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Technical Publication

Installation of
MTU electronic systems

Marine applications

Documentation Part 7

E 530 606 / 06 E

DaimlerChrysler Off-Highway
MTU assuring you:
¯ ISO 9001 certification
Quality assurance in design/development, production, installation and service
¯ CE conformity
-- Guideline 73/23/EEC – Low voltage guideline –
dated February 19, 1973 with amendment dated July 22, 1993
(guideline 93/68/EEC)
-- Guideline 89/336/EEC – Guideline on electromagnetic compatibility –
dated May 3, 1989 with amendment dated April 28, 1992
(guideline 92/31/EEC)
CE conformity is influenced if the product is installed incorrectly, an assembly or system is misused
and/or genuine MTU components are not used.

Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.

Printed in Germany
E 2002 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.

Imprimé en Allemagne
E 2002 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.

Impreso en Alemania
E 2002 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
E 2002 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego od utilizzo, con particolare riguardo alla
riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm ed alla memorizzazione od all’elaborazione in
sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen
GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’ utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
Guide Page I

General information about documentation

Documentation structure

Documentation Title/contents Target group(s)


Part
1 Structure and function Operating personnel etc.

2 Operation Operating personnel

3 Maintenance and repair Plant personnel

4 Service manual Electronic service personnel

5 Illustrated parts catalog Plant personnel, electronic service personnel,


logistics personnel
6 Plant-specific configuration Electronic service personnel, installation
personnel, start-up personnel
7 Mechanical and electrical Installation personnel
installation (electromechanical/mechatronic engineer)
8 Initial start-up Start-up personnel

Note: Not all parts of the documentation are written for every product.

Required knowledge
To understand each part of the documentation, we recommend reading the preceding parts, if applicable.

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Page II Guide

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Mechanical and electrical installation Part 7
Table of contents Page I

Part 7

Mechanical and electrical installation

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Part 7 Mechanical and electrical installation
Page II Table of contents

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Mechanical and electrical installation Part 7
Table of contents Page III

Table of contents

1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1 Organization of the MTU drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Interlinking of the MTU drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Schematic ship wiring diagram (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Equipment identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5 Plant identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.6 Device types according to DIN 40 719, part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.7 Device list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.8 Schematic wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9


2.8.1 Schematic wiring diagram (internal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8.2 Schematic wiring diagram (external) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.8.2.1 Schematic terminal/connector diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8.2.2 Cable connecting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.9 Installation drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.10 Arrangement lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.11 List of measuring points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Assembly wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 MTU cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Ship cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 Plug connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21


4.3.1 Connector types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.2 Connector assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.4 Connector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.5 Assembly instructions for Harting connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.5.1 Assembling a Harting connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.5.2 Connection with spring-cage terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3.5.3 Crimp connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.5.3.1 Tools required to establish a crimp contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.6 Assembly instructions for KJA connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.7 Assembly instructions for KPSE Cannon connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Part 7 Mechanical and electrical installation
Page IV Table of contents

Table of contents (cont.)

4.4 Terminal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39


4.4.1 Screw terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.2 Spring terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.5 Connections with DIN 89 280 cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


4.5.1 Assembling DIN 89 280 cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.6 Assembling HSK cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49


4.6.1 HSK cable gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6.1.1 Mounting in a housing wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6.1.2 Mounting in a housing wall or connector with threaded bore . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.6.2 HSK with EMC cable gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6 Interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6.3 Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.4 Cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7 Installation materials, tools and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.1 Installation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58


7.1.1 Crimp tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.2 Tools for actuating spring-cage terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.3 Tools for fitting wire end ferrules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.2 Installation materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59


7.2.1 Halogen-free ship cables in accordance with DIN 89 159 with classification approval . . . 59

8 Preferred degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


8.1 Degrees of protection against contact and foreign bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.2 Degrees of protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9 Placing orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Mechanical and electrical installation Part 7
Safety requirements Page 1

1 Safety requirements

IMPORTANT:
These safety requirements shall be read and observed by all personnel
involved in operation, care, maintenance, repair, installation or commissioning
of the products described.

Furthermore, the following shall be observed:


¯ The safety requirements (if provided) in other relevant MTU manuals
¯ Warning and safety information and operating and limit values attached to the products as
required
¯ National accident prevention and safety standards
¯ Appropriate regulations usual in the industry
¯ The safety notes (if provided) in the text of this manual

Conventions for safety notes in the text

Where necessary, this manual includes highlighted safety notes indicated by a signal word. These safety
notes shall be observed to avoid injury or damage.

This type of note indicates a danger which may lead to injury or death.

DANGER

This type of note indicates a danger which may lead to damage or


destruction of the product described or another part of the system.

CAUTION

Intended use and user qualifications

All devices and system components may only be put to their intended use.

Operation, maintenance, repair, installation and commissioning shall only be performed by qualified and
authorized personnel.

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Part 7 Mechanical and electrical installation
Page 2 Safety requirements

Safety requirements for installation and commissioning

To ensure constant readiness and reliability of the product, installation and commissioning work shall be
performed in accordance with the instructions given in the appropriate manual by authorized personnel using
suitable or special MTU tools tools as necessary.

Prior to commencing work, the power supply of the appropriate areas must be switched off and secured
against unauthorized switching on. Any measures requiring power supply are expressly defined as such at
the appropriate place in the manual.

Genuine spare parts only may be used to replace defective components or assemblies. The manufacturer
accepts no liability whatsoever for damage caused by using other spare parts. The manufacturer’s warranty
shall also be voided in such cases.

The manufacturer shall not be held liable if unauthorized changes or modifications are made to the product
and the warranty shall be voided.

During installation, protect the assemblies concerned and their surroundings from dust as far as possible.
Should this prove impractical, always clean away any dust or deposits immediately.

Observe the information in the manual pertaining to installation locations and the associated environmental
conditions. Take account of the admissible exposure of the component to external influences as indicated by
the IP rating in the manual.

Use only those connectors, cables and installation materials expressly approved by MTU for mechanical and
electrical installation.

Dimensional tolerances shall be strictly adhered to on installing the product.

The product/assemblies shall be handled carefully at all times.

Mechanical safety features shall be installed as specified in the appropriate manual/installation instructions
and fixing screws secured in accordance with the relevant instructions.

Ensure that the required sealing and protection against the ingress of moisture are afforded on installing in
exposed locations.

On completion of installation work, ensure that no superfluous parts (tools, installation materials etc.) remain
inside devices or the system.

Ensure that a suitable operating voltage is available and check polarity.

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Mechanical and electrical installation Part 7
General information Page 1

2 General information
This manual contains the general guidelines and information required for installing MTU Monitoring and
Control Systems. The information is of a general nature and does not deal with particular problems involved
in installation.

The control consoles in which MTU Monitoring and Control Systems are installed are defined as follows:

¯ Main control console

¯ Auxiliary control console(s)

¯ Engine room control console

The assemblies installed in the main control console are for centralized display and operation. The equip-
ment is generally intended for installation in a console and is unsuitable for installation in exposed control
consoles unless otherwise stated.

Auxiliary control consoles are intended for additional monitoring and control. Additional control consoles may
be installed depending on the Monitoring and Control System concerned. Assemblies and equipment inten-
ded for installation in auxiliary control consoles are generally designed for console installation. The assem-
blies are only suitable for installation in exposed control consoles to a certain extent. Additional steps can be
taken to increase the degree of protection.

The assemblies required in the immediate vicinity of the engine are installed in the engine room. They are
prepared for wall-mounting on flexible mounts.

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Part 7 Mechanical and electrical installation
Page 2 General information

2.1 Organization of the MTU drawings

Every MTU delivery includes the diagrams and drawings to allow the customer to plan installation and wiring
of the equipment (the scope of diagrams and drawings depends on the order).
These MTU drawings are organized as follows:

¯ Cover sheet
- Title
- Drawing number
- Modification sheet

¯ Table of contents

¯ Notes and drawing cross-references

¯ Overview
- Sheets are organized in accordance with rooms, e.g. engine room, bridge etc.
- Schematic ship wiring diagram (SM) showing the entire scope of supply. The schematic
ship wiring diagram includes the equipment list in addition to the graphical representation.
- Installation drawings with technical data of the assemblies
- Lists of measuring points
- Arrangement lettering: Arrangement drawings showing the assembly front panels and their
respective inscriptions
- Schematic wiring diagram (SM): External and internal assembly wiring as necessary. The
schematic wiring diagram includes a graphical representation and the terminal/connector
diagram.

¯ Device list

Individual components installed in the sub-assemblies shown in the ship wiring diagram are not represented
on this diagram. They are listed in the circuit diagram.

