Engine

Crankshaft

Angle Encoderplus

flexible coupling



ConverterBox

Engine Room

Control Room

24V DC

24V DC

Engine No. 3

Engine No. 2

Engine No. 1

Fig. 1-2 Connection of the PMI System with an Angle Encoder, Light Emitting Pickup and/or Proximity

Pickups


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All types o pickup produce a train o electrical pulses which are used to detect

the absolute position o the crankshat. In addition, they produce a separate

pulse which is used to synchronise the PMI System with the TDC position o

Cylinder No. 1.

As indicated in Table 1-1 the choice o appropriate crankshat pickup and its

connection with the PMI System (see Fig. 1-2), depends on the engine layout.

With the Angle Encoder a precise number o crankshat angle/position pulses

are generated (e.g. 1024) per revolution o the crankshat, while with the other

sensors the number o pulses depend on the diameter o the drive shat or the

number o teeth on the turning wheel or trigger ring on the engine.

The crankshat pickup pulses rom the engine are rst ed to either an Interme-

diate Box or Frequency Divider (depends on whether engine is a two-stroke or

our-stroke type) and then on to a Junction Box. From there they are relayed to

the portable PMI Controller which is attached to the pressure transducer and

serves as the systems remote nerve centre or controlling measurements.

All o the equipment is powered by an external 24 V DC source and except or

the pressure transducer and portable PMI Controller, are mounted as a perma-

nent xture in situ with the engine.

For subsequent calculation, display and storage o the data using the PC, the

sotware supplied with the PMI System must be installed.


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Chapter 2

Hardware Installation

This chapter explains how to mount, connect and adjust the hardware o the

PMI System.

For inormation about mounting the crankshat pickup which is to be used or

triggering the system, consult the separate Mounting Guide that is supplied

with the device.

In this Chapter

General ............................................................................................................... 14

Intermediate/Freq. Divider & Junction Boxes ................................................... 16

Converter Box .................................................................................................... 16

Cable and Power Checks ................................................................................... 17

Engine Address & Pickup TDC Checks ............................................................ 19


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The connection o the hardware used by the PMI System, including a Crank-

shat Pickup, is illustrated in Fig. 2-1.

PMIController

PressureTransducer

Intermediate (orFreq. Divider)

Box

Junction Box

Crankshaft PickupSee separate

Mounting Guide



ConverterBox

Control Room

24V DC

(PMI - 1)*

(PMI - 5*)

(PMI - 3*(or 9)*

(PMI - 2 (or 8)

(PMI - 6)

(PMI - 4)

* Item not included

To Junction Boxof Next Engine

(PMI - 7)*

Fig. 2-1 Connection of PMI System with an angle Encoder

To permit easy identication o the appropriate cables used or connecting theequipment, the cables are numbered rom PMI-1 through to PMI-1 as indicat-

ed above. A brie explanation o each o these cables is given below:

PMI1: 24V DC Power Cable to Junction Box: Item not included. Can

be made using a 1 x 2 x 0.75 mm2 screened cable.

PMI2 / 8: Pickup Cable to Intermediate/Freq. Divider Box: 1.5 m long

xed screened cable supplied with the pickup.

PMI3: Intermediate Box: Item not included. Can be made using a 4 x

(2+1) x 0.5 mm2 multi screened cable.

PMI4: Converter Box Cable to PC: 1.5 m long, xed cable suppliedwith Converter. Has Sub-D9 emale plug or connecting to ree

Communication Port on PC.

PMI5: Converter Box Cable to Junction Box: Item not included. Can

be made using a 4 x 2 x 0.5 mm2 screened cable. Max. overall

length o PMI-5 including PMI-7 must not exceed 1200 m or

RS422 operation.

PMI6: PMI Controller Box Cable to Junction Box: Fixed cable sup-

plied with PMI Controller. Has multipin connector or connect-

ing Junction Box. Either 8 m or 15 m long cable supplied, de-

pending on engine size.


