6 Hydraulic Cylinder Unit 2012

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Hydraulic Cylinder Unit (HCU)
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01/01/2012 MAN Diesel & Turbo
Hydraulic Cylinder Unit
<1>
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High pressure pipes
Hydraulic Cylinder Unit
Distribution block Distribution block
End cover
ELFI Valve
Fuel oil pressure booster
Accumulator
Cylinder Lubrication y
Pressure Decay Time and other trouble
shooting issues
01/01/2012 MAN Diesel & Turbo ME-B Hydraulic Cylinder Unit <2>
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Mechanical/Hydraulic Diagram F
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uMechanical/Hydraulic Diagram
HCU HCU
Hydraulic Cylinder Unit Hydraulic Cylinder Unit Hydraulic Cylinder Unit Hydraulic Cylinder Unit
HPS HPS
Hydraulic Power Supply Hydraulic Power Supply
BOLL filter BOLL filter
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Layout of High Pressure Pipes
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Dual cylinder
HCU
HPS
HCU
High Pressure Pipes
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300 bar hydraulic oil 300 bar hydraulic oil
rail from the Safety rail from the Safety
Safety block Safety block
Block to the HCUs Block to the HCUs
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HCU from below
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H.p. pipe H.p. pipe
connection connection
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Fuel Oil Pressure booster Fuel Oil Pressure booster
ME Lubricator ME Lubricator
Fuel Oil Pressure booster Fuel Oil Pressure booster
Accumulator Accumulator
End cover End cover End cover End cover
ELFI valve ELFI valve
3333572.2006.04.12 (2200/OZS)
Distribution block Distribution block
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Distribution Block
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Distribution Block
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Distribution Block
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End cover fore side
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End cover fore side
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End cover aft side
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ELFI for ME-B
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ELFI for ME-B
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ME Fuel Injection System
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ME Fuel Injection System
Suction valve Suction valve Slide Fuel
l
High pressure pipe High pressure pipe
Fuel pump Fuel pump
valve
Fuel pump
l
Fuel pump
l
Fuel oil inlet
8 bar
Fuel oil inlet
8 bar
plunger plunger
Hydraulic
piston
Hydraulic
piston
Membrane
accumulator
Membrane
accumulator
ELFI
Proportional
valve
ELFI
Proportional
valve
To To
To
drain
To
drain
High pressure hydraulic oil inlet High pressure hydraulic oil inlet
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Fuel Oil Pressure Booster
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Fuel Oil Pressure Booster and ELFI valve
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Engine:
Process Adjustment > Max Pressure
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Process Adjustment > Max Pressure
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Engine:
Process Adjustment > Mean Pressure
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Process Adjustment > Mean Pressure
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Engine:
Chief Limiters
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Chief Limiters
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Supervision of ELFI feedback signal
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Supervision of ELFI feedback signal
The ELFI is immediately set to Drain Position (safe position) if:
The ELFI valve feedback signal is not valid, i.e. outside 3.5 - 20.5 mA
The ELFI valve feedback signal indicates a too high (not physical possible)
speed
The ELFI valve feedback signal indicates a position not allowed outside a
window around TDC
Pressing the Re-enable button on the Engine->Chief Limiters Screen
Fuel Injection is re-enabled by either:
Invalidation and then re-validation of the input ch. 30(cyl. A) or ch. 33 (cyl. B)
on the relevant CCU
Resetting the CCU
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Crankshaft related control processes
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Crankshaft related control processes
TDC
Injectionpreparation
Injection start
angle trig
Injection control
Injection
Injection preparation
j
ELFI valve window
supervision
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Engine:
Chief Limiters > Re-enable Fuel Injection
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Chief Limiters > Re-enable Fuel Injection
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Accumulator and HCU F
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Accumulator
Diaphrame Working Principle
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Diaphrame, Working Principle
<36>
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Accumulator
Nitrogen check and charging
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Nitrogen check and charging
The accumulator charge pressure should be
checked within the first week of service.
N h k h ld b d d 4 h Next check should be made around 4 months
later, followed by checking every 6 months.
A minor leakage from the accumulators is
unavoidable, and service experience shows
that a pressure drop in the range of 2-5
bar/month is to be expected.
The charge pressure is dependent on the
accumulator temperature. E.g.:
136 bar @ 20C, 154 bar @ 50C
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Cylinder Lubricator
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Cylinder Lubricator
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Cylinder Lubrication System
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Cylinder Lubrication System
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Cylinder Liner Injection Nozzles
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Cylinder Liner, Injection Nozzles
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Cylinder Liner Injection Nozzles
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Cylinder Liner, Injection Nozzles
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The ME Engine
Cylinder Lubricator
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Cylinder Lubricator
Inductive proximity sensor
giving feedback signal for
Cylinder lub. oil
g g eedbac s g a o
control of piston movement
Lubricator
activation signal
from controller
y
inlet
Fl Flow sensor
Injection plunger
Spacer for
basic setting of
pump
Stroke
adjusting
screw
Drain
oil
outlet
200 to 300 bar system oil supply
pump
stroke
Actuator
piston
Non-return valve
piston
Sealing ring
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Cylinder Lubrication Backup
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Channel J51 on a working CCU
In case of CCU failure, where the ,
CCU cannot be replaced
immediately, backup cylinder
lubrication can be achieved as lubrication can be achieved as
follows:
Connect temporary cables from
two other CCU units, plug 51, to
the solenoid valves on the
lubricators on the units in question. lubricators on the units in question.
The lubrication will be with random
timing.
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Hydraulic Pressure Decay
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Hydraulic Pressure Decay
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Time measurement example:
250
150
200
Start level at 180 bar
100
Bar
50
Stop level at 50 bar
0
0 5 10 15 20 25 30
Seconds
Pressure Decay Time
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Hydraulic System, complete
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Disclaimer
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All data provided in these training materials is non-binding.
Disclaimer
p g g
This data serves informational purposes only and is especially not
guaranteed in any way.
Dependingon the subsequent specific individual projects the relevant data Depending on the subsequent specific individual projects, the relevant data
may be subject to changes and will be assessed and determined
individually for each project. This will depend on the particular
characteristics of each individual project, especially specific site and p j , p y p
operational conditions.

6 Hydraulic Cylinder Unit 2012

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