Connection and Function Test of Electrical System For ME Engine

MAN B&W Diesel A/S
Connection
and
Function Test
of electrical system
for ME Engine
July 2006
MAN B&W Diesel A/S
Table of Contents
1 Power Supply Check 5

1.1 MPC fuse specification 5
2 ID-key Boot Loader Program 5
2.1 Operation 5
2.1.1 Connections and settings – normal operation 6
2.1.2 Start-up normal operation 7
2.2 Programming the ID-key (Network Address) 8
2.2.1 Connections and settings – programming. 8
2.2.2 Programming Sequence for ID-Key 9
2.3 2.3 Troubleshooting LED messages 10
3 Network Test 11
3.1 3.1 Access to Service Terminal 12
4 Updating and Archiving MPC Parameters from the MOP 14
4.1 MPC Parameter update 14
4.2 Archiving Parameter Files 15
4.3 4.3 How to make a copy of ECU-A into ECU-B: 16
4.4 (for Soft Ware version 1.34 or later) 16
4.5 18
5 Connection test of I/O 18
6 Check of Serial Communication between RCS and ECS 18

6.1 How to inspect Serial communication between RCS and ECS 18
6.2 How to simulate values from ECS to RCS 18
7 Adjustment of encoder 19
7.1 Check Tacho system cable 19
7.2 Check of encoder adjustment. 20
7.3 Adjustment of encoder-clockwise 21
7.4 Check of tacho sensor at flywheel. 23
8 Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm 23
8.1 Connection test of ELFI valve without hydraulic pressure 23
8.2 Connection test of ELVA valve without hydraulic pressure 24
8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar) 24
8.4 Connection test of FIVA valve with hydraulic pressure (app. 175 bar) 25
8.5 Connection test of starting air valves 25
8.6 Test of main starting air valve manually on the MOP 25
8.7 Connection test of HCU oil leakage alarm 26
8.8 Hints for connection test and fault finding: 26
9 Test of Swash-plate pumps (Hydraulic-Pressure On) 29
9.1 Functions test 29
9.2 Troubleshooting 30
10 ME Alpha Lubricator Quick Guide 32
Document id: 3090532-9.4.7 Connection and Function Test
Resp.:2300/AAJ/LLL 2
2006-07-11
MAN B&W Diesel A/S
10.2. MOP Screen “Cylinder Lubricators” 32

10.3 Lubrication Amount Calculation: 34
10.4 ALPHA LUBRICATOR WITH ME ENGINES - BREAKING-IN/RUNNING-IN FEED
RATE SETTING 36
11 Appendix 38
11.1 Opening and setting up the Hyper Terminal program 38
11.2. Swash plate position values 39
11.3. Tools for commissioning 39
11.4. Overview MPC connections 40
11.5. MPC LED Indication 41
11.6. Settings of Liquiphant level switch 44
11.7. Connection test scheme 1
Document History:
Date Author Changes
2005-06-09 AAJ ACU4 added
F9 6A » 10A
F4 2A » 3,15A
Connection test scheme for

CCU, ACU,EICU & ECU
changed signal text and
signal ID
2005-07-20 AAJ Adjustment of encoder
updated
2005-08-04 AAJ 2.2.1 Connections and
settings - program is updated
4.1 “MPC Parameter update”

is updated for s-paf file.
“Network address= Sum of

activated Dipswitch” is
deleted
“ECS Network address” is

deleted in Appendix 9
Introducing 6.1 “Check of

tacho system cable”
2005-08-29 AAJ 9. ME Alpha lubricator quick

guide added
4.3 How to make a copy of

ECU A into ECU B added
2005-09-14 AAJ Picture of MOP-screen insert
regarding new
ArcHive/update tool 4.0 and

2006-07-11
MAN B&W Diesel A/S
Network status 3.0

2005-09-27 AAJ Updated 2.2.1 Connections
and settings-programming
(DIP-switch)
2005-10-29 AAJ Updated 2.2.1 Connections
and settings-programming
(DIP-switch) (CCU8)
2006-07-11 AAJ Update 9 ME Alpha
lubricator quick guide text
2006-07-11 AAJ Added 6 Check of Serial
communication between
RCS and ECS

2006-07-11
MAN B&W Diesel A/S
Pre-conditions:
• All MPC (Multi - Purpose Controller) – print cards must be mounted in the respective mounting boxes
on the engine.
• Measurements for earth fault must be made, with multi-meter on all cable connections.
• All cables mounted on plugs for MPC must be marked with plug number and terminal number, and all
cables mounted according to actual plant electrical diagram.
• All cables/plugs to be mounted on MPC-print must be disconnected.
• Battery mounted on MPC board (See chapter 2.1.1)
• Tools according to appendix 10.3
1 Power Supply Check

On all MPC units check polarity and voltage on plug J1: (A power): A = - / B = + (B power): A = - / C= +, the
voltage must be in the range 20-30Vdc.
On Main Operating Panel (MOP A), check the polarity and voltage. The voltage must be in the range 20-30Vdc.
On Main Operating Panel (MOP B), check that the 220/110VAC switch is set according to the power supply.
1.1 MPC fuse specification
In Appendix 11.4 explanation of MPC fuse specification and MPC fuse function.
2 ID-key Boot Loader Program

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

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

2006-07-11
MAN B&W Diesel A/S
2.1.1 Connections and settings – normal operation
See below figures for DIP-switch settings and location of LED, ID-key and service terminal plug on MPC board.
View of MPC board with ID-key connected.
Battery mounted on MPC board
LED ( Led Emitting Diode)
ID-key Mounted on MPC (J206)
Service Terminal Connection (J67)
DIP-switch S1 on MPC-board.
DIP-switch S1
DIP-switch S1: Neutral ⇒ All in off position
• ON ⇒ Binary 1
• OFF ⇒ Binary 0

2006-07-11
MAN B&W Diesel A/S
Multi colour DIP-switch on side of MPC board, settings for connection test and normal service
DIP-switch Nos. 1& 8 must be in off position.
• OFF
• ON
2.1.2 Start-up normal operation
LED messages: Error(red) -> Init(Orange) -> Normal(Green). See appendix 10.5 for details
During start-up, the MPC verifies if the ID-key is connected. It reads the ID number and checks if the ID-key ID
is in the correct format and has a valid range, it reads the DIP-switch S1 value and verifies if it is 0 (Off). The
program completes the ID-key verification and is now ready to continue the boot sequence. Any deviations will
send an error message via the LED.
Initialising BES kernel...OK

Starting dongle verification
Reading Dongle ID...Value = 192
Reading DIP-switch S1... Value = 0
Dongle verification done.
Continuing boot sequence.
Figure 1: Messages sent to a portable PC with Windows Hyperterminal

program that is connected to the service terminal plug J67 on an MPC using
a zero modem cable.

2006-07-11
MAN B&W Diesel A/S
2.2 Programming the ID-key (Network Address)
2.2.1 Connections and settings – programming.

DIP-switch S1 set to value to be programmed.
The service technician can program the ID-key with a new ID using the DIP-switch S1. Any previous value in
the ID-key will be erased.
Switch on DIP- 1 2 3 4 5 6 7 8
switch S1
MPC Network DIP switch S1 Settings
Address
ACU 1 224 Off Off Off Off Off On On On

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

2006-07-11
MAN B&W Diesel A/S
2.2.2 Programming Sequence for ID-Key
LED messages: Code 4,2 and 4,3 (see chapter 2.3 and appendix 11.5)
The program first verifies if the ID-key is connected (2a). In this case, it confirms that the ID-key is not
connected and sends error code 42 through the LED. The service technician may now connect the ID-key for
programming. The program switches to programming mode and reads the DIP-switch S1 value to determine
the new ID number that the user wants to program the ID-key (2b). This value must be a valid ID-key, ID
number or the program will halt. Before programming, the program verifies if the ID-key is connected (2c) and
proceeds to program the new ID number. The MPC is then ready to continue booting and sends code 43 to the
LED. This signals the technician to change the DIP-switch (S1) back to its neutral position (2d). When the DIP-
switch S1 is set to neutral (off), the MPC is now ready to continue normal booting operation.
2a
Starting Basic System...
Testing RAM...
RAM OK 2b
Initialising BES kernel...OK
Starting dongle verification
2c
Reading Dongle ID......not connected!
Switching to programming mode. 2d
Reading DIP-switch... Value = 240
Programming Dongle with DIP-switch value.
Dongle not connected! Please connect dongle.
Dongle programmed successfully
Preparing to boot...
DIP-switch not neutral. Please set DIP-switch to neutral.
Reading DIP-switch... Value = 0
Dongle verification done.
Continuing boot sequence...
Figure 2: Messages from the service terminal of the MPC when programming ID-key with DIP-switch.

2006-07-11
MAN B&W Diesel A/S
2.3 2.3 Troubleshooting LED messages
Problem: The LED flashes code 4,3.
Cause: DIP-switch S1 is not set to neutral. The connected ID-key may have a valid number or a new ID-key ID
number has been programmed. DIP-switch S1 in the MPC must be set to neutral (OFF) for the boot operation
to continue.
Solution: Set DIP-switch S1 to neutral (OFF).
Problem: The LED flashes code 4,2.
Cause: The MPC has read the requested new ID-key, ID from the DIP-switch S1, but cannot program the ID-
key because it is not connected.
Solution: Connect the ID-key to the MPC.
Cause: The MPC has read the requested new ID-key, ID from the DIP-switch S1, but found it to be out-of-
range.
Solution: Disconnect the ID-key. Verify that the DIP-switch S1 is set to a valid value and reset the MPC.
Cause: DIP-switch S1 is set to neutral for normal boot, but the ID-key is not connected.
Solution: Connect the ID-key and reset the MPC.
Cause: The ID number read into the ID-key is invalid.
Solution: Proceed to reprogram the ID-key. Remove the ID-key, set the DIP-switch S1 to the new dongle ID
number and reboot the MPC. Follow the steps used to program the ID-key under section 2.2.1, “Use DIP-
switch S1 to Program the ID-key, ID”.
Cause: ID-key is defective.
Solution: Replace ID-key.
Error code Description

4,2 ID-key not connected
Invalid Dongle ID
Invalid DIP-switch S1 value
Programming ID-key failed
4,3 DIP-switch S1 not neutral

2006-07-11
MAN B&W Diesel A/S
3 Network Test
The network must not be crossed, i.e. net A terminated in plug 65 and net B in plug 66. Check all cable
connections visually and mount the terminating resistor to net A and B as shown below.
In ECU A & B, a 120 ohm terminating resistor

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

must be mounted at the end of the arcnet line A
and B net in the SUB-D9 plug.
Screen for network cable
Terminating resistor.
Network status on the MOP screen
The network status screen contains information on the accessibility of the nodes on the network and on the
status of the cabling of the individual nodes.