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PMI7: Junction Box Cable: Item not included. Is used or intercon-

necting Junction Boxes in multiple engine installations. Can

be made using a 4 x 2 x 0.5 mm2 screened cable. Max. overall

length o PMI-5 including PMI-7 must not exceed 1200 m or

RS422 operation.

PMI9: Freq. Divider Box Cable to Junction Box: Item not included.

Requires 2 x 2 x 0.5 mm2 screened cable, but can be made us-

ing 4 x (2+1) x 0.5 mm2 screened cable.

PMI10 / 11: Terminal/Freq. Divider Box to Pick-up: 5 m cable tted with

connector or pickup. Supplied with the pickup.

PMI12 Terminal Box to Junction Box: Item not included. Requires 2 x

2 x 0.5 mm2 screened cable, but can be made using 4 x (2+1) x

0.5 mm2 screened cable.

PMI13: Junction Box A1 to Junction Box: Item not included. Requires

1 x 2 x 0.5 mm2 screened cable as minimum

The cable connections are shown in the wiring diagrams provided with the PMI

System.

Important: To ensure reliable operation o the PMI System its communication

and power cables must not be routed directly alongside other power cables. I

PMI cables have to be routed over power cables then they should cross at 90.

Cables not included with the PMI System, can be ordered rom MAN Diesel.

For specications and electrical data o the individual cables, please reer tothe installation drawings and wiring diagrams provided with the PMI hardware.

NOTE


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llation To prevent damage, wait until section 2.4 in this chapter beore applying

power to the system.

2.2 Intermediate/Freq. Divider & Junction Boxes

The Junction Box is to be mounted on the indicator side on the top section o

the engine with the Intermediate Box or Freq. Divider Box close by the Crank-

shat Pickup (1.4 m max.). Make sure that the Junction Box is located not more

than 7 metres or 14 metres (depends on length o PMI Controller cable sup-

plied) away rom the urthest cylinder cock, as otherwise it will be out o reach

o the Pressure Transducer.

14

14

52

6 6238

14

14

6

52

6113Mounting Holes

2 x 4.8 for

M4 Screws

Mounting Holes

2 x 5 for

M4 Screws

2335

52

42

Junction Box

Intermediate, Freq.

Divider or Converter

Box

Fig. 2-2 Location of the mounting holes in the PMI Junction Box, Intermediate Box, Freq. Divider Box

and Converter Box

The diverse boxes have two holes or bolting them to a fat, vibration-ree sur-

ace. The Junction Box is to be bolted on a raised support with it connectors

protruding over one side o the support (see Fig. 2-2), so as to allow room or

astening the multipin connector o the PMI Controller.

2.3 Converter Box

Ater connecting the Crankshat Pickup, Intermediate Box and Junction Box,

etc., the output o the Junction Box should be coupled to the Converter Box.

CAUTION


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ation

The Converter Box must be mounted close to the PC which is stationed either

in the engine control room or in some other convenient location. It is supplied

with a 1.5 metre long integral cable (PMI-4) with Sub-D9 emale plug which

should be astened to one o the ree communication ports on the PC.

5-IMPelbaC4-IMPelbaC

1 2 3 4 5 6 7

To

Junction Box

To PC

Com. Port

5 V DC

1 7

Fig. 2-3 Location of the PMI Systems Converter Box. The 5 V DC power input is

on terminals 5 and 6

For connecting the Converter Box to the Junction Box, the cable PMI-5 is used.

This is shown in the wiring diagrams provided with the PMI System and can be

made up using a 4 x 2 x 0.5 mm2 screened cable. The maximum overall length

o the cable, including the extension cables PMI - 7 i more than one JunctionBox is to be installed, must not exceed 1200 m.

2.4 Cable and Power Checks

Beore applying power to the entire system the ollowing power check and

power start up procedure should be carried out to reduce risk o damaging the

system:

Unplug all terminal blocks in the PMI boxes.