The drawing title block is defined in an MTU standard. It includes:

¯ Drawing number/sheet number

¯ Drawing title (German/English)

¯ Drawing scale for mechanical drawings

Technical modifications to an MTU drawing are documented in the drawing in accordance with MTU stan-
dards. The edition of the drawing is noted in the revision field. All revisions are identified by a letter and an
MTU-internal revision number.

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Mechanical and electrical installation Part 7
General information Page 3

2.2 Interlinking of the MTU drawings

MTU installation documentation has a hierarchical structure.

Installation List of
drawing measuring points

EB

Conn. diagram
Terminal diagram Schematic ship
Schematic
wiring diagram (SM)
wiring diagram Arrangement
(internal/external) lettering
SM AO

Fig. 1: MTU drawing system

The schematic ship wiring diagram (overview) is the most important drawing and represents the key to the
other documents supplied by MTU for any specific order. Using the drawing numbers stated in the schematic
ship wiring diagram, the other circuit diagrams (schematic wiring diagrams), arrangement drawings and
assembly drawings and also assembly item numbers can be identified and located.

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Part 7 Mechanical and electrical installation
Page 4 General information

2.3 Schematic ship wiring diagram (overview)

7
8
1
2
6

9
4
5

Fig. 2: Overview showing an example of a ship wiring diagram

Pos. Meaning
1 System identification
2 Cables included in the MTU scope of supply
3 Symbol for shielding
4 Device identifier: e.g. connector X4.5
5 Location identifier
6 Cable identifier/cable type
7 Reference: Cable continues on page 5/column 4
8 Detailed assembly drawings
9 External ship’s cabling

The schematic ship wiring diagram illustrates the electrical connections between all components supplied by
MTU to be installed in the ship by the customer. It represents an overview of the entire MTU scope of supply
for the order concerned. The individual devices can be identified using the ship wiring diagram. The respec-
tive additional schematic external wiring diagram (2/9) is listed for the various devices in the schematic ship
wiring diagram. All other diagrams (AO = Arrangement lettering, EB= Installation drawing, ZB= Assembly
drawing) are listed in the equipment list of the overview or in the supplement to the appropriate drawing.

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Mechanical and electrical installation Part 7
General information Page 5

2.4 Equipment identifiers

Each assembly and each device are identified by equipment identiifers in accordance with DIN 40 719,
part 2.

= 21.1 + A002 --X4.5

Plant (=) =AA.N Location (+) +ANNN Device (-- ) --BNNN

Fig. 3: Example of an equipment identifier

Pos. Meaning
A DIN letter/coded location definition (assignment is included in the device list)
AA Plant identifier (see plant identification table, chap. 2.5, page 6)
B DIN letter/coded device definition (see device type table in accordance with DIN 40 719, chap.
2.6, page 7)
N Number for further sub-division: 1 Starboard, 2 Port
NNN Number for further sub-division

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Part 7 Mechanical and electrical installation
Page 6 General information

2.5 Plant identification

Plant Code = AA.x Assignment

Not assignable 00 Miscellaneous, not assignable to a particular plant,


applicable to several, e.g. cabling

Propulsion plants 20 General


21 Diesel engine plant
22 Gas turbine plant
24 Electrical drives
26 Ship’s propulsion system, e.g. FPP

Electrical systems 30 General


31 Ship’s networks, converters, supply in general
32 Electric power generation plants, generators
33 Switchgear, switchgear devices, fuse cabinets
36 MCS in the ship area, control consoles
37 RCS and MCS at the control stations, process manage-
ments systems, control consoles at control stations
38 Auxiliary and emergency power supply systems

Ship area 40 General


44 Fire extinguishing and fire alarm systems
46 Ventilation and air conditioning systems

The table below shows an example of plant sub-division:

Port Starboard

Control station 2 (1st auxiliary control station) 37.2.2 37.1.2

Control station 1 (main control station) 37.2.1 37.1.1

Diesel engine plant 21.2 21.1

Power supply 31.2 31.1

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Mechanical and electrical installation Part 7
General information Page 7

2.6 Device types according to DIN 40 719, part 2

Code letter Item type Examples


A Assemblies; sub-assemblies Device combinations, constructional
units, printed circuit boards, slide-in
modules
B Converters from non-electrical to elec- Thermocouples, pressure sensors,
trical equipment and vice-versa pulse transmitters, tachogenerators
C Capacitors –
D Binary elements, delay and storage –
facilities
E Various –
F Safety facilities Fuses, protective relays, bimetallic
elements
G Generators, power supplies Transducers, power supply units, power
converters
H Signalling facilities Visual and audible signalling equip-
ment, warning lights, horns
K Relays, contactors –
L Inductors –
M Engines –
N Amplifiers, controllers –
P Measuring equipment, test facilities –
Q Power switching devices Circuit-breakers, isolator switches
R Resistors –
S Switches, selectors Control switches, pushbuttons, limit
switches
T Transformers –
U Modulators, converters for converting –
electrical variables
V Conduits, semi-conductors –
W Transmission paths, hollow conductors, Interconnecting wires, cables, busbars
antennae
X Terminals, connectors, sockets –
Y Electrically-actuated mechanical equip- Actuator drives, actuator magnets,
ment variable-speed drives
Z Terminators, splitters, filters, equalizers, R/C and L/C filters, interference
limiters suppression devices, active filters

Compensators, fork terminators

The corresponding connector numbers are stated for assemblies having several plug connections. These
numbers refer to the respective assembly.

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Part 7 Mechanical and electrical installation
Page 8 General information

2.7 Device list

1
2 3 5 6 7 9
4 8

Fig. 4: Example of a device list

The following information is provided on each item number in the device list (table):

Pos. Meaning
1 Equipment identifier: Precise designation of the assembly
2 Denomination: Device denomination in German and English
3 Device type: MTU type designation
4 Supplier, when ordered by MTU
5 Technical data: Specifications, e.g. voltage
6 Installation drawing: MTU number of the installation drawing for the device/component
7 Part number: MTU part number of the device/component
8 Remarks, e.g. colour, installation location
9 Sheet: Indicates the page on which more information is provided about the device concerned

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Mechanical and electrical installation Part 7
General information Page 9

Cabling

The cable types stated in the schematic ship wiring diagram are recommended by MTU. Should the custo-
mer wish to use other types of cable, the maximum permissible external cable diameter at the connectors
must be taken into consideration.

The electrical properties of cables selected by the customer must be comparable with the specifications of
cable types recommended by MTU. Pay particular attention to the degree of shielding and the capacitance
and inductance per unit length to ensure that the electrical equipment functions correctly. Mechanical
strength, resistance to oil and acid and the longitudinal water tightness of the cables must be ensured.

Note: MTU is in no way responsible for malfunctions, faults or damage resulting from the use of
unsuitable cables.

In addition to the cables represented in the schematic ship wiring diagram, the following information is
included:

¯ Cable number, item designation

¯ Recommended type of cable or MTU item number

¯ Required number of wires (including spare wires) and their cross-section

2.8 Schematic wiring diagram

2.8.1 Schematic wiring diagram (internal)

Fig. 5: Schematic wiring diagram (internal), example

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Part 7 Mechanical and electrical installation
Page 10 General information

These are standard circuit diagrams (see fig. 3) conforming with DIN 40 719, part 3, not related to any parti-
cular order. They are not specifically customized for a particular order. Information and designations in the
diagrams may therefore be related to functions which are not included or required for the order concerned.

The schematic wiring diagram is the circuit diagram of a device. It shows all the electrical components and
the wiring to the connectors or terminal strips within the device.

This diagram is put inside the control boxes and should be kept there.

2.8.2 Schematic wiring diagram (external)

Fig. 6: Schematic wiring diagram (external), example

This is an order-related standard circuit diagram conforming with DIN 40 719, part 3.

This diagram shows the relevant parts of external devices connected to the device concerned. This diagram
includes the terminal and/or connector diagram. The cables which are to be connected are given in the form
of a list (see fig. 7).

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Mechanical and electrical installation Part 7
General information Page 11

2.8.2.1 Schematic terminal/connector diagram

2
3

4
6 5

Fig. 7: Schematic terminal/connector diagram, example

The terminal/connector diagram contains the following information for all the cables and related wires which
are to be connected up by the customer:

Pos. Meaning
1 Cross-reference to the location of the terminal in the circuit diagram
2 Item designation (BMK) of the terminal strip shown in the terminal diagram
3 Target designation
4 Source designation
5 Wire number
6 Cable number

The cable number is identical to the number stated in the schematic ship wiring diagram.

Information about source designation and target designation comprises:

¯ Item designation

¯ Terminal number

Vital information on carrying out the wiring is also included in the schematic ship wiring diagram.

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Part 7 Mechanical and electrical installation
Page 12 General information

2.8.2.2 Cable connecting diagram

Fig. 8: Cable connecting diagram

The cable connecting diagram provides an overview of cable connection assignment. The assignment of all
wires and cables is shown.