2006-07-11
MAN B&W Diesel A/S
The network connection can also be checked using a service terminal, i.e. portable PC with Windows
HyperTerminal program that is connected to the service terminal plug J67 on an MPC using a zero modem
cable.
3.1 3.1 Access to Service Terminal
• Opening and setting up the Hyper Terminal program (see appendix 11.1)
• Connect a PC to the service terminal plug J67.
• Type <manbw> and press enter.
• Use the keyboard arrows to remove the cursor to ‘Control Network Management’ and press enter.
• Use the keyboard arrows to remove the cursor to ‘View Network Map Segment 0 (Arcnet A).
• Check that all MPC’s on the network are ON and that the MPC connected to the service terminal is
shown as MY. See appendix 10.4 for a description of MPC type and HEX network address.
• If an MPC is not ON, check the network cabling and status of the LED on the MPC.
• Repeat the above procedure for Network Map Segment 1 (Archnet B).
In the example below the service terminal is connected to CCU 1(0xF0)->MY, ACU 1(0xE0), ACU 2(0xE1),
ACU 3(0xE2), ECU A(0xD0), ECU B(0xD1), EICU A(0xC0) and EICU B(0xC1) are ON. CCU 2-> are not
connected indicated by ++.
The first column is the first value after 0x, the top row is the second value, i.e. CCU1 = (0x)F0.

2006-07-11
MAN B&W Diesel A/S

2006-07-11
MAN B&W Diesel A/S
4 Updating and Archiving MPC Parameters from the MOP

Preconditions
• The MOP and the MPC’s must be connected by ArcNet.
• The MOP must have the BES_SERVER running and the MPC’s must be set-up according to
chapter 2.
• The node table on the MOP must correspond to the actual system connected.
• The archive files can also be up- or down-loaded using the service terminal on the MPC, but
this scenario is out of the scope of this document.
4.1 MPC Parameter update

This section describes how to update MPC parameters using parameter archive files. The update can be done
running the MPC Archive tool.
On the MOP PC, press “Ctrl” “Esc” at the same time on the keyboard. When windows start menu appears,.
choose “explore” and open: C:\Program Files\MANBW\MOP\Tools
1. Start the MPCArchive program (MpcArchive.exe) and select the “Update” tab.
2. Version a) to be used if the update file is MANBW-spaf and you will update all MPC`c, and version b) if
you only want to update MANB-paf file on one or some MPC`s.
a.
Add the archive files by pressing the “Update system” button and select the s-paf file to be
used for the update (see picture below).
b.
Add the archive files by pressing the “Add Files” button and select the file(s) to be used for the
update. If download is to be made to several MPC’s, press the ‘Shift’ button on the keyboard
and select all the files. The files can be located in a folder on the harddisk or on another media.
The application will attach each file to an MPC, by comparing the ArcNet addresses in the files
with the dongle ID’s/addresses of the MPC’s.
3. Select the MPC(s) to be updated (press the ‘Shift’ button on the keyboard to select more than one
MPC) and press the “Update Par.” button. The MPC(s) will reboot in configuration mode thereby
stopping the application, and the parameter files will be downloaded. The status of the operation can
be seen in the ‘Download Status’ column.
4. After completion (Online Status ->Normal), select the MPC(s) in question and restart the MPC(s) by
pressing “Restart App.”. This will start the application using the new parameters.

2006-07-11
MAN B&W Diesel A/S
4.2 Archiving Parameter Files

This section describes how to extract parameter files from the MPCs.
1. Open the MPC Archive tool.

2. Select a destination directory for the archive files, i.e. C:\temp.
3. Press “Get All” or select one or more MPCs and press “Get Selected” to start extraction of the
parameter archive files. The status of the operation can be seen in the ‘Upload Status’ column.

2006-07-11
MAN B&W Diesel A/S
4.3 4.3 How to make a copy of ECU-A into ECU-B:
4.4 (for Soft Ware version 1.34 or later)

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

2006-07-11
MAN B&W Diesel A/S
The same procedure is used to copy ECUA into ECUB.

2006-07-11
MAN B&W Diesel A/S
4.5
5 Connection test of I/O

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

2 Select <Node Mode>.
3 Select <Test>.
4 Answer y to continue followed by pressing enter
5 Select <System Test>
6 Then choose Input or Output
The Connection test must be done according to the connection test scheme (Appendix 11.7 Connection Test
Scheme).
6 Check of Serial Communication between RCS and ECS
6.1 How to inspect Serial communication between RCS and ECS
• Select ‘Adjust Parameters’ and browse to:

‘I/O Configuration -> Configuration Options -> Non or Old Application Options -> Modbus-RCS
Connection Test’
Verify that this parameter is set to ‘No’. If not Use ‘Node Mode Control’ menu to Set EICU in
‘Configuration’ mode and change the parameter to ‘No’.
• If not already in ‘Normal Mode’ use ‘Node Mode Control’ menu to Set EICU in ‘Normal mode’.
• Choose ‘View/Edit Data tree’ and browse to:
System ->RCS Interface -> IO Variant A -> Data to/from RCS
In some situations ‘IO Variant B’ or ‘Modbus-RCS’ must be selected instead of ‘IO Variant A’.
Choose the active menu (passive menu’s are marked by a square).
6.2 How to simulate values from ECS to RCS
• Use ‘Node Mode Control’ menu to Set EICU in ‘Configuration’ mode. (After the MPC is in configuration
mode type “MANBW + enter).
Connection Test’. Set parameter to ‘Yes’ and activate.

2006-07-11
MAN B&W Diesel A/S
• Use ‘Node Mode Control’ menu to Set EICU in ‘Normal’ mode (After the MPC is in Normal mode type
“MANBW + enter).
• Select ‘Adjust Parameters’ and browse to
‘I/O Configuration -> MODBUS Data -> Modbus-RCS Connection Test’
Select value of interest, change it and activate.
• When test is completed use ‘Node Mode Control’ menu to Set EICU in ‘Configuration mode’
Connection Test’. Set parameter to ‘No’ and activate.
• Use ‘Node Mode Control’ menu to Set EICU in ‘Normal’ mode
• Note when testing EICU-B:
7 Adjustment of encoder
7.1 Check Tacho system cable

To check the tacho system cable the special tacho cable box can be used, both for CW and ACW running
engines by using this box all tacho cables will be checked.
Another way to check the tacho system cable between TSA box and MPC`s, the following can be done but by
this method the cable between encoder and TSA box will not be checked.
On each MPC that is connected to the tacho system there is 8 LED indicators on the PCB see the sketch
below.
The LED can be used to connection test the tacho cabling by following the procedure below:
Prepare a dummy plug as shown below:

2006-07-11
MAN B&W Diesel A/S
Disconnect J1-J2-J3-J4 in both TSA-A & TSA-B

Mount the dummy plug in J1 TSA-A and observe that LED number 9 is ON in PCB.
Mount the dummy plug in J1 TSA-B and observe that LED number 13 is ON in PCB.
DIODE BOARD 13 14 10 11 12 1 2 9
Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A
Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A
Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1
MPC Plug J46 J47 J43 J44 J45 J40 J41 J42
On On 45-225 135-315 0-180 90-270
before before deg deg. deg. deg.
Q1B Q1A
7.2 Check of encoder adjustment.
It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommendations.
Turning gear engaged.
Indicator cocks open.
Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC.
Check that the indicator light for the inner encoder turns ‘ON’ on the TSA-A , when cyl.1 reaches TDC. Turn
engine a few degrees back and forth, confirm that LED turns on/off. If the above is not in order see below for
adjustment of encoder (Chapter 7.3).
INNER encoder is adjusted correctly.
Turn engine 45degrees in the engines rotational direction. I.e. clockwise 45 degrees clockwise and
anticlockwise 45 degrees anticlockwise.
Check that the indicator light for the outer encoder turns ‘ON’ on the TSA-B. If the above is not in order see
below for adjustment of encoder (Chapter 7.3).

2006-07-11
MAN B&W Diesel A/S
OUTER encoder is adjusted correctly.
Check of encoders complete
7.3 Adjustment of encoder-clockwise
It is assumed that the encoders have been mounted, and adjusted according to MBD’s recommend-ations.
Turning gear engaged.
Indicator cocks open. Clamp screw on encoder loose.
Turn engine to cyl. 1 TDC. Check with pin gauge that cyl. 1 is at TDC. Turn the inner encoder (A) until the
Indicator light for the encoder is off (TSA-A). Turn the encoder in AHEAD direction until the LED on TSA-A just
starts to light, and then fasten the encoder to the shaft with the clamp screw.
Inner encoder adjusted.
Turn engine 45 degrees in AHEAD direction. Turn the outer encoder (B) until the Indicator light for the
encoder is off (TSA-B). Turn the encoder in AHEAD direction until the LED on TSA-B just starts to light, then
fasten the encoder to the shaft with the clamp screw.
Outer encoder adjusted.
Function Encoders:

2006-07-11
MAN B&W Diesel A/S
ECU; CCU connection ENCODER:
DIODE BOARD 13 14 10 11 12 1 2 9
Pick Up Q1B Q2B Q2A MMB MSB MMA MSA Q1A
Conn. T.Box TSA-B TSA-B TSA-A TSA-B TSA-B TSA-A TSA-A TSA-A
Plug T. Box J1 J2 J2 J3 J4 J3 J4 J1
MPC Plug J46 J47 J43 J44 J45 J40 J41 J42
On On 45-225 135-315 0-180 90-270
before before deg deg. deg. deg.
Q1B Q1A

2006-07-11
MAN B&W Diesel A/S
7.4 Check of tacho sensor at flywheel.
Turning gear engaged and indicator cocks open. Run out on marker ring checked and found OK.
Turn the engine 90 degrees from TDC cylinder 1, and check that the LED on the sensor is ‘on’.
Check of Tacho sensor complete.
8 Test of ELFI / ELVA & FIVA, Starting Air Valve and Leakage Alarm
Preconditions:
• The Hydraulic system must be flushed and ready for operation.
• Network- and connection-test completed.
• Connect a portable PC with Windows Hyperterminal program that is connected to the service
terminal plug J67 on an MPC using a zero modem cable, and enter <System test> as described
above in chapter 5.
Note: The hydraulic supply pressure must be zero before starting tests 8.1 and 8.2.
8.1 Connection test of ELFI valve without hydraulic pressure

Check the 24V supply to the LVDT before connecting the CANNON cables to the ELFI valve. Use a test box
as shown below or a voltmeter. 24V must be measured between A (24V) and B (0V) on the CANNON plug.
Cannon Plug /
Connection test
box.
MBD Info no.

6 91 100
MBD Part no.