Switch on the external 24 V power supply or the system.

Measure that there is 24 V (18 to 2 V acceptable) on the terminal block or

PMI-1 and that the supply polarity on the terminals matches that shown in

the wiring diagram provided or PMI-1.

Plug the PMI-1 terminal block back into the Junction Box and check that all

three power indicator LEDs in the box are lit. See Fig. 2-4.

I one or more o the indicators ails to light, make the checks indicated in

Table 2-2 overlea.

1.

2.

.

4.


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1 7 14 191581 7

LED-1 LED-2 LED-3

0.8 A Fuse

Extra Fuse

JP3

JP1

JP2

On

Off

JP3

SW-1

Fig. 2-4 PMI Junction Box - switch and jumper setting

5. Check that the 5 V supply, communication and terminal block connections

o cable PMI-5 match the wiring diagram provided and have the correct po-

larity.

6. Plug the terminal block or PMI-5 back in the Junction Box and check that

there is 5 V on the PMI-5 terminal block in the Converter Box and that the

polarity is correct.

7. Plug the terminal block or PMI-5 back in the Converter Box and check the

status o the power indicator LEDs in the Junction Box.

I one or more o the LEDs no longer lights, immediately unplug the PMI-5

terminal block and make the checks indicated in Table 2-1.


o cable PMI- (or 9) match the wiring diagram provided and have the cor-

rect polarity.

Junction Box LED No.

Comments24V

1

15V

2

5V

3

O O O Unscrew and check that the 0.8 A use in the JunctionBox is intact. An extra use is included in the box orreplacement.

Also check that the 24 V DC power input cable PMI - 1is connected correctly, as indicated on the print boardin the box

On O On/O 15 V power regulation is deective. Replace JunctionBox

On On O 5 V power regulation is deective. Replace JunctionBox.

On On On System is OK.

Table 2-1 Junction Box Supply and Cable Checks


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ation

9. Plug the PMI- (or 9) terminal block back in the Junction Box and check

that there is 24 V on the PMI- (or 9) terminal block in the Intermediate/Freq.

Divider Box and that the polarity is correct.

10. Plug the terminal block or PMI- (or 9) back in the Intermediate/Freq. Divider

Box and check the status o the power indicator LEDs in the Junction Box.

I one or more o the LEDs no longer lights, immediately unplug the terminal

block and make the checks indicated in Table 2-1.


or the Crankshat Pickup Cable PMI-2 (or 8) in the Intermediate/Freq. Di-

vider Box match the wiring diagram provided and have the correct polarity.

12. Plug the PMI-2 (or 8) terminal block back in the Intermediate/Freq. Divider

Box and check the status o the power indicator LEDs in the Junction Box.

I one or more o the LEDs no longer lights, immediately unplug the terminal

block and check it again, as it is likely that one or more o the connections

is incorrect.

With multi engine plants, repeat the above procedure or each set o PMI

boxes in the system.

2.5 Engine Address & Pickup TDC Checks

Open the Junction Box(es) and set the address switch and jumpers as indi-

cated in Fig. 2-4 and Table 2-2.

Whereas JP must always be set to On, the setting o JP 1 and JP 2 de-

pends on the address switch setting given to the engine.

2. Apply power to the Junction Box and engage the turning gear o the engine

until cylinder No. 1 is at TDC.

. Check that the green indicator light is lit on the Intermediate Box. I not lit,

it is likely that the crankshat pickup needs readjustment. See Mounting

Guide or the particular pickup.

JunctionBox

SingleEngine

Plant

Multi Engine Plant

1st. Main

Engine

2nd. Main or 1st.Aux. Engine

SubsequentEngines

Last

Engine

Address Switch 0 0* 1 2,, 4, etc. X

Jumper JP 1 & 2 On O O O On

Jumper JP 3 On On On On On

Table 2-3 Junction Box Address switch and Jumper settings

With multi engine plants, repeat the above pro cedure to set the appropriate ad-dress and synchronise the PMI System with the TDC o Cylinder No. 1 o each

o the other engines.