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Mechanical and electrical installation Part 7
General information Page 13

2.9 Installation drawing

Fig. 9: Installation drawing, example

The installation drawing (EB) contains all the technical specifications relevant to installation and the precise
mechanical dimensions of a given device.

Observe limit values


Ensure that none of the limit values specified on the installation drawing are
violated (temperature, air humidity, shock, vibrostability, etc.).

CAUTION

Also included are the dimensions for mounting the device in the ship and those to be taken into considera-
tion when installing the device, e.g.:

¯ Installation position

¯ Distance from the floor

¯ Distance from the wall

¯ Space for cable entries

¯ Space for shock absorbers

¯ Space for opening doors

The drawing scale is stated in the title block. Any dimensions which are not drawn to scale are underlined.

Installation drawings are generally standard diagrams not related to a particular order. Front panels and
inscriptions shown in these drawings may therefore show functions which are not relevant or not required for
the order concerned.

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Part 7 Mechanical and electrical installation
Page 14 General information

2.10 Arrangement lettering

1
2

Fig. 10 : Arrangement lettering, example

The arrangement lettering (AO) drawing shows the schematic arrangement and inscription of the calottes of
all operating and display panels. The following information is included for each calotte:

Pos. Meaning
1 Calotte colour
2 Calotte inscription either as text or graphic symbol

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Mechanical and electrical installation Part 7
General information Page 15

2.11 List of measuring points

Fig. 11 : List of measuring points, example

MTU supplies a list of measuring points for extensive Monitoring and Control Systems, providing information
about all measuring and control signals including measuring range, alarm function, delay time etc.

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Part 7 Mechanical and electrical installation
Page 16 Installation

3 Installation
This chapter includes general information about the installation of all monitoring and control components and
is not specifically related to a particular order. Important general information for mounting, installation and
connection to other components is provided for each device.

Note: This information is binding to ensure trouble-free operation of devices installed.

The configuration of devices in the control consoles must take general ergonomic factors into account (see
documentation: Ergonomic guidelines for console design, Part 2). Make sure that the units can be operated
easily.

Ensure that devices installed in the engine room are fitted as directed. The devices should be arranged in
such a way as to allow visual contact with the engine when they are being operated.

Note: Pay particular attention to the required degree of waterproofing. Particular care is required when
installing devices in consoles and on flying bridges to ensure that the operating side of the
devices are not splashed with water. The installation notes in the following sections apply in
individual cases.

Installation work carried out by the customer must be executed correctly. MTU shall in no way be respon-
sible for malfunctions, faults and damage resulting from incorrect installation of the devices, caused particu-
larly by dust, drillings, paint mist etc. during construction. Pay attention to the following information:

Notes on wiring

¯ The systems must be wired up and installed in accordance with the specifications in the MTU
wiring diagrams.

¯ Use the grounding inserts supplied for connecting shields on cable entries.

¯ Never attempt to shorten prefabricated connecting cables with integral connectors supplied by
MTU. Contact MTU in good time if shorter or longer connecting cables are required (delivery
time approx. 10 – 12 weeks).

¯ MTU can also supply connecting cables specifically suited to meet customer requirements on
request during the planning phase.

¯ Observe additional information in chap. 4.2, page 18.

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Mechanical and electrical installation Part 7
Installation Page 17

Installation notes

¯ Devices must be installed as intended and delivered. Never remove protective housings.

¯ Use the accessories supplied by MTU to install the devices.

¯ Degrees of protection and fixing points stated in the installation drawings are binding.

¯ Devices must be adequately protected against the ingress of water. Consult MTU in case of
doubt.

¯ Modifications to devices and the installation of additional facilities require our approval.

¯ Use tools recommended by MTU for correct installation.

Plug connections

¯ MTU always supplies the appropriate mating connectors and parts for plug connections.

¯ A sufficient number of spare pins are supplied by MTU for wiring plug connections. Always
insert a pin even when not in use. Spaces in the sealing insert must be fitted with filler pins to
prevent the ingress of water into the connector.

¯ The customer may only seal shrink-fit parts on connectors after they have been checked by
MTU inspection personnel.

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Part 7 Mechanical and electrical installation
Page 18 Wiring

4 Assembly wiring

4.1 MTU cables

MTU supplies prefabricated cables for wiring the monitoring and control components in the main and auxi-
liary control consoles. These cables are fitted with suitable connectors and have a standard length of 4
meters unless otherwise stated.

Note: Never attempt to shorten a prefabricated cable to avoid impairing operational reliability.

MTU can also supply cables of different lengths. They must, however, be ordered from MTU in good time
(see chap. 3, “Notes on wiring”). The following information is required:

¯ Number of the ship wiring diagram

¯ MTU item number of the comparable standard cable

¯ Current path number stated in the ship wiring diagram

¯ Desired length (in meters)

A standard cable of a similar length is supplied as a rule. Cable lengths which are not included in the MTU
program are charged at extra cost.

4.2 Ship cables

Types of cable recommended in the ship wiring diagram are to be used for wiring the monitoring and control
components. If other, equivalent types of cable are used, pay particular attention to the maximum permis-
sible outer diameter. If cables other than those specified by MTU are to be used, we strongly recommend
consulting the MTU project department (fax: 7541 – 90 – 6123) to avoid impairing operational reliability.

The shield must be grounded at both ends. Fit wire end ferrules to the ends of cables intended for terminal
connection (screw terminals). Use metal cable entries only to ensure electromagnetic compatibility.

Cable entries which are not in use must be sealed off.

Cable routing

The following guidelines apply to the routing of ship cabling:

¯ Signal cables must be divided into categories and routed in separate conduits. All signal lines
for MTU Monitoring and Control Systems must be divided into the categories “Insusceptible,
susceptible”.

¯ Never route signal cables directly next to power cables.

¯ Never route signal cables parallel to antenna or RF cables.

¯ Route cables such that they are not subjected to vibration, particularly cables which are routed
to the engine and gear.

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Mechanical and electrical installation Part 7
Wiring Page 19

¯ When laying cables, make sure that they are not kinked beyond admissible limits. The bending
radius must not be less than 10 x the cable diameter.

r
r ≧ 10 x d

Fig. 12 : Admissible radius on laying cables

¯ Route the cables such that they are not subjected to chafing.

¯ Route the cables such that neither the cables nor their connections are subjected to strain.
Provide strain relief if necessary.

¯ Route the cables keeping them as short as possible.

¯ Maintain a suitable distance to exhaust pipes or other components which give off heat. Insulate
suitably if necessary.

¯ Protect cables by means of suitable cable ducts or covers in places where there is a risk of
damage.

¯ Avoid damaging cables when routing.

¯ Never route cables over sharp edges.

¯ Identify the ends of the cables after routing.

¯ Never route cables around areas which are still hot from welding.

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Part 7 Mechanical and electrical installation
Page 20 Wiring

Wire cross-sections

The wire cross-sections for signal cables are stated in the schematic ship wiring diagram (SM). Cross-
sections smaller than the specified values are inadmissible.

The required cross-sections for cables to the starter, alternator and batteries are stated in the diagrams in
MTU drawing no. 500 001 05 99.

Cross-section
mm2 AWG1)
0.08 28
0.14 26
0.25 24
0.34 22
0.5 20
0.75 19
1 18
1.5 16
2.5 14
4 12
1) AWG specifications are approximate
values depending on strand structure.

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Mechanical and electrical installation Part 7
Wiring Page 21

4.3 Plug connections

4.3.1 Connector types

Various types of connector are used for wiring the monitoring and control components. The precise connec-
tor designation is printed on each connector. The MTU item numbers for the connectors used are listed in
the schematic ship wiring diagram/component list. Information concerning installation materials is given in
chap. 7, page 58.

4.3.2 Connector assignment

The type of connector used is stated in the schematic overview/component list (SM). The number and desig-
nation of the connector contacts to be assigned are listed in the corresponding wiring/terminal or connector
diagram.

4.3.3 Tools

The following special tools are recommended for assembling connectors to ensure the reliability of a plugged
connection:

¯ Crimp tool (fixed or adjustable)


¯ Pinning tool
¯ Depinning tool
¯ Stripping pliers
¯ Cable knife

Refer to chap. 7, page 58 for more information about tools.

4.3.4 Connector assembly

Make sure that the following items are compatible when preparing to assemble a connector:

¯ Type of connector

¯ Type of pin/socket

¯ Crimp tool insert

Based on the type of connector involved, the correct pins/sockets and the right crimp tool insert must be
selected.

Connector assignment is defined in the schematic ship wiring/connector diagram.