1880536-0

2006-07-11
MAN B&W Diesel A/S
Use the following sequence on each ELFI valve:
Service terminal in Input / output

1. Check that ‘Shut Down’ (input ch. 32) is Off
2. Disconnect power supply for ELFI amplifier (J9)
3. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is Off
4. Reconnect power supply for ELFI amplifier (J9)
5. Check that ‘ELFI Amplifier OK’ signal (input ch. 20) is On
--------------------------------------------------------------------------------------------------
6. Set amplifier enable (output ch. 60) to On
7. Set ‘InFi_AMP. Setpoint’ (output ch. 70) to 0V
8. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA
9. Check ‘ELFI Actual Current’ (input ch. 33) is 0V
10. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to Maximum 1.3V
11. Check ‘ELFI Position Feedback’ (input ch.30) is 18-20mA
12. Check ‘ELFI Actual Current’ (input ch. 33) is 1.3 V
13. Set shut down On via safety system
14. Check ‘Shut Down’ (input ch. 32) is On
15. Check ‘ELFI Position Feedback’ (input ch. 30) is 4-7mA
16. Check ‘ELFI Actual Current’ (input ch. 33) is 0V
17. Set ‘InFi_Amp. Setpoint’ (output ch. 70) to 0V
Reset the safety system and check that channel 32 (shutdown signal) goes OFF.
Repeat the above procedure for all cylinders.
8.2 Connection test of ELVA valve without hydraulic pressure

Use the test box shown in chapter 8.1 or the following procedure:
During the test, set output channel 49 ON/OFF two or three times and check that the valve reacts
(clicks). During input test, check that channel 23 (Exhaust valve alive) is ON.
The output channel 49 should be set to ON when finish testing.
8.3 Connection test of ELVA valve with hydraulic pressure (app. 175 bar)
Use a test box shown in chapter 8.1 or the following procedure:
Set output channel 49 ON/OFF two or three times

If ELVA valve is alive (input ch.23 is ON), reset ELVA valve by powering CCU on/off ⇒ Check that ELVA valve
alive is not active ( input ch. 23 is OFF).
Note Exhaust valve pos. (input channel 34) (range 4-9 mA).
Activate Exhaust valve by output channel 49 and check that alive goes ON (input channel 23).
Activate Exhaust valve a few times by output channel 34 and determine the lifting height, reading in the service
terminal is between 7 - 9 mA.
The output channel 49 should be set to ON when finish testing.

2006-07-11
MAN B&W Diesel A/S
8.4 Connection test of FIVA valve with hydraulic pressure (app. 175 bar)
Preconditions:
• The Hydraulic stand-by pumps is ON (175 Bar)
• The F.O. Supply is ON (7-8 Bars)
• Spring air Exhaust valve is ON
• Check the Type of Amplifier- It has to be a FIVA Amplifier (See it on the type label on the back side of
Amplifier).
Service terminal in Input/Output:

1. Disconnect power supply for FIVA amplifier (J9)
2. Check that ‘Value Amplifier OK’ signal (Input ch.20)=OFF
3. Reconnect power supply for FIVA amplifier (J9)
4. Check that ‘Value Amplifier OK’ signal (Input ch.20)=ON
5. Set ‘Amplifier Enable’ (Output ch.60)=ON
6. Set ‘4107V, Set Point’ (Output ch.70)=0V
7. Check ‘Prop. Valve position feedback’ (Input ch.30)=4-7mA
8. Check ‘Prop. Valve Actual Current’ (Input ch.33)=0V
9. Set ‘4107V, Set Point’ (Output ch.70)=3.5V
10. F.O. valve on unit opens (Sound) [Only test this once]
11. Check ‘Prop. Valve position feedback’ (Input ch.30)=18-20mA
12. Check ‘Prop. Valve Actual Current’ (Input ch.33)=3.5V
13. Set ‘4107V, Set Point’ (Output ch.70)=0V
14. Exhaust valve on unit opens (Sound)
8.5 Connection test of starting air valves
1. During output test channel 50 is activated and it is controlled that the valve reacts
(click or extern magnetic field tester).
2. The test is repeated for every single cylinder.
8.6 Test of main starting air valve manually on the MOP
1. Starting-air is cut of manually – Turning gear disengaged – Control air on – Main Starting Valve in
service position.
2. Main Starting Valve is activated manually; either by handle or push bottom. ⇒ Main starting air
valve must open.
3. Turning-gear engaged.
4. Main starting air valve is activated manually (on pilot-valve) ⇒ no reaction means that the
pneumatic turning-gear interlock is ok.
5. Turning-gear disengaged.
6. Activate both activating-valves (V-1 & V-2), for the main starting-valve (one at a time via the MOP)
⇒ Main starting valve must open (after an eventually fault, point 1 – 2 is repeated).
7. The Slow turn valve is activated (via MOP) manually. Start is activated either by handle or push
button. ⇒ Only the Slow turning valve must open.

2006-07-11
MAN B&W Diesel A/S
8.7 Connection test of HCU oil leakage alarm

Service Terminal in input / output in the CCU, check that channel 27 is OFF. (Because this is an option it can
be done by means of a “cheat” plug).
Cheat Plug mounted in channel 27 on MPC board.
Jumper between terminal A and B
Resistor between terminal C and D ( 6,8 k ohm)
8.8 Hints for connection test and fault finding:

In general:
All electronic components are pre-adjusted before delivery. They are only to be adjusted mechanically at
initialisation, and the written values are to be entered in the relevant parameters.
Connection test:
• The required output set point has to be entered using the service terminal, in order to achive the
correct analogue output.
• When changing to input view, you must answer “no” to “reboot”, otherwise all outputs will be reset.
MOP:
A short “power-off” can block restart, therefore turn off the power and wait for at least 10 seconds until the MOP
has a black screen, and then turn the voltage on.
LVDT amplifiers for pump-regulation:
• The amplifier must show 12 mA in the service terminal with the sensor disconnected.
• The Swash-plate sensor must be mounted correctly. If the signal is “out of range” at one end, it has to
be adjusted mechanically. (Electrical adjustment of the LVDT amplifier must only be done after
consulting MAN B&W Diesel A/S).
ELVA:
• The ELVA valve may indicate an error alarm if the plug has been disconnected or the power to the
relevant CCU has been off. The alarm can be terminated by function-test of the valve, or by starting the
engine and seeing if the alarm resets (no fuel is supplied until the valve functions).
Manual activation of ELFI and ELVA:

2006-07-11
MAN B&W Diesel A/S
After the oil has been drained from one (or all) HCUs, it may be necessary to activate the ELFI & ELVA valves
manually. (Slow turn with the indicator valves open before starting as the engine will otherwise start
unintentionally during air run).
Manually activate the ELFI valve by

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

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

2006-07-11
MAN B&W Diesel A/S
Reset button for MPC
(The reset button on the side on the

MPC board)
Sensor and actuator error:
At sensor or actuator error, there can be four (4) main error sources:
Sensor error
1. Unmonitored fuse has blown. (See fuse specification Appendix 9.4)

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

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

2006-07-11
MAN B&W Diesel A/S
9 Test of Swash-plate pumps (Hydraulic-Pressure On)
9.1 Functions test

Follow the procedure below to calibrate the engine driven hydraulic pumps:
• Turn on the startup pumps on the startup pump switchboard by switching to “Local Control” and press
“Manual start” to enable swivelling with the swashplate. The hydraulic System pressure must be
above 50 bar.
• Set the MPC in connection test mode via the service terminal:
Access to service terminal:
o Open and set up the Hyper terminal program (see appendix 11.1)
o Connect a PC to the service terminal plug J67 on the MPC
o Type <manbw> and press enter
• Start ACU x (x= 1 – 3) in “Test” mode. The Service Terminal path for this operation is “Node Mode
Control => Test”.
• Move the proportional valve to its fail-safe position and check the feedback signals from the
swashplate and the proportional valve. The swashplate feedback position is a 4-20mA sensor. The
proportional valve feedback is a 6-18mA sensor.
Use the following procedure to move the proportional valve to fail safe position:
o “System Test => Connection Test => Output Test” set ch. 48 to On.
o “System Test => Connection Test => Output Test” set ch. 70 to 0V.
o “System Test => Connection Test => Input Test”
1. In the below table, note the signal value of the proportional valve feedback, ch. 30.
This value should be close to 18mA. If this is not the case, see the Trouble Shooting
section below.
2. In the below table, note the signal value of the swashplate feedback, ch. 34. This value
should be close to 20mA. If this is not the case, see the Trouble Shooting section
below.
3. Check that the swashplate physically is in its full ahead position via the indicator on the
pump (15 deg in the AH direction).
• Move the proportional valve to the opposite end position and check the feedback signals from the
swashplate and the proportional valve.
o “System Test => Connection Test => Output Test” make sure that ch. 48 is set to On.
o “System Test => Connection Test => Output Test” set ch. 70 to Maximum 2.6V. (on pumps
larger than 500 cc, the value should be Maximum 3.8V).
o “System Test => Connection Test => Input Test” now follow the 3 points below

2006-07-11
MAN B&W Diesel A/S
1. In the table below, note the signal value of the proportional valve feedback, ch. 30.
This value should be close to 6mA. If this is not the case, see the Trouble Shooting
section 9.2 below.
2. In the below table, note the signal value of the swashplate feedback, ch. 34. This value
should be close to 4mA. If this is not the case, see the Trouble Shooting section 8.2
below.
3. Check that the swashplate physically is in its full astern position via the indicator on the
pump (15 deg in the AS direction).
• Insert the parameters in ACU 1 – 3 using the Service Terminal parameters as given below in the table.
• The values should be noted in table in Appendix 11.2
Proportional valve Proportional valve Swashplate max. Swashplate min.

MPC
max. value (mA) min. value (mA) value (mA) value (mA)
ACU 1
ACU 2
ACU 3
Adjust parameters => Adjust parameters => Adjust parameters => Adjust parameters
Parameter Edit parameters => Edit parameters => Edit parameters => => Edit parameters
path on the IOConfig => IOConfig => IOConfig => => IOConfig =>
MPC in Ch30,1238-x,Prop. Ch30,1238-x,Prop. Ch34,1222-x,Swash- Ch34,1222-1,Swash-
Service Valve Feedback => Valve Feedback => Plate Position => Plate Position =>
Terminal Scaling => Row 2 Scaling => Row 1 Scaling => Row 2 Scaling => Row 1
Input (mA) Input (mA) Input (mA) Input (mA)
9.2 Troubleshooting
If one of the swashplate position feedback sensors mA indications are far away from the two other
swashplate mA values:
• Tighten the swashplate position indicator LVDT sensor on that pump.
If, when moving the proportional valve to the end position, the proportional valve position feedback or
the swashplate position feedback value displayed remains constant (typically around 12 mA):
• Proportional valve: Check connections between the proportional valve position feedback sensor and
the H.F. Jensen LVDT amplifier for the proportional valve
• Swashplate: Check connections between the proportional valve position feedback sensor and the H.F.
Jensen LVDT amplifier for the proportional valve
• when the proportional valve is tried forced to the end positions, it is most likely caused by missing
connection between the sensor at the pump and the sensor’s LVDT amplifier. This could be a missing
connection between the proportional valve position feedback sensor and the H.F. Jensen LVDT
amplifier for the proportional valve. In the case of constant swashplate indication it could be caused by
a missing connection between the swashplate position feedback sensor and the H.F. Jensen LVDT
amplifier for the swashplate.
• If, during the calibration, the feedback signals of the swashplate and the proportional valve is reversed,
jumpers in the position feedback LVDT amplifiers are not correctly positioned. This can be observed
as:
o When the proportional valve is supposed to signify its max. value position (e.g 18mA) and the
feedback indicates min. value (e.g. 6mA), then the signal range has been reversed.
o When the swashplate is supposed to signify its max. value position (e.g 20mA) and the
feedback indicates min. value (e.g. 4mA), then the signal range has been reversed.