1.


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Chapter3Commissioningt

heSystem

Chapter

Commissioning the System

In this chapter it is explained how to install the PMI sotware on your PC, start

the entire system and check the engine registration, communication and trig-

gering with the PMI Controller and Crankshat Pickup. Also, details are given

about how to make reerence measurements.

In this Chapter

Installing the PMI Sotware ................................................................................ 22

Checking Engine Registration ............................................................................ 22

Setting Up Communication ................................................................................ 24

Trigger and TDC Test.......................................................................................... 26

System Reerence Measurements ..................................................................... 28

0-Diagram Measurements ......................................................................... 28

E-Load Measurements ............................................................................... 29

Checking & Editing Reerence Measurements ................................................. 0

Technical Assistance .......................................................................................... 4


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Chapter3

CommissioningtheS

ystem

3.1 Installing the PMI Software

The PMI sotware is normally supplied on a CD, containing both the PMI appli-

cation program and engine specic data concerning your diesel engine plant.

To install the PMI program and its data:

Insert the CD in your CD-ROM drive.

Open the Start menu in the bottom let corner o the display and choose

Run.

Type d:\setup.exe. (I your CD-ROM Drive is not letter D, type the appropri-

ate letter instead.)

Select OK.

Follow the instructions on screen.

With WIN NT .5.1, WIN95 or later, the installation sotware will automatically

install a PMI System icon on the windows desktop or opening the program. In

addition, it will be listed in the programs menu and sub older contained in the

Start menu.

3.2 Checking Engine Registration

Fig. 3-1 The primary elements of the PMI Systems main window

Click on the PMI System icon on the windows desktop or on the corre-sponding program listed in the Program menu on your PC.

1.

2.

.

4.

5.

1.PMI System

Title bar

Menu bar

Toolbar

Status Line


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heSystem

The main window o the PMI System should now appear as indicated in Fig.

-1 overlea.

2. Select Open Engine contained in the File menu on the ar let o the dis-

play.

The Open Engine dialogue shown in Fig. -2 will now appear which lists

the individual names and types o engine in your plant that are registered

or use with the PMI System.

I the name o the engine to be checked is not listed, then select an engine

type that matches the particular engine. Later the name o the engine can

be edited.

Fig.3-2 The Open Engine dialogue

Fig. 3-3 The Edit Engine Data Torsion dialogue

. Click on the name o the engine or type o engine on which communication

is to be checked and activate the Edit tool button at the top o the dia-

logue. Alternatively, right-click anywhere in the dialogue to open the quick-access menu, and then select Edit.

NOTE


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4. Select the Torsion tab o the Edit Engine dialogue which is opened (see

Fig. -) and check that the address number indicated near the top right-

hand corner o the dialogue matches the SW1 address switch setting o the

particular engine. See section 2.5 or recommended settings.

I they do not match, change the dialogues address number accordingly.

Only entries which are not dimmed may edited.

5. Set the Trigger System section o the dialogue to correspond with the lo-

cation (i.e. Fore or At) o the Crankshat Pickup on the engine.

I an LE-Pickup is installed at the drive end (normally at) o the crankshat,

then the ollowing additional data must be keyed in:

The diameter o the drive shat. Units: metre.

The distance o the triggering system to the turning wheel. Units: metre.

When another type o pickup is used, both the Diameter ... and

Distance .... should normally be let blank or set to 0.

6. Click the OK button to store the settings chosen and return to the Open

Engine dialogue.

7. For multi engine plants, repeat steps to 6 or the other engines listed in

the Open Engine dialogue and then close the dialogue by clicking on the

Cancel button.

8. Select Exit in the File menu and then switch o the PC and the 24 V sup-

ply to the PMI System.

9. Next, asten the standard plug o the Converter Box to a ree communica-

tion port on the back o the PC and then switch the 24 V supply and the PC

back on again to make the system ready or the remainder o the setup pro-

cedure given below.