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Part 7 Mechanical and electrical installation
Page 22 Wiring

4.3.5 Assembly instructions for Harting connectors

Preparing the cable

1. Strip back the outer insulation (13/c) to


expose a length suitable for the Harting con-
nector used. Do not damage or cut the shield.

2. Disentwine the shield and roll it back over the


cable.

3. Strip back the inner insulation to expose a


suitable length (13/b). Do not damage the
a
insulation of the individual cores in so doing.
b
4. Strip back all cores to expose a suitable length
(13/a) using stripping pliers. This depends on
c
the type of contacts in the connector:
-- Spring-cage terminal connection, see
chap. 4.3.5.2, page 24.
-- Crimp connection, see chap. 4.3.5.3,
page 25.
Fig. 13 : Preparing the cable
Assembling connector and cable gland

5. Slide the parts of the cable gland over the


cable (fig. 14), see also chap. 4.6.2, page 51.
After fitting contacts on the ends of the cores,
it may not be possible to slide the gland over
the cable.

6. Prepare the ends of the cores for connection


in accordance with the wiring diagram:
-- Spring-cage terminal connection, see
chap. 4.3.5.2, page 24.
-- Crimp connection, see chap. 4.3.5.3,
page 25.

7. Assemble the Harting connector, see chap.


4.3.5.1, page 23.

8. Finish off assembling the cable gland, see


chap. 4.6.2, page 51.

Fig. 14 : Preparing the cable gland

Risk of contact damage


Take care not to bend open the
contact pins or sockets with the
test prods when carrying out
CAUTION tests.

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Mechanical and electrical installation Part 7
Wiring Page 23

4.3.5.1 Assembling a Harting connector

Assemble the Harting connector as shown in fig.


15 and screw it tight.

Pos. Name
1
1 Upper housing
2 Contact pins (crimp connection only)
The contact pins must be crimped
onto the ends of the cores and inser-
ted in the pin insert with the pinning
tool, see chap. 4.3.5.3, page 25.
3 Pin insert
4 Socket insert
2 5 Contact sockets (crimp connection
only)
The contact sockets must be crimped
7 onto the ends of the cores and inser-
7
ted in the socket insert with the pin-
ning tool, see chap. 4.3.5.3, page 25.
3
6 Lower housing
7 Fixing screws for pin insert
7
8 8 8 Fixing screws for socket insert
7
4 8

Fig. 15 : Assembling a Harting connector

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Part 7 Mechanical and electrical installation
Page 24 Wiring

4.3.5.2 Connection with spring-cage terminals

This technique establishes a vibration and impact


proof connection. It is suitable for solid and litz
conductors ranging between 0.14 and 2.5 mm2
1 2 2 1 without having to prepare the ends of the cores.

Pos. Name
3 3
1 Opening to release the contact with a
screwdriver
2 Opening for the end of the core
3 Spring-cage terminal

Wire-end ferrules should not be used in this type of


terminal. The connections are not screwed down,
they are clamped and secured by a spring. The
1 2 2 1 spring ensures consistent contact quality. Voltage
drop at the contacts is low.
It is not necessary to change systems which have
Fig. 16 : Spring-cage connection been delivered with wire-end ferrules already fitted
providing that the wire-end ferrules have been pro-
perly secured with a crimping tool. However, no
wire-end ferrules should be fitted on new installa-
tions.
The contact is opened with a screwdriver as
specified by DIN 5264 with a size of approx.
3.0 x 0.5 mm.

Note:
Only insert one conductor in each terminal.

Proceed as follows to connect the end of a core:

1. Strip the end of the core back to expose 8 to


a b 12 mm.

2. Insert the screwdriver (17/a).

3. Open the terminal (17/b).

4. Insert the end of the core in the terminal


c d (17/b).

5. Pull out the screwdriver to close the terminal


(17/c).

6. Check that the end of the core is firmly


seated.
Fig. 17 : Connecting the end of a core
The end of the core is now clamped in place
(17/d).

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Mechanical and electrical installation Part 7
Wiring Page 25

4.3.5.3 Crimp connection

A good crimp connection is air-tight and thus


corrosion-proof. It is effectively a cold weld. The
1
main criteria influencing the quality of a crimp con-
nection is the firm seating of the litz wire in the
connecting part of the contact. This determines
contact resistance and corrosion-proofing of the
2 connection.
Figure 18 shows a cross-section through a Harting
connector with crimp contacts.

Pos. Name
1 Core end
2 Crimp contact
3 Core end stripping length

Proceed as follows:
3
1. Strip approx. 8 mm of insulation off the core
end.

2. Fit a crimp contact over the core end.

3. Crimp the contact with a crimping tool (19/1).

Fig. 18 : Crimp connection (Harting) 4. Insert the contact in the Harting connector
with the pinning tool (20/1).

4.3.5.3.1 Tools required to establish a crimp contact

Crimping tool

The crimping tool (19/1) is used to establish crimp


connections on the contacts of the Harting connec-
tor (MTU order no.: 001 538 71 30).
Cores with conductor cross-sections ranging
between 0.14 mm2 to 2.5 mm2 can be crimped
with this tool.

Fig. 19 : Crimping tool (Harting)

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Part 7 Mechanical and electrical installation
Page 26 Wiring

Pinning tool

This tool is used to install contacts in Harting con-


nectors (MTU item no.: 001 538 49 30).
An assembly tool is recommended to insert the
contacts in the insulator for conductor cross-sec-
tions of less than 0.75 mm2. The contact is inser-
ted in the tool with the crimped conductor and
pressed into the chamber in the insulator as far as
it will go from the connection side.

Fig. 20 : Pinning tool (Harting)

Depinning tool

Contacts can be removed from Harting connectors


with this tool (MTU item no.: 001 538 50 30).
A depinning tool is used to replace the contacts in
a contact insert. The tool is pushed over the con-
tact from the connector side of the plug connector
until it meets noticeable resistance in the contact
carrier. Exerting additional pressure on the tool
releases the contact forcing it out on the connec-
tion side.

Fig. 21 : Depinning tool (Harting)

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Mechanical and electrical installation Part 7
Wiring Page 27

4.3.6 Assembly instructions for KJA connectors

5. Push a shrink-fit hose (22/1), shrink-fit part


(22/2) and adapter (22/3) over the cable.

1 2 3

Fig. 22 : Assembling a KJA connector (1)

6. Determine the length of the terminal housing


(lx ) and cut off the outer sheath of the cable
20 mm more than the length of the terminal
housing (lx + 20 mm).

lx
lx + 20 mm

Terminal housing

Fig. 23 : Assembling a KJA connector (2)

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Part 7 Mechanical and electrical installation
Page 28 Wiring

7. Loosen the shield (24/1) and roll it back.


Remove the inner sheath (24/2) to about
10 mm and strip the individual wires (24/3)
approx. 6 mm  3 mm (for contact sizes 12,
16 and 20).
1 2

10 mm

Fig. 24 : Assembling a KJA connector (3)

8. Place contacts (25/1) over the stripped wires.


The wire must be visible in the aperture (25/2)
2 on crimping. Use the following tool for crim-
ping:
-- Crimp tool M22 520/1-01,
MTU item number 000 538 11 30
-- Crimp tool M22 520/1-04,
1 MTU item number 013 531 59 83
-- Pliers to tighten the terminal housing,
MTU item number 013 531 54 83
-- Spare jaws for pliers,
MTU item number 013 531 53 83

Fig. 25 : Assembling a KJA connector (4)

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Mechanical and electrical installation Part 7
Wiring Page 29

9. Slide the terminal housing (26/1) over the


wires. Press the contacts into the connector
(26/2) with the tools listed below (see fig. 27
and fig. 28).

1 2

Fig. 26 : Assembling a KJA connector (5)

Required tools:

¯ Inserter tools
- Size 20: MS 27 495 A 20, MTU item number 013 531 55 83
- Size 16: MS 27 495 A 16, MTU item number 013 531 56 83

¯ Ejector tool
- Size 20: MS 27 495 R 20, MTU item number 013 531 57 83
- Size 16: MS 27 495 R 16, MTU item number 013 531 58 83

Contact cavities which are not assigned must be fitted with appropriate contacts or dummy plugs.

If no dummy plugs are available, wires can also be crimped in the contacts which are not required. The wires
are then cut out of the insulation at the point of exit. This ensures the necessary sealing and strain relief of
the individual wires.

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Part 7 Mechanical and electrical installation
Page 30 Wiring

10. Move the tip of the inserter tool down the con-
ductor up to the shoulder of the contact.

Fig. 27 : Inserting a contact (1)

11. Insert the contact at the rear of the connector


and push it forwards until it engages.
12. Remove the tool.
13. Check that the contact has been inserted pro-
perly by pulling the conductor gently.