2006-07-11
MAN B&W Diesel A/S
The correct position of the jumpers are illustrated below:

2006-07-11
MAN B&W Diesel A/S
10 ME Alpha Lubricator Quick Guide
10.1. Testbed ME Lubricator test procedure
10.2. MOP Screen “Cylinder Lubricators”
1. Indicator “Flow”
Shows the ordered lube oil amount (l/h).
Note: If one or more lubricators is not working correct (ex. Feedback Failure) this will
not show the correct value.
2. Indicator “Total”
Shows the total ordered Amount (l) since last power up of the ECU.
Note: As with “1” this indicator depends on all lubricators working correct.
3. Button “Prelube”
Activates Prelubrication on all cylinders and evaluates feedback from the lubricators.
2006-07-11
MAN B&W Diesel A/S
Note: Can only be activated if hydraulic pressure is present. This demands that
engine is in “Standby” state or manual operation of the hydraulic start-up pumps.
4. Indicator “LCD”
Indicates if Load Change Dependent lubrication is active.
5. Button “S%”
Fuel sulphur % used for the Adaptive Cylinder oil Control (ACC). Se Service Letter
SL05-455 /HRJ September 2005
Note: When running on diesel fuel (Engine Shop) set the S%=3.2
6. Button “Feed Rate Factor”

Used together with S% to calculate the Basic FeedRate setting.
7. Indicator “Basic FeedRate”

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

Minimum feedrate limiter that secures the feedrate will never be below this amount
even if the S% or FeedRate Factor or adjust factor is set low.
Note: The limiter is converted to a minimum activation frequency that means that the
actual feedrate (g/kW) can be higher at load’s <100%.
9. Indicator “Actual FeedRate” Cylinder 1..N

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

Adjust the Basic Feedrate Setting for the cylinders Individually.
11. Button “Running In” Cylinder 1..N

Is used for running in piston rings and cylinder liners.
Note:
For Running In=0% the lubrication amount regulator make load regulated lubrication
when Index is > approx 40% and changes to speed regulation when Index is < 40%.
This leads to an almost constant feedrate down to 40% index.
For Running In >0% the lubrication amount regulator changes from load regulated
lubrication to speed (rpm) regulated lubrication. This means that activation frequency
is constant and independent of load. Because of the relation between speed and load
the actual feedrate will increase when load is decreasing with a constant activation
2006-07-11
MAN B&W Diesel A/S
frequency.
12. Button “ Lubricator Test Sequence”

Start’s a continuous activation ( app.1000 activations) of the lubricator.
Note: Can only be activated if hydraulic pressure is present. This demands that
engine is in “Standby” state or manual operation of the hydraulic start-up pumps.
13. Check of the activation sequence of the Alpha lubricator
The activation frequency can be checked via the HyperTerminal for each cylinder
(CCU) in the following picture and read “Activations Without Error”:
10.3 Lubrication Amount Calculation:
The lube oil amount Is calculated individually for each cylinder. On basis of the
FeedrateFactor and the S% a basicfeedrate is calculated, this is converted to Mnominal
act/rev at MCR. All the limiters are also calculated at MCR and converted to act/rev.
The calculation of the activation rate depending on load and speed is performed in this way:

2006-07-11
MAN B&W Diesel A/S
Note:
MaxFeedRate, MaxFeedRateRunIn, MinActFreq, LcdFac and MinIndexWithPowerLube are
parameters that are not available on the MOP screen. These has to be set by Service
Terminal if adjustment is required.
Be aware of the limiter order.
Ex. (6S60ME-C)
Feedrate Factor: 0.34
S% 3.2
BasicFeedRate 1.09 g/kWh
MinFeedRate 0.7 g/kWh
FeedRate Adjust 1.1
MinIndexWithPowerLube 0.4
MCR Speed 105 rpm

MCR Load per cyl. 2260 kW
InjectionMass 1.0 g
Index [0;1]

2006-07-11
MAN B&W Diesel A/S
M nominel (Activation frequency)

=(BasicFeedRate(g/kWh)*MCRLoad(kW))/(60*MCRSpeed(rpm)*InjectionMass)
=0.39
If no limiters are active and “Running In” =0%, not LCD and Index >0.4.
M(actual)=Mnominal*FeedRateAdjust*Index
=0.39*1.1*Index =>(Load regulation)
If no limiters are active and “Running In” =0%, not LCD and Index <=0.4.
M(actual)=Mnominal*FeedRateAdjust* MinIndexWithPowerLube
=0.39*1.1*0.4 =>(Speed regulation)
If no limiters are active and “Running In”=100% and not LCD

M(actual)= Mnominal*FeedRateAdjust*(1+(Running In)/100)
=0.39*1.1*(1+(Running In)/100) =>(Speed regulation)
10.4 ALPHA LUBRICATOR WITH ME ENGINES - BREAKING-IN/RUNNING-IN FEED

RATE SETTING
1/ "How to adjust Basic Feed Rate for breaking-in / Running-in period ?"
The recommended feed rates for running in of new or reconditioned liners and coated piston
rings according to SL05-455/HRJ are:

2006-07-11
MAN B&W Diesel A/S
Step 1: 1.7 g/kWh for the first 5 hours

Step 2: 1.5 g/kWh for 5 hours to 250 hours
Step 3: 1.2 g/kWh for 250 hours to 500 hours
For step 1, 2, and 3 : Part load reduction proportional to engine load (power).
We propose to obtain this in the following way:

a/
Set feed rate factor to 0.34 g/kWh
b/
Set S% to 3 ~ (2.94 exactly)
c/
Step 1: Set feed rate adjust factor to 1.7
2/ "How do the following MOP fields influence on Basic Feed Rate:

a/ "Feed Rate Adjust Factor",
b/ "Running In [%] ?"
Neither "Feed Rate Adjust Factor" nor "Running In [%] influence the basic feed rate. The
basic feed rate is calculated as "S%" times "Feed Rate Factor".
However when the "running in [%]" differs from 0 the amount calculation algorithm changes
from load (power) to RPM. The setting of "Feed Rate Adjust Factor" has no influence on the
algorithm.
3/ "Part-load control for breaking-in / Running-in period. ?"
With the introduction of SL05-455/HRJ our recommendation for part load amount calculation
during running in has changed from the previous RPM dependent to load (power)
dependent.

2006-07-11
MAN B&W Diesel A/S
11 Appendix
11.1 Opening and setting up the Hyper Terminal program
• Select ‘Start’ and ‘Run’, write hypertrm.exe in the dialogue box and select ‘OK’.
• The Hyper Terminal program will start up, and a ‘New Connection’ dialogue box will appear. Write e.g.
Service Terminal and select ‘OK’.
• In the next dialogue open the ‘Connect using’ box/field and select the port to be used, i.e. COM1 and
select ‘OK’.
• In the next dialogue, set up the port settings as follows and select ‘OK’:
o Bits per second: 9600
o Data bits: 8
o Parity: None
o Stop bits: 1
o Flow control: Xon/Xoff

2006-07-11
MAN B&W Diesel A/S
11.2. Swash plate position values
Proportional valve Proportional valve Swashplate max. Swashplate min.

MPC
max. value (mA) min. value (mA) value (mA) value (mA)
ACU 1
ACU 2
ACU 3
Indication adjustment:
Readings in: Main Menu / View / edit data-tree / I/O Configuration-channel 34 / Swash plate position.
Full angle Ahead = mA

Full angle Astern = mA
11.3. Tools for commissioning
1. PC with Hyper terminal installed and a zero modem cable

2. Electronic or mechanic tool for measuring of highest/lowest point on trigger/tacho rings.
3. Tacho sensor adjusting tool (marked).
4. Portable pressure measuring tool for the hydraulic system (mini-mesh connection).
5. Multimeter oscilloscope and mA signaller.
6. Magnetic field indicator for Solenoid valve spools.
7. A number of plugs for I/O fault finding.
8. Test box for testing ELVA/ELFI.
9. Programs and data files for the whole system.
10. Portable PMI equipment with special cable and inverter plug (for mounting in TSA box) for
connection, (see picture below).
Portable PMI equipment with special

cable and inverter plug (for mounting in
TSA box) for connection.

2006-07-11
MAN B&W Diesel A/S
11.4. Overview MPC connections
• Check that each Fuse is the specified type.
Overview J-Fuse plugs on MPC:

J-plug number Function of fuse
1 Powersupply
2 Powerfailure
3-9 Power Out 24V
10 Connecting terminals (Loop etc.)
20-37 Analog In
40-47 Fast Digital In(Galv. Isolated)
48-53 Fast Digital In/out(Galv. Isolated)
60-61 Digital Out(Galv. Isolated)
65-66 Network connections
67 Service terminal
70-71 Analog Out(Galv. Isolated)
80-85 Digital Out(Galv. Isolated)
206 Dongle Key connect
210 Battery

2006-07-11
MAN B&W Diesel A/S
11.5. MPC LED Indication
This following describes MPC LED indications. The first part of the document describes the syntax of the LED
indication and assigns a short description to each of the used indications. The second part presents a more
detailed description of the different indications.
Syntax
The MPC LED may be issuing indications by either emitting constant light or by flashing. The LED indications
are uniquely identified by the color that the MPC LED emits.
Flashing LED indication consists of two pulse trains separated in time by 1-second pauses. Each of these
Kdrev\ME_Testbed_Procedure\Proc_1\
pulse trains represents an integer. All pulses are be set against a yellow background. The first pulse train will
3090532-9.0_ver.3.21.doc
alternate between the yellow background and a red foreground, whilst the second will use green as foreground.
First digit Second digit
1 second 1 second
pause pause
For identification of the indication the user must therefore note the number of red and green pulses. The first
digit is the number of red pulses and the second digit is the number of green pulses. In the illustration above,
the indication code would thus be (2,3).
Indications
Constant
Colour Short name Short description
Red ERROR Either early initialization or fatal error
Orange INIT Initialization, no parameters available or non-normal
node mode
Green NORMAL Application up and running
Flashing
Digits Short name Short description
(1,1) CTRL_PRG Onboard control programming in progress
(2,1) APPLOAD_SCAN Application download in progress – scanning for server
(2,2) APPLOAD_DOWNLOAD Application download in progress – downloading
program
(2,3) APPLOAD_DIP Application download completed – reset yellow DIP
switch set to ON
(3,1) BOOTLOAD_SCAN Bootloader download in progress – scanning for server
(3,2) BOOTLOAD_DOWNLOAD Bootloader download in progress – downloading
program
(4,1) DONGLE_VERIFY Checking node ID-key
(4,2) DONGLE_ERROR ID-key error – missing, broken or not programmed
(4,3) DONGLE_DIP Node ID DIP switch not correctly reset – reset it to 0x00

2006-07-11
MAN B&W Diesel A/S
Detailed Description of LED indications
ERROR (Red)
This code is used primarily for indicating if the MPC has experienced a fatal error. However, the MPC will also
use this indicating during early initialization. Therefore the user should only take this code as an indication of
error if it persists more than 10 seconds.
INIT (Orange)
Generally this code is used for indicating initialization. But the MPC may also use this indication to signal one of
the following conditions:
No parameters: No valid parameters are available to the application software.