3.3 Setting Up Communication

Check that all hardware has been mounted, connected and adjusted as de-

scribed in the previous sections o this and the preceding chapter.

Connect the Pressure Transducer to the PMI Controller Box. See Fig. -4.

Fasten the multipole plug o the PMI Controller to the Junction Box on the

engine to be checked.

Always connect the Transducer to the PMI Controller beore connecting the

Controller to the Junction Box. Connecting the Transducer while powering

the Controller can damage the Controller.

4. Start the PMI Program on the PC and check that the name o the engine is

shown in the title bar o the main window.

1.

2.

.

PMI System

CAUTION

NOTE


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I the name o another engine is shown instead, select Open Engine in the

File menu and choose the correct engine in the Open Engine dialogue.

0OWERg/Ng

3TART2EADY

#ANCEL%RROR

0-)4RANSDUCER

'REEN)NDICATOR

'REEN"UTTON

2ED"UTTON

Fig. 3-4 The top panel of the PMI Controller box

Fig. 3-5 The Tools menu Options dialogue

5. Select Options in the Tools menu.

This opens the dialogue shown in Fig. -5, which should be set as ollows:

Communication Port: 1, 2, or 4, depending on which port o thePC is coupled to the Converter Box o the

PMI System.

Calibration Factors: Transducer Value The transducer sensitiv-ity at 20 - 2 C and 250 bar, as specied on

the calibration chart supplied with the trans-

ducer.

System Value A xed value o 0.95 match-ing the system amplication o the O-line

PMI System.

Measuring Settings: Averaging Period Sets the number o work

cycles over which the measurement is aver-

aged. Should normally be set or averaging

over 10 work cycles.

Single Trig. Normal setting or triggering

with an Angle Encoder.

Double Trig. Normal setting or other pick-ups.


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Click the OK button at the bottom o the dialogue to save the settings cho-

sen and exit the dialogue.

6. Select Communication - On in the Tools menu.

Ater a short wait the PMI System will respond by opening the Trigger and

TDC Test dialogue explained in section .4 below.

I a No connection ........ status message is fagged instead, then it will be

necessary to check the communication port setting or the cable connec-

tions to the Junction Box. See section . and 2. respectively.

Similarly, i the status message Missing trigger pulses is obtained and the

engine is running, check the cable connections to the Crankshat Pickup

and Intermediate or Freq. Divider Box. See section 2.2.

3.4 Trigger and TDC Test

When communication is achieved or the rst time, the PMI System will display

the Trigger and TDC Test dialogue shown in Fig. -6.

Fig. 3-6 The Triger and TDC Test dialogue

The use o the Trigger and TDC Test dialogue is as ollows:

No. of pulses detected: This provides an actual count o the number o crank

angle pulses detected per work cycle.

When triggering is stable only one count will be displayed. To store the

count or uture trigger tests, click the Save button. You can then proceed

with the reerence measurements described in section .5.

I triggering is unstable, then the latest ve counts will be listed. See below

to help determine the cause.

No. of pulses stored for engine: The crank angle pulse count. Zero is indicated

or the rst test.

Pulse deviation (min./max): Gives the minimum and maximum percentage de-

viation o the crank angle pulses relative to their mean repetition time.


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Large deviations indicate irregular rotation or deective operation o the

pickup.

To obtain a graphic view o the trigger pulse deviation, click on the Display

button in the dialogue. See Fig. -7.

Fig. 3-7 The Triger Deviation dialogue

TDC Pulse

Crank Angle Pulses

A

Fig. 3-8 The Timing of the TDC and Crank Angle Pulses

TDC pulse relative to trigger pulse: Indicates relative position o the leading

edge o the TDC pulse with respect to the start and end o the crank pulseperiod. For correct synchronisation the leading edge must be positioned

between 15 and 85% o the crank pulse period.