Fig. 28 : Inserting a contact (2)

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Mechanical and electrical installation Part 7
Wiring Page 31

14. Screw the terminal housing to the connector.


(Assembly is greatly facilitated by using an
appropriate socket.)
15. Insert the cylinder housing with the contacts
Shrink-fit hose before fitted into the socket.
shrinking
16. Screw on the terminal housing holding the
socket with a pair of pliers.
17. Carefully shrink on the shrink-fit hose with a
hot-air blower.

Fig. 29 : Assembling a KJA connector (6)

18. Roll the shield (30/1) forwards over the outer


thread of the terminal housing (30/2).

1 2

Fig. 30 : Assembling a KJA connector (7)

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Part 7 Mechanical and electrical installation
Page 32 Wiring

19. Screw on the adapter (31/1) ensuring that the


shield is evenly distributed around the shrink-
fit hose under the shield (31/2). Fold back any
projecting shielding material (31/3).

1 3
2

Fig. 31 : Assembling a KJA connector (8)

20. Shrink on the shrink-fit part (32/1) as shown in


fig. 32.

Fig. 32 : Assembling a KJA connector (9)

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Mechanical and electrical installation Part 7
Wiring Page 33

4.3.7 Assembly instructions for KPSE Cannon connectors

1. Push the shrink-fit part (33/1) and adapter


(33/2) over the cable.

1 2

Fig. 33 : Assembling a KPSE Cannon


connector (1)

2. Strip away 50 mm – 70 mm of the outer


sheath of the cable depending on the cable
diameter and number of wires.

50 mm – 70 mm

Fig. 34 : Assembling a KPSE Cannon


connector (2)

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Part 7 Mechanical and electrical installation
Page 34 Wiring

3. Loosen the shield (35/1) and roll it back. Push


on the shrink-fit hose (35/2). Remove the
inner sheath (35/3) to about 10 mm and strip
the individual wires (35/4) in accordance with
the table “Stripping lengths” below.
1 2 3

Fig. 35 : Assembling a KPSE Cannon


connector (3)

Stripping lengths

Contact size Conductor cross-section Stripping length (in mm)


20 AWG 18 – AWG 26 5
16 AWG 14 – AWG 20 6.5
12 AWG 12 – AWG 14 6.5

4. Fit contacts (36/1) over the stripped wires and


crimp them. The wire must be visible in the
2 aperture (36/2). Use the following tools for
crimping:
-- Cannon crimp tool M22 520/1-01,
MTU item number 000 538 11 30
-- Crimp insert M22 520/1-02,
1 MTU item number 000 538 12 30

Fig. 36 : Assembling a KPSE Cannon


connector (4)

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Mechanical and electrical installation Part 7
Wiring Page 35

Turret trigger latch

Turret in released position


Data plate

Positioner identification
colour code

Socket head screws Spring clip lock

Selector knob

Selector index

Fig. 37 : Adjustable crimp tool M22 520/1-01

The crimp tool must be adjusted according to the specifications in the table below.

Crimp tool settings

Wire cross-section Selector knob settting


0.14 26
0.25 24
0.34 22
0.50 22
0.75 20
1.00 18
1.50 16
2.50 14
AWG 26 26
AWG 24 24
AWG 22 22
AWG 20 20
AWG 18 18
AWG 16 16
AWG 14 14
AWG 12 12

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Part 7 Mechanical and electrical installation
Page 36 Wiring

5. Push the terminal housing (38/1) over the


wires. Wet the contact cavity with spirit or
alcohol before inserting contacts. Insert con-
nector pins or sockets into the connector
(38/2) by hand. Then press them in with the
inserter tool listed below until the contact
engages noticeably in the cavity.

1 2

Fig. 38 : Assembling a KPSE Cannon


connector (5)

Cannon inserter tools

¯ Size AWG 20: Type MS 24 256 A 20

¯ Size AWG 16: Type MS 24 256 A 16

¯ Size AWG 12: Type MS 24 256 A 12

Cannon ejector tools

¯ Size AWG 20: Type MS 24 256 R 20

¯ Size AWG 16: Type MS 24 256 R 16

¯ Size AWG 12: Type MS 24 256 R 12

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Mechanical and electrical installation Part 7
Wiring Page 37

Contact cavities which are not assigned must be fitted with appropriate contacts or dummy plugs.

If no dummy plugs are available, wires can also be crimped in the contacts which are not required. The wires
are then cut out of the insulation at the point of exit. This ensures the necessary sealing and strain relief of
the individual wires.

6. Screw the terminal housing (39/2) onto the


connector (39/3). (Assembly is greatly facilita-
ted if an appropriate socket is used.)
7. Insert the connector housing with the contacts
inserted into the connector socket.
8. Screw on the terminal housing countering the
socket with a pair of pliers.
9. Carefully shrink on the shrink-fit hose (39/1)
with a hot-air blower.

1 2 3

Fig. 39 : Assembling a KPSE Cannon


connector (6)

10. Roll the shield (40/1) forwards over the conical


part of the terminal housing (40/3). Press the
metal braiding into the V-shaped groove and
secure it with rustproof wire (40/2). Fold back
protruding metal braiding and press it onto the
1 2 cone.

Fig. 40 : Assembling a KPSE Cannon


connector (7)

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Part 7 Mechanical and electrical installation
Page 38 Wiring

11. Screw on the adapter (41/1).

Fig. 41 : Assembling a KPSE Cannon


connector (8)

12. Push the shrink-fit part (42/1) over the metal


braiding and shrink it on. The shrink-fit part
must be engaged in the groove around the
1 connector. Shrink on from the connector/from
the connector groove end towards the cable.

Fig. 42 : Assembling a KPSE Cannon


connector (9)

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Mechanical and electrical installation Part 7
Wiring Page 39

4.4 Terminal connections

4.4.1 Screw terminals

After the cable has been appropriately prepared, cables are connected to terminal strips as follows:

1. Strip the wires with stripping pliers as dictated


by the type of wire end ferrule used.
2. Push on the wire end ferrule and crimp it with
the crimp tool.
3. Use the appropriate type of wire end ferrule
(colour-coded) for the respective cable cross-
section.
4. Insert one stripped cable wire into each wire
end ferrule only.
5. Press the wire end ferrules firmly onto the
cable. The appropriate tool is described in
Wire end ferrule chap. 6.
6. Identify the wire with the terminal number
Stripped cable Assembled wire using the identification sleeves provided and
end ferrule secure it tightly in the terminal.

Fig. 43 : Cable with wire end ferrule

There are two types of wire end ferrule:

¯ Wire end ferrule with synthetic collar

¯ Wire end ferrule without synthetic collar

They are shown in figures 44 and 45.

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Part 7 Mechanical and electrical installation
Page 40 Wiring

Wire end ferrule with synthetic collar:


For conductors ranging from 0.5 mm2 to 16 mm2.

Length

Synthetic collar

Fig. 44 : Wire end ferrule with synthetic collar

Wire end ferrule without synthetic collar:


For conductors ranging from 0.5 mm2 to 10 mm2.

Length

Fig. 45 : Wire end ferrule without synthetic collar

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Mechanical and electrical installation Part 7
Wiring Page 41

Wire end ferrules with synthetic collar

Wire cross-section Stripping length Colour Length


(mm2) (mm) code (mm)
0.5 10 orange 14.0
0.75 11 white 14.6
1.0 11 yellow 14.6
1.5 11 red 14.8
1.5 21 red 24.6
2.5 11 blue 15.2
2.5 21 blue 25.0
4.0 12 grey 16.0
4.0 20 grey 25.0
6.0 15 black 20.0
6.0 20 black 26.0
10.0 16 ivory 21.5
10.0 22 ivory 27.5
16.0 16 green 22.7
16.0 22 green 28.7

Wire end ferrules without synthetic collar

Wire cross-section Stripping length Length


(mm2) (mm) (mm)
0.5 6 6
0.75 6 6
0.75 10 10
1.0 6 6
1.0 10 10
1.5 7 7
1.5 10 10
2.5 7 7
2.5 12 12
4.0 9 9
4.0 12 12
6.0 12 12
10.0 12 12
10.0 18 18

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Part 7 Mechanical and electrical installation
Page 42 Wiring

4.4.2 Spring terminals

Do not use wire end ferrules for spring terminals. The connections are not established by screws, they are
clamped and secured by a spring. The spring ensures consistent contact quality. Voltage drop at the con-
tacts is low.

It is not necessary to change systems which have been delivered with wire end ferrules already fitted provi-
ding that the wire end ferrules have been properly secured with a crimping tool. However, no wire end
ferrules should be fitted on new installations.

Strip the appropriate wires by 8 mm – 10 mm before establishing a connection with a spring terminal.

General information about spring terminals

Fig. 46 : Function of a spring terminal

The large-surface clamp of the CAGE CLAMP spring presses against the conductor without damaging it. This
also applies to wires which are connected and disconnected several times.