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

2006-07-11
MAN B&W Diesel A/S
Flowchart
Error code LED 4,2
Missing dongle or
invalid value or
invalid checksum
Copy dongle
value to RAM
[error] Indicate dongle

error via LED
[ok]
Invalid DIP switch

value (neutral or out-
of-range)
Copy DIP-switch
value to RAM
[error]
Halt
[ok]
Program value
Check DIP switch
from DIP-switch
setting
to dongle
Remains here until

dongle has been
[not neutral]
programmed!
[neutral]
Indicate non-
neutral DIP-
switch via LED
Wait for neutral

DIP-switch
Return LED to
previous state
Error code LED 4,3

2006-07-11
MAN B&W Diesel A/S
11.6. Settings of Liquiphant level switch
High pressure leak flow

Mounted in ACU-3 plug 21
Leakage from hydraulic unit-leak Alarm level

Leakage from hydraulic unit-leak Shout down level


2006-07-11
MAN B&W Diesel A/S

2006-07-11
MAN B&W Diesel A/S
Settings of dipswitch:

2006-07-11
11.7. Connection test scheme
ACU 1
Power Filter Board
Power input/Output plugs etc.
Plug No. Cabel ID Channel Type Signal ID Type Action Check
1 WPACU1 Power input A Power Supply Input A Analog 24 Vdc Check A= - / B= +
1 WPACU1 Power input B Power Supply Input B Analog 24 Vdc Check A= - / C= +
2 Power failure
3 W1202-A 2A output unfilt.
4 3.15 output unfilt.
5 WLOP3 2A output unfilt.
6 WLOP3 2A output unfilt. Power for Engine not ready Plug J83 Check A= - / B= +
7 WLOP3 2A output unfilt. Power for Start air distr. system in service Plug J84 Check A= -/ B= +
8 2A output unfilt Power for Main starting valve in service Plug J85 Check A= -/ B= +
9 Intern to J90 10A output filtered Power for prop-valve control amplifier Plug J90 Check C= -/ D= +
Control Main I/O Board

Analog/Digital Input
Power on = reading in
20 Intern to J91 Low BW 1224-1 Prop valve amp. O.k. (DI) service terminal is on
21 W1111-A Low BW 1111-A Main starting Valve Blocked input (DI superv) Activate valve
22 W1109-A Low BW 1110-A Turning gear engaged input (indication) (DI superv) Activate turning gear
23 W1109-A Low BW 1109-A Turning gear disengaged input (DI superv) Activate turning gear
24 W1112-A Low BW 1112-A Main Starting valve "In Service" input (DI superv) Activate valve
25 W1116-A Low BW 1116-A Start Air Distribution system in service (DI superv) Activate valve
Activate push buttom
26 WLOP3 Low BW 2158-A Lamp test on LOP
Lekage from hydraulic unit-leak shutdown level SHD
27 W1236 Low BW 1236 (NO) (DI superv) Activate the sensor
MAN B&W Diesel A/S
ACU 1
Loop Terminals
Channel
Plug No. Cabel ID Type Signal ID Type Action Check
10 A
10 B
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
ACU 1
Proportional valve position feedback Dismount the plug on valve and the reading in
30 W1238-1.1 High/Low BW 1238-1 (AL) service terminal to be app. 12mA
Dismount the plug on valve and see the
Hydraulic pressure after non-return change of setting from mA to #value# reading
31 W1201-1 High/Low BW 1201-1 valve (AL) in service terminal
Lube oil pressure at pump inlet after change of setting from mA to #value# reading
32 W1204-A High/Low BW 1204-A filter (AL) in service terminal
change of setting from mA to #value# reading
33 W1208-A High/Low BW 1208-A Hydraulic booster pressure (AL) in service terminal
34 W1222-1.1 High/Low BW 1222-1 Swash-plate position feedback (AL) in service terminal
35 High/Low BW
36 W8503-A High/Low BW 8503-A Control air pressure (AL) in service terminal
37 W8501-A High/Low BW 8501-A Starting air pressure (AL) in service terminal

7/11/2006
MAN B&W Diesel A/S
ACU 1
Fast Digital Input
40 TPU ch.0 8621-1 Blower 1 remote/local-fail (DI) Check on / off signal in service teminal
41 TPU ch.1 8623-1 Blower 1 running (DI) Check on / off signal in service teminal
1212-A Start Up pump
or or Change of switch in starter box for Start-up
44 TPU ch.4 1218-1 El. Driven pump 1 remote/local-fail (DI) pump
1213-A Start up pump running
or or
45 TPU ch.5 1219-1 El. Driven pump 1 running (DI) Check on / off signal in service teminal
46 TPU ch.6
Intern to When on in J47 it must be off in J80 and visa
47 J80 TPU ch.7 System by-pass 1202-A supervision versa

Fast Digital Output
See internal elctric drawning 0794621-8.1and
48 Intern to J91 TPU ch.8 1223-1 Prop valve amplifier enabel (DO) check fysical.
49 WLOP3 TPU ch.9 2106-A Load Limitation-Local indication (DO) Activate in sevice terminal and check in LOP
50 WLOP3 TPU ch.10 2107-A Start failure (DO) Activate in sevice terminal and check in LOP
51 WLOP3 TPU ch.11 1264-A Aux. Blowers Warning (DO) Activate in sevice terminal and check in LOP
52 WLOP3 TPU ch.12 1263-A Aux. Blowers Running (DO) Activate in sevice terminal and check in LOP
53 WLOP3 TPU ch.13 2181-A Turning Gear Disengaged (DO) Activate in sevice terminal and check in LOP

7/11/2006
MAN B&W Diesel A/S
Switch Output (memory mapped latch)

Simulate a start block ad check indication in
60 Start blocked (LOP indication) (DO) LOP
1210-1 Start Up Pump start/stop
or or
61 WSTS1 1217-1 El.driven pump 1 start/stop(DO) Check pump start / stop
ACU 1
Control Network
65 WNACU2A Line A - Network line A Check with service terminal in EICU
66 WNACU2B Line B - Network line B Check with service terminal in EICU
Serial communication
68
AO-DO Daughter Board

Analog Output (controlled by QSPI)
Intern to Set output to valve and check on pump
70 J91 1240-1 Swash-plate command (set point) (AO) feedback is the same on ch.34
Hydraulic pressure (for LOP indication )
71 1250 (AO)

7/11/2006
MAN B&W Diesel A/S
ACU 1
Contact Output (memory mapped latch)
System by-pass valve solenoid A (DO- When on in J47 it must be off in J80 and visa
80 W1202-A 1202-A superv) versa
81 8620-4 Blower 4 start/stop (DO) (option)
Give command to blower from service
82 WAUXB1 8620-1 Blower 1 start/stop (DO) terminal
Engine not ready output for the LOP Give command from service terminal and
83 WLOP3 2210-A (DO) check in LOP
Start air distribution system in service Give command from service terminal and
Main starting valve in service position Give command from service terminal and

0 Amper. =full ah and 1.5 Amper. = full
astern.on swash plate. Remember hydraulic
90 W1238-P1 Supply for prop.valve via amplifier pressure
Intern to J-
20-48-
70+resistor See internal elctric drawning 0794621-8.1and
91 6K8 check fysical.

7/11/2006
MAN B&W Diesel A/S
ACU 2
Power Filter Board
1 WPACU2 Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
1 WPACU2 Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 Power failure
3 2A out
4 3.15A out
5 2A out
6 2A out
7 2A out
8 2A out
Intern to 10A output
9 J90 filtered Supply for prop-valve control amp. C= - / D= +

7/11/2006
MAN B&W Diesel A/S
ACU 2
20 Low BW 1224-2 Prop valve amp. O.k. (DI) Power on = reading in service terminal is on
Main starting Valve Blocked input (DI
21 W1111-B Low BW 1111-B superv) Activate valve
22 W1109-B Low BW 1110-B Turning gear engaged input (DI superv) Activate turning gear
Turning gear disengaged input (DI
23 W1109-B Low BW 1109-B superv) Activate turning gear
Main Starting valve "In Service" input
24 W1112-B Low BW 1112-B (DI superv) Activate valve
Start Air Distribution system in service
25 W1116-B Low BW 1116-B (DI superv) Activate valve
26 Low BW 2158-B Lamp test Activate push buttom in LOP
Leakage from hydraulic unit-leak alarm
27 W1235 Low BW 1235 level (NO) (DI superv) Activate the sensor

7/11/2006
MAN B&W Diesel A/S
ACU 2
Loop Terminals
10 A
10 B
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J
10 J

7/11/2006
MAN B&W Diesel A/S
ACU 2
Proportional valve position feedback Dismount the plug on valve and the reading in
30 W1238-2.1 High/Low BW 1238-2 (AL) service terminal to be app. 12mA
31 W1201-2 High/Low BW 1201-2 filter (AL) in service terminal
32 W1204-B High/Low BW 1204-2 filter (AL) in service terminal
33 1208-B High/Low BW 1208-4 Hydraulic booster pressure (AL) in service terminal
34 W1222-2.1 High/Low BW 1222-2 Swash-plate position feedback (AL) in service terminal
35 High/Low BW
36 W8503-B High/Low BW 8503-B Control air pressure (AL) in service terminal
37 W8501-B High/Low BW 8501-B Starting air pressure (AL) in service terminal
High/Low BW

7/11/2006
MAN B&W Diesel A/S
ACU 2
Fast Digital Input
1212-B Start Up pump remote/local-fail
or or Change of switch in starter box for Start-up
44 TPU ch.4 1218-2 El. Driven pump 2 remote/local-fail(DI) pump
1213-B Start up pump running
or or
45 TPU ch.5 1219-2 El. Driven pump2 running(DI) Check on / off signal in service teminal
46 TPU ch.6
47 TPU ch.7