I either o the readings is less than 15 % or greater than 85 %, then the

pickup is not correctly adjusted or is deective.

Repeating the Test:

To repeat the Trigger Test, click on the Repeat button in the dialogue.


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Storing Test Count:

When a stable trigger pulse count is displayed, click on the Save button in the

dialogue. This will store the pulse count or use in subsequent trigger tests.

Ater storing a count, click on the Close button to return to the main window.

For multi engine plants, repeat section . and .4 to check communication and

triggering with the other engines.

3.5 System Reference Measurements

3.5.1 0-Diagram Measurements

0-Diagram measurements are used to correct pressure measurements so that

they refect the actual TDC o each o the respective cylinders o an engine. Inorder to do this, a set o 0-Diagram measurements must be made at the time

o installing the PMI System on an engine.

For main engines, reerence measurements are to be made in calm weather

conditions and deep water. No rudder movements or change o ships course

are to be made during measurements.

The procedure or making 0-Diagram measurements is as ollows:

Run the engine at 50 to 75% load.

Start the PMI Program on the PC and check that the name o the engine isshown in the title bar o the main window.

I not, open the appropriate engine by selecting Open Engine in the File

menu and select it in the dialogue which is opened.

. Select Communication On in the Tools menu.

The PMI Program will now check communication. At rst the status line

will fag a red marker which shortly ater should change to a green marker

showing that the system is ready.

I the program continues to show a red marker, then it is likely that the PMI

Controller and Transducer have yet to be connected to the engine. See nextstep.

4. I not already connected, connect the Pressure Transducer to the PMI Con-

troller and the multipole plug o the PMI Controller to the Junction Box. See

Fig. 2-1 and -4.

Always connect the Pressure Transducer to the PMI Controller beore con-

necting the Controller to the Junction Box. Connecting the Transducer while

powering the Controller can damage the Controller.

5. Set the uel pump index to zero (or lit the uel pump roller guide, depending

on the type o engine) to shut o the uel oil to the particular cylinder to bemeasured.

1.

2.

CAUTION

NOTE


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6. Mount the Pressure Transducer on the indicator cock o Cylinder No. 1 and

open the indicator cock.

The system is ready or measurements when the green light on the PMI

Controller begins to repeatedly fash. However, make sure that at least 2

minutes have elapsed between changing the uel pump index and starting

the measurement. This is necessary to obtain stable operation with clean

compression.

7. Press the green Start button on the PMI Controller to start the measure-

ment.

The green light will then be extinguished or a period and then light again

when the measurement has been completed.

8. Immediately close the indicator cock when the measurement has been

completed and return the uel pump index to its original setting (or lower theuel pump roller, depending on the type o engine).

9. Remove the Pressure Transducer rom the indicator cock and mount it on

the indicator cock o the next cylinder to be measured.

Always check that the indicator cock is closed beore removing the trans-

ducer. Failure to do this can result in release o extremely hot combustion

gasses which can severely injure personnel.

10. Repeat steps 5 to 9 until you have completed measurements on all cylin-

ders.

11. Return to the PC and stop measurements by pressing the Esc. key on the

keyboard or by selecting End Measurement in the Tools menu.

Alternatively, you can stop measurements by unscrewing the multipole plug

o the PMI Controller rom the Junction Box. This is useul i you want to

make another set o measurements beore returning to the PC. To be able

to do this it is important that you unscrew the plug only when the green

Start button is lit and that you wait at least 10 seconds beore reconnect-

ing the plug.

Stopping measurements automatically stores them in the PMI Systems

database.

The 0-Diagram measurement le must be renamed and specically selected

as deault as described in section .6.

3.5.2 E-Load Measurements

Immediately ater having prepared a set o 0-Diagram measurements another

set o reerence measurements must be made using the same procedure and

load conditions as stated in section .5.1, but this time without altering the uel

pump index o the cylinders.