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Mechanical and electrical installation Part 7
Wiring Page 43

Clamping a wire in a spring terminal

A wire can be clamped in the spring terminal using


a special tool or a screwdriver as specified in
DIN 5264. The tool is illustrated in fig. 47 (MTU
item number 001 538 38 30).

Fig. 47 : Special tool

1. Insert a screwdriver or special tool (see fig.


48) into the aperture as far as it will go.

Fig. 48 : Clamping a wire (1)

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Part 7 Mechanical and electrical installation
Page 44 Wiring

2. The screwdriver blade or the special tool auto-


matically holds the CAGE CLAMP spring in
the open position enabling the conductor to be
inserted.

Fig. 49 : Clamping a wire (2)

3. Pull out the screwdriver or special tool – the


conductor is firmly clamped.

Fig. 50 : Clamped wire

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Mechanical and electrical installation Part 7
Wiring Page 45

PIM with spring-cage terminals

Figure 51 shows the arrangement of the spring-


cage terminals on a PIM.

The openings (51/1) and (51/3) are used to


actuate the spring-cage terminal. The openings
(51/2) and (51/4) are used to insert the stripped
end of the wire.
Proceed as follows to actuate the spring-cage ter-
minals on the PIM:
Note:
This requires a suitable screwdriver in accor-
dance with DIN 5264 or MTU tool item no.
002 538 09 30.

1 1. Insert a screwdriver or actuation tool into the


2 actuator opening as far as it will go (e.g. 51/1)
3 to release the spring-cage terminal concerned.

2. Insert the stripped end of the wire into the


4 appropriate terminal opening (e.g. 51/2) (or
pull it out when disconnecting).

3. Pull the screwdriver or actuator tool out to


close the spring-cage terminal.

4. Check that the end of the wire is firmly seated.


Fig. 51 : PIM with spring-cage terminals
The end of the wire has thus been clamped in
place.

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Part 7 Mechanical and electrical installation
Page 46 Wiring

4.5 Connections with DIN 89 280 cable glands

Ship cables are routed into closed housings using cable glands according to DIN 89 280 when connectors
are not used. MTU supplies these cable glands. They prevent the ingress of splashwater and dirt into the
housing.

Nut

Housing panel Screw fixture Sealing fixture

Fig. 52 : Cable gland according to DIN 89 280

Select the size of cable gland appropriate to the outer diameter of the cable. The diameter of the bore in the
housing panel depends on the size of cable gland selected. The table below provides an overview of the
possible cable glands:

Nominal size M18 x 1.5 M24 x 1.5 M30 x 2 M36 x 2 M45 x 2 M56 x 2 M72 x 2
Bore diameter
(mm) 19 25 31 37 46 57 73
Max. cable dia-
meter (mm) 10.5 17.5 20.5 26.5 32.5 41.5 56.5

All cable glands supplied are suitable for the recommended types of cable.

Note: If cables other than those recommended by MTU are used, the cable glands and the correspon-
ding sealing rings and grounding inserts must be selected on the basis of the outer diameter of
the cable.

Two types of cable gland are differentiated:

¯ Cable glands for shielded cables

¯ Cable glands for non-shielded cables

The glands differ only internally. Cable glands for shielded cables are provided with two grounding inserts for
shield connection inside the screw fixture.

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Mechanical and electrical installation Part 7
Wiring Page 47

Cable glands for Cable glands for


non-shielded cables shielded cables

Seal Inner grounding insert Seal

Outer grounding insert

Fig. 53 : Types of cable gland according to DIN 89 280

The table below shows the relationship between cable dimensions and the cable glands and grounding
inserts to be used.
Select the seal so it encloses the outer sheath of the cable as tightly as possible.

Grounding insert (mm) For cable diameter (mm)


Nominal cable Manufacturer
gland size designation Inner (d) Outer (D) Under the wire Outer diameter
mesh
M18 x 1.5 A1 6 10 5.5 9.5
A2 7 11 6.5 10.5
M24 x 1.5 A3 6 10 5.5 9.5
A4 7 11 6.5 10.5
A5 8 12 7.5 11.5
A6 0.5 14.5 10 14
A7 13 17 12.5 16.5
A8 14.5 18.5 14 18
M30 x 2 A9 15.75 18.5 15 18
A10 17.75 20.5 17 20
M36 x 2 A11 19.75 22.5 19 22
A12 21.75 24.5 21 24
A13 23.75 26.5 23 26
M45 x 2 A14 26.75 29.5 26 29
A15 29.75 32.5 29 32
M56 x 2 A16 34.75 37.5 34 37
A17 38.75 41.5 38 41
M72 x 2 A18 43.75 46.5 43 46
A19 48.75 51.5 48 51

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Part 7 Mechanical and electrical installation
Page 48 Wiring

4.5.1 Assembling DIN 89 280 cable glands

Note: When assembling cable glands ensure that the cable gland, seal and grounding inserts are
appropriate to the cable used.

The work to be performed to assemble a DIN cable gland is described below.

Note: Steps 5, 6 and 7 are only necessary when using shielded ship cables.

1. Make a bore of the appropriate diameter (in


accordance with the table in chap. 4.5).
2. Strip the cable as shown in fig. 54.

approx. 30 mm

Fig. 54 : Stripping the cable

3. Tighten the screw fixture (55/2) with the nut


1 (55/1) at the housing.
2 4. Push the sealing fixture (55/7) and seal (55/5)
6 over the outer sheath of the cable.
5. Push the outer grounding insert (55/4) over
the shield (55/6) up to the edge of the outer
insulation.
6. Push the inner grounding insert (55/3) over
the inner cable insulation.
3 7. Clamp the shield (55/6) between the two
grounding inserts.
5 8. Insert the cable with the grounding inserts and
4 the seal through the screw fixture (55/2).

7 9. Screw the seal fixture (55/7) into the screw


fixture (55/2) and tighten it.
10. Seal the cable entry with sealing compound
Fig. 55 : Installation of the cable gland with or seal a shrink-fit hose additionally with adhe-
cable sive.

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Mechanical and electrical installation Part 7
Wiring Page 49

4.6 Assembling HSK cable glands

HSK cable glands are used by MTU for leading through cables. They feature a patented anti-vibration and
anti-rotation element.
Cable glands with metric threads are used. The EMC version is used to establish contact between the cable
shielding braid and the housing.

4.6.1 HSK cable gland

HSK cable glands with metric threads fulfill DIN 40 050 protection index IP 68 up to 10 bar and are resistant
to oil and petrol.

Note: Use HSK cable glands with EMC if a cable shield is to be connected to the housing, see chap.
4.6.2, page 51.

4.6.1.1 Mounting in a housing wall

Fig. 56 shows the correct arrangement of the parts


when assembling the cable gland.

4
Pos. Name

3 1 Cable

2 2 Union nut
3 Intermediate sleeve
4 Housing wall
1 5 5 Counternut

Proceed as follows to fit the cable gland:

1. A suitably large bore must be made in the


housing wall (56/4) if this is not already the
case. Countersink the bore 1 mm deep at 45_
to ensure that the seal makes proper contact
Fig. 56 : HSK-K cable gland (57). Refer to the table below for details of
bore diameters (57/d):

1 mm Nominal size Through-hole


45_
M 12 x 1.5 12.2 mm
M 16 x 1.5 16.2 mm
M 20 x 1.5 20.2 mm
M 25 x 1.5 25.2 mm
d
M 32 x 1.5 32.2 mm
M 40 x 1.5 40.2 mm

Fig. 57 : Through-hole M 50 x 1.5 50.2 mm


M 63 x 1.5 63.2 mm

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Part 7 Mechanical and electrical installation
Page 50 Wiring

2. Insert the intermediate sleeve through the


bore as shown in fig. 56.

3. Screw the counternut (56/5) onto the inter-


mediate sleeve and tighten it using a suitable
tool. Counter the intermediate sleeve (56/3)
when tightening.

4. Insert the cable (56/1) through the union nut


(56/2) and the intermediate sleeve (56/3).
Slacken off the union nut beforehand if neces-
sary to allow the cable to be inserted without
exerting undue force.

5. Screw the union nut (56/2) over the inter-


mediate sleeve (56/3) as far as possible by
hand.

6. Tighten the union nut (56/2) at the inter-


mediate sleeve using a suitable tool.

4.6.1.2 Mounting in a housing wall or connector with threaded bore

Fig. 58 shows the correct arrangement of the parts


when assembling the cable gland.

4
Pos. Name
3 1 Cable

2 2 Union nut
3 Intermediate sleeve
4 Housing wall
1
Proceed as follows to fit the cable gland:

1. Screw the intermediate sleeve into the threa-


ded bore as shown in fig. 58 and tighten it with
a suitable tool.