7/11/2006
MAN B&W Diesel A/S
ACU 2
Fast Digital Output
Channel
48 Intern to J91 TPU ch.8 1223-2 Prop valve amplifier enabel (DO) check fysical.
49 TPU ch.9 2106-B Load limitation (local indc) (DO)
50 TPU ch.10 2107-B Start failure (DO)
51 TPU ch.11 1264-B Aux.blower Warning (DO)
52 TPU ch.12 1263-B Aux.blower Warning (DO)
53 TPU ch.13 2181-B Turning Gear Disengaged (DO)

60 W1216-A
1210-2 Start Up Pump start/stop
or or
61 WSTS2 1217-2 El.driven pump 2 start / stop(DO) Check pump start / stop

7/11/2006
MAN B&W Diesel A/S
ACU 2
Control Network
68

7/11/2006
MAN B&W Diesel A/S
ACU 2
71 8601 Scavenge air pressure (AO)

80 2108 Start blocked (for LOP indication) (DO)
81 8620-5 Blower 5 start/stop (DO)
Give command to blower from service
82 WAUXB2 8620-2 Blower 2 start/stop (DO) terminal
83 WLOP3 2210-B Engine not ready (LOP indication) (DO)
Start air distribution system in service for Give command from service terminal and
84 WLOP3 1116-B LOP indication check in LOP
Main Starting Valve in service position for Give command from service terminal and
85 WLOP3 1112-B LOP indication check in LOP

astern.on swash plate. Rember hydrulic
90 W1238-P2 Supply for prop.valve via amplifier pressure
Intern to J-
20-48-
70+resistor See internal elctric drawning 0794621-8.1and
91 6K8 check fysical.

7/11/2006
MAN B&W Diesel A/S
ACU 3
Power Filter Board
2 Power failure
3 W1202-B 2A out
4 3.15A out
5 2A out
6 2A out
7 2A out
8 2A out
10A output
9 Intern ti J90 filtered Supply for prop-valve control amp. C= - / D= +

20 Low BW 1224-3 Prop valve amplifier O.k. (DI) Power on = reading in service terminal is on
21 Low BW 1234 High pressure leak flow (NO) (DI superv)
22 Low BW 1233 High pressure leak pressure (AL superv)
Filter failure (basck fluhsing filter) (NC)
23 Low BW 1231 (DI)
24 Low BW 1232 Filter by-pass open (NC) (DI)
25 Low BW 1237 HCU common leak - oil (DI)
26 Low BW 1239 HCU common leak - fuel (DI)
27 Low BW

7/11/2006
MAN B&W Diesel A/S
ACU 3
Loop Terminals
10 A
10 B
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
ACU 3
W1238- Dismount the plug on valve and the reading in
30 3.1 High/Low BW 1238-3 Proportional valve position feedback (AI) service terminal to be app. 12mA
Hydraulic pressure after non-return valve change of setting from mA to #value# reading
31 W1201-3 High/Low BW 1201-3 (AI-superv) in service terminal
W1204- Lube oil pressure at pump inlet after filter change of setting from mA to #value# reading
32 C High/Low BW 1204-3 (AI) in service terminal
Lube oil pressure at pump inlet after filter change of setting from mA to #value# reading
33 W1221 High/Low BW 1204-5 (AI) in service terminal
W1222- change of setting from mA to #value# reading
34 3.1 High/Low BW 1222-3 Swash-plate position feedback (AI) in service terminal
35 High/Low BW
36 High/Low BW
37 High/Low BW

7/11/2006
MAN B&W Diesel A/S
ACU 3
Fast Digital Input
40 TPU ch. 0 8621-3 Blower 3 remote/local-fail (DI)
41 TPU ch.1 8623-3 Blower 3 running (DI)
42 TPU ch. 2
43 TPU ch. 3
44 TPU ch. 4 1218-3 El. Driven pump 3 remote/local-fail
45 TPU ch. 5 1219-3 El. Driven pump 3 running
46 TPU ch. 6
Intern to Change of DO in Service terminal parameter
47 J80 TPU ch.7 System by-pass 1202-B supervision 80
Fast Digital Output
48 TPU ch.8 1223-3 Prop valve amplifier enabel (DO) check fysical.
49 TPU ch.9
50 TPU ch.10
51 TPU ch.11
52 TPU ch.12
53 TPU ch.13

7/11/2006
MAN B&W Diesel A/S
ACU 3
60
61 1217-3 El. Driven pump 3 start/stop (DO)
Control Network
65 WN-XA Line A - Network line A Check with service terminal in EICU
WNACU3
65 A Line A - Network line A Check with service terminal in EICU
66 WN-XB Line B - Network line B Check with service terminal in EICU
WNACU3
66 B Line B - Network line B Check with service terminal in EICU
68

7/11/2006
MAN B&W Diesel A/S
ACU 3
71 WALCU 8230 Actual Handel position for LCD AO) See in Alpha lub procedure

System by-pass valve solonoide (DO- When on in J47 it must be off in J80 and visa
80 W1202-B 1202-B superv) versa
81 WALCU 8231 Ahead/Astern (DO) See in Alpha lub procedure
82 8620-3 Blower 3 start/stop (DO)
83 WALCU 8232 Engine stop MCU (DO) See in Alpha lub procedure
84 WALCU 8233 Engine stop BCU (DO) See in Alpha lub procedure
85 WALCU 8234 Prelubrication command (DO) See in Alpha lub procedure

W1238- astern.on swash plate. Rember hydrulic
90 P3 Supply for prop.valve via amplifier pressure
Intern to
J-20-48-
70+resist See internal elctric drawning 0794621-8.1and
91 or 6K8 check fysical.

7/11/2006
MAN B&W Diesel A/S
ACU 4
Power Filter Board
2 Power failure
3 2A out
4 3.15A out
5 2A out
6 2A out
7 2A out
8 2A out
10A output Supply for by-pass valve motor control
9 Intern ti J90 filtered amplifier C= - / D= +

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

7/11/2006
MAN B&W Diesel A/S
ACU 4
Loop Terminals
10 A
10 B
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
ACU 4
30 High/Low BW
31 High/Low BW
32 High/Low BW
33 High/Low BW
34 High/Low BW
35 High/Low BW
36 High/Low BW
37 High/Low BW

7/11/2006
MAN B&W Diesel A/S
ACU 4
Fast Digital Input
40 TPU ch. 0
41 TPU ch.1
42 TPU ch. 2
43 TPU ch. 3
44 TPU ch. 4
45 TPU ch. 5
46 TPU ch. 6
47 TPU ch.7
Fast Digital Output
48 TPU ch.8 8754 Var. By-pass amplifier enabel (DO)
49 TPU ch.9
50 TPU ch.10
51 TPU ch.11
52 TPU ch.12
53 TPU ch.13

7/11/2006
MAN B&W Diesel A/S
ACU 4
60
61
Control Network
65 WN-XA Line A - Network line A Check with service terminal in EICU
WNACU3
65 A Line A - Network line A Check with service terminal in EICU
66 WN-XB Line B - Network line B Check with service terminal in EICU
WNACU3
66 B Line B - Network line B Check with service terminal in EICU
68

7/11/2006
MAN B&W Diesel A/S
ACU 4
70 8755 Var. Bypass Amp. (Set point) (AO)
71

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

90
91

7/11/2006
MAN B&W Diesel A/S
CCUs
Power Filter Board
1 WPCCU1 Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
1 WPCCU1 Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 Power failure
3 2A out
Supply to ELVA amplifier. Polarity on
4 W4108-1 3.15A out ELVA plug = B+ og C- Polarity on plug J4 A= - / B= +
5 2A out
6 2A out
7 2A out
8 2A out
W4102- 10A output
9 1.1 filtered Supply to ELFI / FIVA amplifier Polarity on plug J9 A= - / B= +

Disconect plug J9 and see change of value in
20 Internal Low BW 4105 ELFI / FIVA amplifier OK (DI) service terminal, Please refer to chapter 6.1
21 Low BW 8285 Cyl. Lube Oil Supply Fail (DI-superv)
22
Check cabling between ELVA plug and plug J
23 W4108-1 Low BW 4109 ELVA valve OK (DI) 23, please refer to chapter 6.3
24
25
26
H.P. Fuel Pipe Leakage (NO) (DI- option (check by dummy plug), Please refer to
27 Low BW 4112 superv) chapter 6.6

7/11/2006
MAN B&W Diesel A/S
CCUs
Loop Terminals
Cabel
Plug No. ID Channel Type Signal ID Type Action Check
10 A
10 B
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
CCUs
W4102- Check cabling between ELFI plug and plug J
30 1.2 High/Low BW 4102 ELFI/FIVA Position feedback (AI) 30, Please refer to chapter 6.1
Check cabling between Fuel pump plunger
31 W4114-1 High/Low BW 4114 Fuel pump Plunger Position (AI-superv) plug and plug J 31
Simulate shut down in safty system and check
in service terminal. And check ELFI and ELVA
Shut Down Saftey system (DI- Special feedback go to zero, Please refer to chapter
32 WSCCU1 High/Low BW 2002 superv) 6.1
Same mA value as in ch.70, Please refer to
33 Internal High/Low BW 4106 ELFI/FIVA Amp. actuel current (AI) chapter 6.1
Check cabling between Exhaust Valve plug
34 W4111-1 High/Low BW 4111 Exhaust valve position (AI-superv) and plug J 34, Please refer to chapter 6.3
35
36
37

7/11/2006
MAN B&W Diesel A/S
CCUs
Fast Digital Input
Check of cabling between TSA-A / B and MPC
Channel
40BC WTCCU1A TPU ch.0 4001-A Marker Master - Tacho set A (Di) Simulate tacho signal in TSA-A
41BC WTCCU1A TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Simulate tacho signal i TSA-A
42BC WTCCU1A TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Simulate tacho signal i TSA-A
43BC WTCCU1A TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Simulate tacho signal i TSA-A
44BC WTCCU2B TPU ch.4 4001-B Marker Master - Tacho set B(Di) Simulate tacho signal i TSA-B
45BC WTCCU2B TPU ch.5 4001-B Marker Slave - Tacho set B(Di) Simulate tacho signal i TSA-B
46BC WTCCU2B TPU ch.6 4003-B Quadrature 1 - Tacho set B (Di) Simulate tacho signal i TSA-B
47BC WTCCU2B TPU ch.7 4004-B Quadreture 2 - Tacho set B (Di) Simulate tacho signal i TSA-B

Fast Digital Output
48 TPU ch. 8 Data Aq.Synchronization (internal signal)
Check cabling between ELVA plug and plug J
49 W4108-1 TPU ch.9 4108 ELVA Valve (DO) 49, Please refer to chapter 6.2
Change value and check solenoid valve
(ZV1121-A item 30), Please refer to chapter
50 W1120-1 TPU ch.10 1120 Start air pilot valve (DO) 6.4
51 TPU ch.11 8281 Cyl. Lubricator Pilot Valve (DO)
52 TPU ch. 12 8282 Cyl. Lubricator Feedback (movement)
8283 Cyl. Lubricator Feedback (Flow) (DI)
or Or
Cylinder TDC Pulse (for
53 TPU ch. 13 commissioning)(DO)

7/11/2006
MAN B&W Diesel A/S
CCUs
Must be on when it is o.k. Please refer to
60 Internal 4104 ELFI/FIVA Amplifier Enable (DO) chapter 6.1
61
Control Network
WNCCU
65 1A Line A - Network line A Check with Service terminal in EICU
WNCCU
65 2A Line A - Network line A Check with Service terminal in EICU
WNCCU
66 2B Line B - Network line B Check with Service terminal in EICU
WNCCU
66 1B Line B - Network line B Check with Service terminal in EICU
68
Same mA value as in ch.70 (output value 1.2
70 Internal 4107 ELFI/FIVA Valve Control (AO) to 1.5), Please refer to chapter 6.1
71 Reserved for commisioning

7/11/2006
MAN B&W Diesel A/S
CCUs
80
81
82
83
84
85

Value between 0 Amper. and 1.5 Amper.
90 Internal Supply for ELFI valve via amplifier Output.
Intern to J- See internal elctric drawning and check
91 20-32-33-70 fysical.