With these reerence measurements, all cylinders are employed to drive theengine and thereore play an equal role in powering the engine and share ap-

WARNING


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proximately the same load. In this case the measurements are termed E-Load

measurements and are used to automatically compensate or torsional defec-

tions in the crankshat.

3.6 Checking & Editing Reference Measurements

To ensure that the O-Diagram and E-Load measurements are used or cor-

recting uture pressure measurements on your engine, they must be renamed

and selected as deault.

To do this proceed as ollows:

Select Open Measurement in the File menu and locate the set o 0-Dia-

gram measurements in the dialogue which is opened.

New measurements are listed with the letter m, ollowed by the date and

time o storage, e.g. m990124_10407. See Fig. -9.

Fig. 3-9 The Open Measurement dialogue as viewed with the List function

Fig. 3-10 The Edit Cylinder Observations dialogue. The curve indicated is typical

of what can be expected for a 0-Diagram observation

1.


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2. Select the measurement and then activate the Observations button in the

toolbar o the dialogue or right-click in the dialogue.

The Observations... command opens the dialogue shown in Fig. -10.

By clicking on the +/- symbol at the start o each cylinder heading you can

expand or contract a heading.

To examine an observation, click on its heading. Its pressure curve is then

displayed on the right-hand side o the dialogue.

. Check that one observation is present or each cylinder and that their pres-

sure curves have the approximate shape and orm as indicated in Fig. -10

(or Fig. -11 or E-Load measurements).

I no observations are listed or a cylinder or their curves appear to be very

distorted, then the measurement must be repeated.

I more than one observation is available per cylinder, then delete those

which are not needed by selecting each o them in turn and pressing the

Delete button at the bottom o the Edit Cylinder Observations dialogue.

Be careul when deleting observations as there is no Undo unction.

4. When all curves look correct, click the Close button to return to the Open

Measurement dialogue and then open the measurement by clicking the

Open button.

Fig. 3-11 The Edit Cylinder Observations dialogue. The curve indicated is typical

of what can be expected for an E-Load observation

5. Next select Calculated Values in the View menu and check that the mean

indicated pressure pi or each cylinder is negative. See Fig. -12.

Negative values signiy that there is no combustion o uel oil as is required

or O-Diagram measurements. You can proceed with step 6.

I the values are positive, then the most likely reasons are:

NOTE


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The uel pump index has not been set to zero.

The index has been set to zero, but not enough time has elapsed beore

the measurement was started, i.e. some uel oil is still present in the cylin-

der and has not had time to ully combust.

The index has been set to zero, but leaking uel valves result in combus-

tion or heating o uel oil in the cylinder.

In each case the measurement must be repeated ater correcting the most

likely cause o the problem.

Fig. 3-12 A Calculated Values scheme for a 0-Diagram reference measure-

ment on a four cylinder engine

Fig. 3-13 The Edit Measurement dialogue

6. Return to the Open Measurement dialogue and then activate the Editcommand in the toolbar o the dialogue.


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This opens the Edit Measurement dialogue shown in Fig. -1.

7. Click in the measurement eld o the Edit Measurement dialogue and

rename the measurement to signiy that it is a 0-Diagram reerence mea-

surement.

e.g. 0DIAG_70_990124_104

where the rst ve characters indicate the type o le, the next characters

indicate the engine load, the next seven characters indicate the date and

the last ve characters indicate the time that the measurement was stored.

8. Open the list-boxes immediately below the measurement eld and reset

them so that they appear empty and do not reer to earlier 0-Diagram and

E-Load reerence les.

9. Key in the appropriate value or the scavenge air pressure o the engine inthe p(scav): data eld and press the OK button to close the Edit dia-

logue and save your changes to the reerence measurements.

I no scavenge air pressure reading is available, then the program itsel will

automatically estimate it. To orce estimation the p(scav): data eld must

be set to 0 or 0.00.

10. Inspect the E-Load reerence measurements and check and edit them as

outlined in steps 1 to 9.