2. Insert the cable (58/1) through the union nut


Fig. 58 : HSK-K cable gland (58/2) and the intermediate sleeve (58/3).
Slacken off the union nut beforehand if neces-
sary to allow the cable to be inserted without
exerting undue force.

3. Screw the union nut (58/2) over the inter-


mediate sleeve (58/3) as far as possible by
hand.

4. Tighten the union nut (58/2) at the inter-


mediate sleeve (58/3) using a suitable tool.

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Mechanical and electrical installation Part 7
Wiring Page 51

4.6.2 HSK with EMC cable gland


HSK-M-EMC cable glands are waterproof, high-level EMC cable glands for cables with braided shields. They
are made of metal and have a clamping insert made of plastic. They ensure low-resistance 360_ contact
between the braided shield of the cable and the housing. Furthermore, they fulfill DIN 40 050 protection in-
dex IP 68 up to 10 bar.

Fig. 59 shows the correct arrangement of the parts


when assembling the cable gland.
5 6
Pos. Name
4 1 Cable
3 2 Union nut
2 3 Clamping insert

1 4 Intermediate sleeve
5 Housing wall
6 Counternut

Proceed as follows to assemble the cable gland:

1. A suitably large bore must be made in the


housing wall (59/5) if this is not already the
Fig. 59 : HSK-M-EMC cable gland case. Countersink the bore 1 mm deep at 45_
to ensure that the seal makes proper contact
(60). Refer to the table below for details of
bore diameters (60/d):

1 mm Nominal size Through-hole


45_ M 12 x 1.5 12.2 mm
M 16 x 1.5 16.2 mm
M 20 x 1.5 20.2 mm
M 25 x 1.5 25.2 mm
d M 32 x 1.5 32.2 mm
M 40 x 1.5 40.2 mm
M 50 x 1.5 50.2 mm
Fig. 60 : Countersinking
M 63 x 1.5 63.2 mm

2. Through-hole:
Insert the intermediate sleeve in the bore as
shown in fig. 59.
Threaded bore:
Screw the intermediate sleeve into the threa-
ded bore and tighten with a suitable tool.

3. Through-hole:
Screw the counternut (59/6) onto the inter-
mediate sleeve (59/4) and tighten with a
suitable tool. Counter the intermediate sleeve
(59/4) when tightening.

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Part 7 Mechanical and electrical installation
Page 52 Wiring

4. Push the union nut (59/2) over the cable


(59/1).

5. Push the clamping insert (59/3) over the cable


(59/1).

6. Strip off a suitable length of cable insulation


(61).

Fig. 61 : Stripping a cable

7. Push the clamping insert (62/1) up to the


stripped cable shield and fold the shield back
over the clamping insert.
2
1

Fig. 62 : Clamping insert

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Mechanical and electrical installation Part 7
Wiring Page 53

8. Push the end of the cable (63/1) through the


intermediate sleeve (63/2) until the clamping
1 insert (63/3) makes contact in the intermediate
sleeve (63/2).
2
3
4

Fig. 63 : Assembling the cable gland

9. Screw the union nut (63/4) over the inter-


mediate sleeve (63/2) and tighten it with a
suitable tool.

Fig. 64 : Cable gland assembled

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Part 7 Mechanical and electrical installation
Page 54 Ambient conditions

5 Ambient conditions
The following general ambient conditions apply for monitoring and control components in a main control con-
sole, auxiliary control consoles and in the engine room. Values specific to a particular device are listed in the
respective description of the device or in the installation drawing.

Power supply 24 VDC 20 %

Residual ripple 5 % within the specified voltage limit

Ambient temperature 0 °C … 50 °C

Shock See installation drawing

Vibration See installation drawing

Relative humidity 0 % … 90 %, non-condensing

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Mechanical and electrical installation Part 7
Interference suppression Page 55

6 Interference suppression

6.1 Introduction

On-board high intensity radio interference represents a major source of disturbance for devices and
systems. It is also of little significance whether the devices and systems concerned involve low-level signal
electronics, or are used for the processing of information or power electronics involving control and auxiliary
electronic systems.

Furthermore, malfunctions or even failure of devices or component parts may result if cables are routed
incorrectly or poorly leading to interference.

Device 1 Device 2

Power
supply

Grounding system

Frame

Fig. 65 : System interference

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Part 7 Mechanical and electrical installation
Page 56 Interference suppression

6.2 Grounding
Devices are grounded on the one hand to ensure personal safety by avoiding hazardous currents. On the
other hand, grounding is necessary for reasons of EMC to allow induced, radio-frequency interference cur-
rents in shields and housings to be grounded.

Monitoring and control components, cable shielding and the radio system must not have a common ground.
This also applies to sonar system grounding.

The individual devices must be grounded at the intended grounding connections. The grounding lines should
be kept as short as possible and have an adequate cross-section.

Particular attention must be paid to planning and realizing the grounding system on ships with non-metallic
hulls. The grounding plates must have a surface area of at least 1.5 m2 and be attached on each side of the
keel. They must be interconnected using a conductor with a minimum cross-section of 100 mm2. Separate
grounding systems must be provided for antennae and transmitters and for sonar, Monitoring and Control
Systems and other electrical equipment.

All the grounding lines on each deck are star-connected to a distributing plate. The connection of distributing
plates between decks and to the grounding plates must be established with an adequately dimensioned
cross-section.

An exemplary grounding system is illustrated in fig. 66.

Safety ground Antennae ground Electrical ground


Engine, control, regulating and monitoring system

Radio room
General monitoring systems
Sonar

Grounding plates
Distributing plates

Fig. 66 : Schematic representation of the grounding system

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Mechanical and electrical installation Part 7
Interference suppression Page 57

6.3 Shielding

All shielded cables must be carefully grounded. Always ground the shields to the housing potential. Shielding
on one side is only acceptable in exceptional cases. The shields must be grounded at the intended shielding
inserts of the metallic or metal-plated cable entries or connectors (see chap. 4, page 18).
So-called “pig-tail grounding” of a shield is unacceptable. “Pig-tail grounding” means that the shield is con-
nected to a grounding terminal or stud via a wire “pig-tail”. When a shield is connected via a “pig-tail”, the
shield is generally inserted into the area to be protected additionally violating the concept of complete shiel-
ding or sheathing. This results in a part of the cable or line being unshielded. Furthermore, the “pig-tail”
represents a higher shield resistance which considerably reduces the shielding effect and increases the ten-
dency of the shield to emit radio interference.

Internal shields are intended to prevent line feedover within a cable. Internal shields are usually connected to
the reference potential of the circuit which they cover. If the transmission path is electrically isolated on one
side, the internal shields are usually only connected to circuit ground on the transmitter side, i.e. on the side
with the higher signal energy. Internal shields can often only be connected via a “pig-tail”. Make sure that the
unshielded part of the conductor is as short as posssible.

Internal and external shields must be carefully separated and must not be in electrical contact. The shields
are usually of different potential which may result in undesirable malfunctions or faults in the circuits in case
of an electrical connection between the shields.

6.4 Cable routing

Route data and signal cables away from supply or power cables. Avoid laying cables in parallel next to each
other. The distance between these lines should be at least 30 cm.
Data and signal cables may only cross disturbing cables or lines at an angle of 90°.

Cable and grounding bar paths must always be kept as short as possible. All lines for the grounding of
antennae and transmitters must be routed at a suitable distance from all other lines (at least 2 m). These
cables or lines must be crossed at an angle of 90°.

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Part 7 Mechanical and electrical installation
Page 58 Installation materials

7 Installation materials, tools and accessories


Trouble-free operation of the Monitoring and Control Systems can only be achieved in the long run if the
systems are installed using suitable tools and installation materials.

The tools and installation materials required for installation are available from MTU. Orders or requests for
quotations and delivery times should be made stating

¯ The MTU item number

¯ The required quantity

Note: Tools, test equipment, ship cables or installation materials should be requested or ordered from
MTU in good time to allow them to be delivered together with or prior to delivery of the Monito-
ring and Control System.

7.1 Installation tools

7.1.1 Crimp tools

Tool MTU item number


Hand crimp tool (MS3191A) 000 538 01 30
Inserter tool AWG 16 (CIT-F80-16) 000 538 02 30
Inserter tool AWG 12 (CIT-F80-12) 000 538 03 30
Ejector tool AWG 16 (CET-F80-16) 000 538 04 30
Ejector tool AWG 12 (CET-F80-12) 000 538 05 30
Crimp insert AWG 16 socket (600092) 000 538 06 30
Crimp insert AWG 16 pin (600091) 000 538 07 30
Crimp insert AWG 12 pin/socket (600216) 000 538 08 30
Guide pin 000 538 09 30
Guide pin 000 538 10 30
Hand crimp tool for Harting connectors 001 538 71 30
Pinning tool 001 538 49 30
Depinning tool 001 538 50 30

7.1.2 Tools for actuating spring-cage terminals


Spring-cage terminals can be actuated with the following tools only:
¯ A suitably sized screwdriver as specified in DIN 5264 may be used in principle.
¯ Wago terminals in the Local Operating Panel: MTU tool item no. 001 538 38 30
¯ Spring-cage terminals on PIMs: MTU item no. 002 538 09 30

Risk of damaging spring-cage terminals


Only use suitable tools to actuate spring-cage terminals. The terminals may
otherwise be damaged resulting in poor contact and malfunction.