7/11/2006
MAN B&W Diesel A/S
ECU A
Power Filter Board
1 WPECUB Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
1 WPECUB Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 Power failure
3 2A out Slow turning valve (J80)
4 3.15A out Main starting valve (J82)
5 2A out Manuel slow down request-at LOP (J83)
6 2A out Forced command take over (J84)
7 2A out
8 2A out
10A output
9 filtered

20 Low BW 1218-4 El. Driven pump 4 remote / local-fail (DI)
21 WLOP2 Low BW 2152-A Increase limiter (DI superv) Press Increase Limiter button on LOP
22 WLOP2 Low BW 2151-A Stop Switch LOP (DI superv) Turne stop switch on LOP
23 WLOP2 Low BW 2114-A Air Run LOP (DI superv) Activate air run switch on LOP
24 WLOP2 Low BW 2115-A Slow Turning LOP (DI superv) Activate slow turning switch on LOP
Activate Forced take control button on
25 WLOP2 Low BW 2153-A Take Command (LOP) (DI superv) LOP
2156-A Speed Set Up button
or Or
2150-A Speed set from local control panel(DI
26 WLOP2 Low BW superv) Activate speed up switch on LOP
27 WLOP2 Low BW 2157-A Speed Set Down button (DI Superv) Activate speed down switch on LOP

7/11/2006
MAN B&W Diesel A/S
ECU A
Loop Terminals
10 A
10 B
10 B
10 C
10 D
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
ECU A
30 WLOP1 High/Low BW 2155-A Start Switch-Local (DI superv) Activate switch for Start
31 High/Low BW 2103-A Actual Pitch (Analog) From remote control
Start Air Distribution System blocked (DI Activate switch for Start Air Distributer
32 W1117-A High/Low BW 1117-A superv) valve
33 Astern - local (DI superv)
34 WSS-EUA High/Low BW 2001-A Shut down from Safty System (DI superv) Signal from safty system
35 W8601-A High/Low BW 8601-A Scavenge air pressure (Analog) Sensor PT 8601-A
36 High/Low BW 2195-A Clutch status (DI superv)
37 High/Low BW 5350-A Limiter signal from Dual Fuel Control
Fast Digital Input

40AD WTP-A 24Vdc to TSA-A A= - / D= +
40BC WTECUA TPU ch.0 4001-A Marker Master - Tacho set A (Di) Simulate tacho signal in TSA-A
41BC WTECUA TPU ch.1 4002-A Marker Slave - Tacho set A (Di) Simulate tacho signal i TSA-A
42BC WTECUA TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) Simulate tacho signal i TSA-A
43BC WTECUA TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) Simulate tacho signal i TSA-A
44BC WTCCU1B TPU ch.4 4001-B Marker Master - Tacho set B(Di) Simulate tacho signal i TSA-B
45BC WTCCU1B TPU ch.5 4002-B Marker Slave - Tacho set B (Di) Simulate tacho signal i TSA-B
46BC WTCCU1B TPU ch.6 4003-B Quadrature 1 - Tacho set B (Di) Simulate tacho signal i TSA-B
47BC WTCCU1B TPU ch.7 4004-B Quadreture 2 - Tacho set B (Di) Simulate tacho signal i TSA-B

7/11/2006
MAN B&W Diesel A/S
ECU A
Fast Digital Output
Extra input for dual speed measurment
48 TPU ch.8 4030-A (DI)
49 TPU ch.9 4031-A (DI)
Extra marker for dual speed measurment
50 TPU ch.10 4032-A (DI)
51 TPU ch.11 4033-A (DI)
52 TPU ch.12 8287-A Lube back-up (DO)
53 TPU ch.13 1219-4 El.driven pump 4 running (DI)

60 2146-A Zero pitch request (DO)
61 2005-A Reset shut down-from ECS (DI superv)
Control Network
WNCCU1
65 A Line A - Network line A Check with Service terminal in EICU
66 120 OHM Line B - Network line B Check termination resistor
WNCCU1
66 B Line B - Network line B Check with Service terminal in EICU

7/11/2006
MAN B&W Diesel A/S
68
ECU A
Change value and check in HMI-panel
70 LUB R1 2184 Calculated Governor Index (AO) for Alpha Lub.
Starting air Pressure for LOP Indication.
71 8501 (AO)

Change value and check solonoid valve
80 W1114 1114 Slowturning valve (Do) (ZV1114 item 36)
1243-A Astern signal for 4. Trukne pumpe
or or
81 1217-4 El.driven pump 4 start/stop(DO)
Change value and check solonoid valve
82 W1121-A 1121-A Main Starting Valve (Do) (ZV1121-A item 30)
Slow Down Request-Manual at local
83 2206-A (DO)
84 2154-A Forced Command Take over-LOP (DO)
Increase limitation-feedback for LOP
85 2159-A indication (DO)

7/11/2006
MAN B&W Diesel A/S
ECU B
Power Filter Board
1 WPECUB Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
1 WPECUB Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 Power failure
3 2A out
4 W1121-B 3.15A out Main Starting valve J82 A= - / B= +
5 2A out
6 2A out
7 2A out
8 2A out
10A output
9 filtered

20 Low BW 1218-5 El.driven pump 5 remote/local-fail (DI)
21 WLOP2 Low BW 2152-B Increase limiter (DI superv) Press Increase Limiter button on LOP
22 WLOP2 Low BW 2151-B Stop Switch (DI superv) Turne stop switch on LOP
23 WLOP2 Low BW 2114-B Air Run (DI superv) Activate air run switch on LOP
24 WLOP2 Low BW 2115-B Slow Turning (DI superv) Activate slow turning switch on LOP
Activate Forced take control button on
25 WLOP2 Low BW 2153-B Take Command (DI superv) LOP
2156-B Speed Set Up button (DI superv)
or or
26 WLOP2 Low BW 2150-B Speed set from local control panel Activate speed up switch on LOP
27 WLOP2 Low BW 2157-B Speed Set Down button (DI Superv) Activate speed down switch on LOP

7/11/2006
MAN B&W Diesel A/S
ECU B
Loop Terminals
10 A
10 B
10 B
10 C
10 D
10 C
10 D
10 E
10 F
10 G
10 H
10 I
10 J

7/11/2006
MAN B&W Diesel A/S
ECU B
30 WLOP2 High/Low BW 2155-B Start Switch-Local (DI superv) Activate switch for Start on LOP
31 High/Low BW 2103-B Actual Pitch (Analog) From remote control
Start Air Distribution System blocked (DI Activate switch for Start Air Distributer
32 W1117-B High/Low BW 1117-B superv) valve
33 High/Low BW 2135-B Astern-Local (DI superv)
WSS-
34 EUA High/Low BW 2001-B Shut down from Safty System (DI superv) Signal from safty system
35 W8601-B High/Low BW 8601-B Scavenge air pressure (Analog) Sensor PT 8601-B
36 High/Low BW 2195-B Clutch status (DI superv)
Limiter signal from Dual Fuel Control (AL
37 High/Low BW 5350-B superv)
Fast Digital Input

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

7/11/2006
MAN B&W Diesel A/S
ECU B
Fast Digital Output
48 TPU ch.8 4030-B (DI)
49 TPU ch.9 4031-B (DI)
50 TPU ch.10 4032-B (DI)
51 TPU ch.11 4033-B (DI)
52 TPU ch.12 8287-B Lube back-up (DO)
53 TPU ch.13 1219-5 El. Driven pump 5 running (DI)

60 2146-B Zero pitch request (DO)
61 2005-B Reset shut down-from ECS (DI superv)
Control Network
WNACU1
65 A Line A - Network line A Check with Service terminal in EICU
65 120 OHM Line A - Network line A Check termination resistor
WNACU1
66 B Line B - Network line B Check with Service terminal in EICU
68

7/11/2006
MAN B&W Diesel A/S
ECU B
Raw unsigned speed (for
70 commissioning)
Change value in service terminal and
71 WLOP2 1250 Hydraulic Pressure (AO) check indication on LOP

80
1243-B Astern signal for 5. Trukne pumpe
or or
81 1217-5 El.driven pump 5 start/stop(DO)
Output for Main Starting Valve control Change value in service terminal and
82 W1121-B 1121-B (DO) check indication on LOP
Slow Down Request-Manual, at local
83 2206-B (DO)
84 2154-B Forced Command take over-LOP (DO)
Increase limitation-feedback for LOP
85 2159-B indication (DO)

7/11/2006
MAN B&W Diesel A/S
EICU A
Power Filter Board
1 WPEICUA Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
1 WPEICUA Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 WAMS1A Power failure 2201-A Power failure signal for AMS (DO) Check signal in AMS (NC)
3 2A out
4 3.15A out
5 2A out
6 2A out
7 2A out
8 2A out
10A output
9 filtered

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

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

7/11/2006
MAN B&W Diesel A/S
EICU A
30 High/Low BW Stop-bridge (DI superv)
31 High/Low BW Start-bridge (DI superv)(CPPonly)
32 High/Low BW Stop-ECR (DI superv)

33 High/Low BW Start-ECR (DI superv)(CPPonly)
34 High/Low BW Take command ECR (DI superv)
35 High/Low BW Astern-ECR (DI superv)(CPPonly)
36 High/Low BW Pitch set point (AL superv)(CPPonly)
Aux.systems ready (DI superv)(HW-
37 High/Low BW CPPonly)
Fast Digital Input