The check in step 5 concerns 0-Diagram measurements only, and or E-

Load measurements should be ignored.

In this case it is suggested that E-Load measurements be renamed as ol-

lows:

ELOAD_70_990124_1055

Fig. 3-14 The Edit Engine Data General dialogue

NOTE

NOTE


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11. Press OK to close the Edit dialogue and save your changes to the reer-

ence measurements.

12. Select Open Engine in the File menu and activate the Edit unction in the

toolbar o the dialogue.

This opens the Edit Engine Data dialogue shown in Fig. -14.

1. Open the 0-Diagram list-box near the bottom right-hand corner o the Edit

Engine Data dialogue and select the name o the 0-Diagram reerence

measurement.

14. Open the E-Load list-box and select the name o the E-Load reerence

measurement.

15. Press the OK button to exit both the Edit Engine Data and Open Engine

dialogues and store your new 0-Diagram and E-Load as deault settings.

3.7 Technical Assistance

I you experience diculties in installing or using the PMI System, then check

whether you can nd an answer to the problem by ollowing the instructions

and advice given in the corresponding sections o this guide and in the sepa-

rate Users Guide which is provided.

I you cannot nd the answer, you are welcome to contact MAN Diesel whose

address and phone number are given on the back cover o this Guide.

When you call by phone, you should have the PMI System documentation at

hand and be prepared to give the ollowing inormation:

The name o the vessel or plant.

The version and build number o your PMI System sotware indicated under

About in the Help menu.

The operating system and type o hardware that you are using.

A brie account o what happened and what you were doing when the prob-

lem occurred.

The exact wording o any messages that appeared on your screen.

Details about how you tried to solve the problem.

When you mail us, we ask you to include the above inormation, plus any rel-

evant computer printouts which might be helpul.


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Index

Index

MMounting Guide

Chapter Overview ....................................... 8

Text Conventions ........................................ 8

Mounting PMI Boxes ........................................ 16

OO-Diagram Measurements .............................. 28

On-line Help ....................................................... 8

PPD-Pickup .......................................................... 9

PMI System

Basic System .............................................. 9

Cable & Power Checks ............................. 17

Mounting PMI Boxes ........................... 16, 17

On-line Help ................................................ 8

Screened Cables ...................................... 15System Connections ................................. 14

RReerence Measurements ................................ 28

SScreened Cables .............................................. 15

Setting Up Communication.............................. 24

Sotware Installation ........................................ 22

TTDC - Pickup Sync. .......................................... 19

Technical Assistance ....................................... 4Transducer Calibration Factor ......................... 25

Trigger and TDC Test ....................................... 26

AAngle Encoder .................................................... 9

CChecks

Cable & Power .......................................... 17Com. Port ............................................ 25, 26

Communication ......................................... 24

Engine Address ......................................... 19

Engine Registration ................................... 22

Measuring Settings ................................... 25

Reerence Measurements ......................... 0

TDC - Pickup Sync.................................... 19

Transducer Calibration .............................. 25

Trigger & TDC Test .................................... 26

Converter Box .................................................. 16

Crankshat Pickups ............................................ 9

Angle Encoder ............................................. 9LE-Pickup .................................................... 9

PD-Pickup ................................................... 9

EEditing Measurements ..................................... 0

E-Load Measurements..................................... 29

Engine Address Checks ................................... 19

Engine Registration .......................................... 22

FFreq. Divider Box.............................................. 16

IIntermediate Box .............................................. 16

JJunction Box .................................................... 16

LLE-Pickup ............................................................ 9


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DK-2450 Copenhagen SV

Denmark

Telephone: +45 33 85 11 00

Teleax: +45 33 85 10 30

[email protected]

www.mandiesel.com

Copyright MAN Diesel A/S. Reg. No. 39 66 13 14

Reproduction permitted provided source is givenSubject to modifcation in the interest o technical progress

3520-0006-00ppr May 2007 Item no. 1142959-6

installation guide for off-line

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