CAUTION

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Mechanical and electrical installation Part 7
Installation materials Page 59

7.1.3 Tools for fitting wire end ferrules

The following tools are available for fitting wire end ferrules:

¯ Wire stripping pliers, MTU item number 000 538 42 30

¯ Wire end ferrule crimp tool, MTU item number 001 538 06 30

7.2 Installation materials

Trouble-free operation of Monitoring and Control Systems can only be achieved in the long run when
suitable materials are used to install the systems. If the necessary materials are unavailable on site, they
can be obtained from MTU.

7.2.1 Halogen-free ship cables in accordance with DIN 89 159 with classifica-
tion approval

The recommended ship cables can be obtained from MTU if required. The cables are also available in short
lengths. Place your orders or requests for quotation of prices and delivery times stating

¯ The type of cable (e.g. FMGCG)

¯ The nominal cross-section (e.g. 10 x 2 x 0.75 mm2)

¯ The required length

Do not hesitate to contact MTU for information about other ship cables and materials which are available.

Ship power cable type MGCG with shield in accordance with DIN 89 158

¯ Structure:
- Tinned copper conductor
- Ethylene-propylene-rubber insulation resistant to heat and ageing
- Common wire sheathing comprising filler, polyester foil, copper braiding, polyester foil
- Synthetic rubber outer sheath on a polychloroprene basis

¯ Wire identification:
- Up to six wires: Colour-coded
- From seven wires on: Grey with printed numbers

¯ Sheath colour: Black

Nominal cross- Max. cable Weight Load


section diameter in kg/km capability
in mm2 in mm in A
2 x 1.5 13.1 240 17
3 x 1.5 13.7 270 14

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Part 7 Mechanical and electrical installation
Page 60 Installation materials

Nominal cross- Max. cable Weight Load


section diameter in kg/km capability
in mm2 in mm in A
4 x 1.5 14.5 310 14
5 x 1.5 15.8 360 12
7 x 1.5 17.1 420 10
10 x 1.5 21.2 650 9
12 x 1.5 22.0 680 9
14 x 1.5 22.8 750 8
16 x 1.5 24.0 850 8
19 x 1.5 25.1 950 7
24 x 1.5 29.6 1200 7

Ship telecommunications cable type FMGCG with shield in accordance with


DIN 89 159

¯ Structure:
- Tinned copper conductor
- Ethylene-propylene-rubber insulation resistant to heat and ageing
- Common wire insulation comprising two layers of polyester foil, copper braiding, polyester
foil
- Synthetic rubber outer sheath on a polychloroprene basis

¯ Wire identification: All wires grey with printed numbers

¯ Sheath colour: Black

Nominal cross- Max. cable Weight Load


section diameter in kg/km capability
in mm2 in mm in A
2 x 2 x 0.75 11.0 170 7.5
4 x 2 x 0.75 14.5 290 6.0
7 x 2 x 0.75 18.5 410 4.5
10 x 2 x 0.75 21.0 580 4.0
14 x 2 x 0.75 24.0 740 3.5
19 x 2 x 0.75 28.0 930 3.5
24 x 2 x 0.75 30.5 1200 3.0

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Mechanical and electrical installation Part 7
Degrees of protection Page 61

8 Preferred degrees of protection


In Germany, the degrees of protection for electrical equipment are preferably designated as follows:

IP 4 4

Code letters

First digit

Second digit

Fig. 67 : Example of the designation of a degree of protection

The meaning of the first and second digits are explained below.

8.1 Degrees of protection against contact and foreign bodies

First digit Extent of protection


Denomination Explanation
0 No protection No particular protection of personnel against unin-
tentional contact with live or moving parts
No protection of the equipment against the ingress
of solid matter/foreign bodies
1 Protection against large foreign bodies Protection against unintentional large-surface con-
tact with live parts or internal movements, but no
protection against deliberate access to these parts
Protection against the ingress of solid matter/
foreign bodies of a diameter exceeding 50 mm
2 Protection against medium-sized foreign Protection against finger contact with live parts or
bodies internal movements
Protection against the ingress of solid matter/
foreign bodies of a diameter exceeding 12 mm
3 Protection against small foreign bodies Protection against contact with live parts or internal
movements with tools, wires or similar thicker than
2.5 mm
Protection against the ingress of solid matter/
foreign bodies of a diameter exceeding 2.5 mm
4 Protection against granulose foreign Protection against contact with live parts or internal
bodies movements with tools, wires or similar thicker than
1 mm
Protection against the ingress of solid matter/
foreign bodies of a diameter exceeding 1 mm

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Part 7 Mechanical and electrical installation
Page 62 Degrees of protection

Denomination Explanation
5 Protection against dust deposits Full protection against contact with live parts or
internal movements

Protection against harmful dust deposits: The


ingress of dust is not prevented entirely, however
dust is not allowed to ingress in quantities which
impair operation
6 Protection against the ingress of dust Full protection against contact with live parts or
internal movements

Protection against the ingress of dust

8.2 Degrees of protection against water

Second Extent of protection


digit
Denomination Explanation
0 No protection No particular protection
1 Protection against dripping water falling Dripping water falling vertically onto the assembly
vertically must have no harmful effect
2 Protection against dripping water falling Dripping water falling at an angle of up to 15° from
up to 15° from the vertical the vertical must have no harmful effect
3 Protection against spray-water Water falling at an angle of up to 15° from the verti-
cal must have no harmful effect
4 Protection against splash-water Water sprayed on the assembly from all directions
must have no harmful effect
5 Protection against jet-water A jet of water from a nozzle directed at the assem-
bly from all directions must have no harmful effect
6 Protection against deck-water Water must not ingress the assembly in damaging
quantities in case of temporary flooding, e.g. in high
seas
7 Protection against immersion Water must not ingress the assembly in damaging
quantities when it is immersed in water at a certain
pressure for a certain time
8 Protection against continuous sub- Water must not ingress the assembly in damaging
mersion quantities when it is submerged under water at a
certain pressure for longer than a defined minimum
time

 MTU – 03.2003 – E 530 606 / 06 E


Mechanical and electrical installation Part 7
Placing orders Page 63

9 Placing orders
The following information is required for handling orders or requests for parts and
materials:

¯ MTU item number of the required parts (enquiries cannot be answered unless the item number
is stated)
Exception: Ship cables and cable materials

¯ Number of required parts (the quantities may refer to one engine or the entire quantity)

¯ MTU order: MTU order number under which the engines are/were delivered

¯ Delivery date: Desired date of delivery for the parts

¯ Transportation: Desired form of transport (e.g. by sea, road or air)

¯ Delivery site: Destination to which the parts should be delivered

Direct your enquiries together with the information listed above to the MTU project department.

E 530 606 / 06 E – 03.2003 –  MTU


Part 7 Mechanical and electrical installation
Page 64 Placing orders

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 MTU – 03.2003 – E 530 606 / 06 E


Abbreviations Page i

Abbreviations
% Percent
° Degree of angle
°C Degrees Celsius

A Ampere
AC Alternating Current
AO Anordnungszeichnung, arrangement drawing
AWG American Wire Gauge

BMK Betriebsmittelkennzeichnung, item designation

cm Centimeter

d Inner diameter
D Outer diameter
DC Direct Current
DIN Deutsches Institut für Normung, German National Standards Institute

E Einkerbungslänge, nick length


EB Einbauzeichnung, installation drawing
EMC Electromagnetic Compatibility

FMGCG Ship telecommunications cable with shield in accordance with DIN 89 159

IP Ingress Protection (degree of protection according to DIN 40 050)

kg Kilogram
km Kilometer
kW Kilowatt

l Length
LD Lochdurchmesser, bore diameter
LED Light Emitting Diode
LT Lochtiefe, bore depth

E 530 606 / 06 E – 03.2003 –  MTU


Page ii Abbreviations

Abbreviations (cont.)

m Meter
mA Milliampere
mm Millimeter
MGCG Ship power cable with shield in accordance with DIN 89 159

RF cable Radio Frequency cable

SM Schematic diagram

V Volt
VG Verteidigungsgerätenorm, defense equipment standard

ZB Zusammenbauzeichnung, assembly drawing

 MTU – 03.2003 – E 530 606 / 06 E