40 WPMS TPU ch.0 1190-A Shaft generator req (DI) Check signal from PMS
41 TPU ch.1 2112-A Standby request (DI)
42 TPU ch.2 2101A FWE request (DI)
43 TPU ch.3 2120-A Local Control (DI)
44 TPU ch.4 2122-A Bridge Control (DI)
ECR Control- control station request
(ECR Control-separate rpm for CPP)
45 TPU ch.5 2121-A (DI)
46 TPU ch.6 2190-A At Sea (for indication on MOP )(DI)
2191-A Prepare start
or Or
2129-A ECR Control-combinatormode for CPP
47 TPU ch.7 (DI)

7/11/2006
MAN B&W Diesel A/S
EICU A
Fast Digital Output
Fix rpm indication on bridge
48 WRCS1A TPU ch. 8 2171-A (CPPonly)(DO) Check indication on RCS
Load limitaion indication on bridge
Manual slow down req. On bridge
50 TPU ch. 10 2172-A (CPPonly)(DO)
51 TPU ch. 11 2175-A Near limit (CPPonly)(DO)
2210-A Engine stopped for AMS (DO)
or or
52 TPU ch. 12 2197 Main engine running
Load limitation indication on ECR

Check indication on safty sys.
60 WSA 2021-A Cancellable shd. Down (DO) (Resistor f. supervision)
61 WAMS1A 2202-A System failure for AMS (DO) Check indication on RCS
Control Network
65 WEICUA Line A - Network line A Check with Service terminal in EICU
66 WEICUB Line B - Network line B Check with Service terminal in EICU

7/11/2006
MAN B&W Diesel A/S
68 WRCS2A RS422 Serial conn to RCS Check connection by ohming
EICU A
Engine speed(AO)
2183-0 Fuel index (calculated governor index)
2184-0 (AO)
2401-0 Speed set point(AO)
1250-0 Hydraulic pressure(AO)
2410-0 Scavenge air pressure(AO)
2411-0 Start air pressure(AO)
2402-0 Raw unsigned speed(AO)
2403-0 Index Margin(AO)
70 2404-0 Actual Pitch (AO)
Engine speed(AO)
2183-1 Fuel index (calculated governor index)
2184-1 (AO)

7/11/2006
MAN B&W Diesel A/S

1191-A Shaft generator Permission (DO)
80 Check signal in PMS
Non cancelabel shut down request to safety Check indication on safty sys.
81 WSB 2020-A system (DO) (Resistor f. supervision)
2005-A Reset shut down from ECS (DO)
or or Check indication on safty sys.
82 WSB 2207-A Reset shoutdown - from ECS (Resistor f. supervision)
2130-A Ahead command
or Or
83 2110 Engine blocked(HW CPP)(DO)
2131-A Astern command
or Or
84 2111 Engine ready(HW CPP)(DO)
85 2147 Slow command (CPPonly) (DO)

7/11/2006
MAN B&W Diesel A/S
EICU B
Power Filter Board
WPEICU
1 B Power input A Power Supply Input A Analog 24 Vdc A= - / B= +
WPEICU
1 B Power input B Power Supply Input B Analog 24 Vdc A= - / C= +
2 WAMS1B Power failure 2201-B Power failure signal for AMS (DO) Check signal in AMS (NC)
3 2A out
4 3.15A out
5 2A out
6 2A out
7 2A out
8 2A out
10A output
9 filtered

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

7/11/2006
MAN B&W Diesel A/S
EICU B
30 High/Low BW Stop-bridge (DI superv)
31 High/Low BW Start-bridge (DI superv)(CPPonly)
32 High/Low BW Stop-ECR (DI superv)
33 High/Low BW Start-ECR (DI superv)(CPPonly)
34 High/Low BW Take command ECR (DI superv)
Astern-ECR (backup-reversing)(DI
35 High/Low BW superv)(CPPonly)
36 High/Low BW Pitch set point (AL superv)(CPPonly)
Aux.systems ready (DI superv)(HW-
37 High/Low BW CPPonly)
Fast Digital Input

40 WPMS TPU ch.0 1190-B Shaft generator req (DI) Check signal from PMS
41 TPU ch.1 Standby request (DI)
42 TPU ch.2 FWE request (DI)
43 TPU ch.3 Local Control (DI)
44 TPU ch.4 Bridge Control (DI)
ECR Control- control station request
45 TPU ch.5 (ECR Control-separate rpm for CPP) (DI)
46 TPU ch.6 At Sea (for indication on MOP )(DI)
2191-B Prepare start
or Or
2129-B ECR Control-combinatormode for CPP
47 TPU ch.7 (DI)

7/11/2006
MAN B&W Diesel A/S
EICU B
Fast Digital Output
Fix rpm indication on bridge (CPPonly)
2171-B or
or Forced command take over-ECR
48 WRCS1A TPU ch. 8 2128 indication (HW CPP)(DO) Check indication on RCS
Load limitaion indication on bridge
49 WRCS1A TPU ch. 9 2170-B (CPPonly)(DO) Check indication on RCS
Manual slow down req. On bridge
50 TPU ch. 10 2172-B (CPPonly)(DO)
51 TPU ch. 11 2175-B Near limit (CPPonly)(DO)
Engine stopped for AMS (DO)
2210-B or
or Astern back-upmode (backup reversing)
52 TPU ch. 12 2126 to pitch control function (HW CPP only)
Load limitation indication on ECR
53 WRCS1A TPU ch. 13 2180-B (CPPonly)(DO) Check indication on RCS

Check indication on safty sys.
60 WSA 2021-B Cancellable shd. Down (DO) (Resistor f. supervision)
61 WAMS1A 2202-B System failure for AMS (DO) Check indication on RCS
Control Network
65 WEICUA Line A - Network line A Check with Service terminal in EICU
66 WEICUB Line B - Network line B Check with Service terminal in EICU

7/11/2006
MAN B&W Diesel A/S
68 WRCS2A RS422 Serial conn to RCS Check connection by ohming
EICU B
2183-0 Engine speed(AO)
2184-0 Fuel index (calculated governor index) (AO)
2183-1 Engine speed(AO)
2184-1 Fuel index (calculated governor index) (AO)

7/11/2006
MAN B&W Diesel A/S

1191-B Shaft generator Permission (DO)
or or
80 2127 SG disconnection failed (HW CPP) Check signal in PMS
Non cancelabel shut down request to safety Check indication on safty sys.
81 WSB 2020-B system (DO) (Resistor f. supervision)
2005-B Reset shut down from ECS (DO)
or or Check indication on safty sys.
82 WSB 2207-B Reset shoutdown - from ECS (Resistor f. supervision)
2130-B Ahead command
or Or
83 2123 Local command take over to RCS(HW CPP)(DO)
2131-B Astern command
or Or
84 2124 Local command take over to RCS(HW CPP)(DO)
2147 Slow command (CPPonly)
or Or
85 2125 Bridge command take over to RCS(DO)

7/11/2006
MAN B&W Diesel A/S
TSA-A
Fast Digital Input
Check when aligning the pick-up to
J3 WTMMA TPU ch.0 4001-A Marker Master - Tacho set A (Di) the trigger ring on the flywheel
J4 WTMSA TPU ch.1 4002-A Marker Slave - Tacho set A (Di) the trigger ring on the flywheel
J1 WTQ1A TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) the trigger ring on the flywheel
J2 WTQ2A TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) the trigger ring on the flywheel
TSA-B
Fast Digital Input
J3 WTMMB TPU ch.0 4001-A Marker Master - Tacho set A (Di) the trigger ring on the flywheel
J4 WTMSB TPU ch.1 4002-A Marker Slave - Tacho set A (Di) the trigger ring on the flywheel
J1 WTQ1B TPU ch.2 4003-A Quadrature 1 - Tacho set A (Di) the trigger ring on the flywheel
J2 WTQ2B TPU ch.3 4004-A Quadrature 2 - Tacho set A (Di) the trigger ring on the flywheel

7/11/2006

Connection and Function Test of Electrical System For ME Engine

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Connection and Function Test of Electrical System For ME Engine

Hochgeladen von

Copyright:

Verfügbare Formate

MAN B&W Diesel A/S

1 Power Supply Check 5

6 Check of Serial Communication between RCS and ECS 18

10.2. MOP Screen “Cylinder Lubricators” 32

Connection test scheme for

4.1 “MPC Parameter update”

“Network address= Sum of

“ECS Network address” is

Introducing 6.1 “Check of

2005-08-29 AAJ 9. ME Alpha lubricator quick

4.3 How to make a copy of

Document id: 3090532-9.4.7 Connection and Function Test

Network status 3.0

Document id: 3090532-9.4.7 Connection and Function Test

1 Power Supply Check

1.1 MPC fuse specification

2 ID-key Boot Loader Program

• Check the validity of the ID-key, ID before boot is allowed.

Document id: 3090532-9.4.7 Connection and Function Test

2.1.1 Connections and settings – normal operation

View of MPC board with ID-key connected.

Battery mounted on MPC board

LED ( Led Emitting Diode)

ID-key Mounted on MPC (J206)

Service Terminal Connection (J67)

DIP-switch S1: Neutral ⇒ All in off position

Document id: 3090532-9.4.7 Connection and Function Test

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

2.1.2 Start-up normal operation

Initialising BES kernel...OK

Reading Dongle ID...Value = 192

Reading DIP-switch S1... Value = 0

Dongle verification done.

Continuing boot sequence.

Figure 1: Messages sent to a portable PC with Windows Hyperterminal

Document id: 3090532-9.4.7 Connection and Function Test

2.2 Programming the ID-key (Network Address)

2.2.1 Connections and settings – programming.

ACU 1 224 Off Off Off Off Off On On On

Document id: 3090532-9.4.7 Connection and Function Test

2.2.2 Programming Sequence for ID-Key

Switching to programming mode. 2d

Reading DIP-switch... Value = 240

Programming Dongle with DIP-switch value.

Dongle not connected! Please connect dongle.

Dongle programmed successfully

DIP-switch not neutral. Please set DIP-switch to neutral.

Reading DIP-switch... Value = 0

Dongle verification done.

Continuing boot sequence...

Document id: 3090532-9.4.7 Connection and Function Test

2.3 2.3 Troubleshooting LED messages

Problem: The LED flashes code 4,3.

Solution: Set DIP-switch S1 to neutral (OFF).

Problem: The LED flashes code 4,2.

Solution: Connect the ID-key to the MPC.

Solution: Connect the ID-key and reset the MPC.

Cause: The ID number read into the ID-key is invalid.

Cause: ID-key is defective.

Solution: Replace ID-key.

Error code Description

Document id: 3090532-9.4.7 Connection and Function Test

In ECU A & B, a 120 ohm terminating resistor