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Technical Publication

Local Operating Panel LOP 1–06


MTU/DDC series 4000 and
DDC/MTU series 2000
Marine applications
(Main drive and on–board equipment)

Documentation
Parts 1, 2, 3, 4, 5

E 532 067 / 00 E

S Structure and function


S Operation
S Maintenance and repair (Plant personnel)
S Maintenance and repair (Service personnel)
S Illustrated parts catalog

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
FRIEDRICHSHAFEN

Table of contents

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
General information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Use and structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1.1 Use of Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1.2 Structure of Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


1.1.2.1 External structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Central display area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Function key assignment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Graphic page symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1.2.2 Internal structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.2.1 General notes on Local Operating Panel LOP 1 functions . . . . . . . . . . . . . . 31

1.2.2 Central tasks of Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . . 33

1.2.3 Bus system of the Local Operating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


1.2.3.1 Redundant field bus of the Propulsion Control System . . . . . . . . . . . . . . . . . 35
1.2.3.2 Sensor/actuator bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.2.4 Function of the various assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


1.2.4.1 Control panel PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2.4.2 Display DIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.2.4.3 Peripheral Interface Module PIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2.5 Engine start and engine stop sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43


1.2.5.1 Engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.2.5.2 Electrical start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2.5.3 Flame start (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2.5.4 Pneumatic start (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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FRIEDRICHSHAFEN

Table of contents (cont.)

1.2.5.5 Priming (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46


1.2.5.6 Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.2.6 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48


1.2.6.1 Engine emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.2.7 Safety system override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.2.8 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.2.9 Internal status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53


1.2.9.1 Printed circuit board CIB 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2.9.2 Printed circuit boards in the Peripheral Interface Module . . . . . . . . . . . . . . . 54

1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.2 User interface on Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . 63

2.3 Taking into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.4 Switching off the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.6 Changing between Local mode and Remote mode . . . . . . . . . . . . . . . . . . . . 70

2.7 Engine ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.8 Engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.9 Changing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.10 Clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.10.1 Reversing gear with Fixed Pitch Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.10.2 Reduction gear with Controllable Pitch Propeller or waterjet . . . . . . . . . . . . 78

2.10.3 Reversing gear with waterjet incorporating flush function . . . . . . . . . . . . . . . 79


2.10.3.1 Engaging and disengaging the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.10.3.2 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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Guide Page III
FRIEDRICHSHAFEN

Table of contents (cont.)

2.11 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.12 Emergency engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.13 Overspeed test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.13.1 Overspeed test with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

2.13.2 Overspeed test with engine at a standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2.14 Alarm handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.15 Safety system override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.16 Using display panel DIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.16.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2.16.2 Page selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89


2.16.2.1 Opening the Overview page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.16.2.2 Opening Graphic pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Scrolling down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Scrolling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.16.2.3 Opening the Measured value list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.16.2.4 Opening the Alarm page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.16.2.5 Opening the Help page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.16.3 Adjusting brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92


2.16.3.1 Adjusting brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.16.3.2 Adjusting contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.16.4 Language switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2.16.5 Horn acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2.16.6 System settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95


2.16.6.1 Setting the date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.16.6.2 Setting a printer driver and “Setting printer baud rate” . . . . . . . . . . . . . . . . . 97

2.16.7 Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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Page IV Guide
FRIEDRICHSHAFEN

Table of contents (cont.)

3 Maintenance and repair (Plant personnel) . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106


3.2.2.1 Task summary for scheduled maintenance work . . . . . . . . . . . . . . . . . . . . . . 106
3.2.2.2 Task overview – visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2.2.3 Checking firm attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2.2.4 Checking connectors for firm seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.2.2.5 Checking cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2.2.6 Visually inspecting the operating buttons and operating panels . . . . . . . . . 111
3.2.2.7 Visually inspecting the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2.2.8 Checking internal assemblies for firm seating . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.2.2.9 Task overview – cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2.2.10 Cleaning Local Operating Panel LOP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.2.11 Cleaning connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.3.1 Faults without fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.3.2 Plain text fault messages on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.4.1 Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.4.2 Replacing mechanical control assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.4.3 Replacing a multi-LED of a function key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

3.4.4 Removing control panel PAN with bus connection . . . . . . . . . . . . . . . . . . . . . 156

3.4.5 Installing control panel PAN with bus connection . . . . . . . . . . . . . . . . . . . . . . 158

3.4.6 Replacing dialog socket outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.4.7 Replacing Peripheral Interface Module printed circuit boards . . . . . . . . . . . 162

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Table of contents (cont.)

3.4.8 Replacing display panel DIS seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

3.4.9 Replacing control panel PAN seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.4.10 Replacing power circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3.4.11 Replacing plug-in fuses on BOB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

4 Maintenance and repair (Service personnel) . . . . . . . . . . . . . . . . . . . . . . . 175

4.1 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

4.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.2.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.3.1 Faults without fault code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4.3.2 Faults indicated in plain text on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

4.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.4.1 Removing display panel DIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

4.4.2 Installing display panel DIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4.4.3 Removing control panel PAN with bus connection and fixed wiring . . . . . . 186

4.4.4 Installing control panel PAN with bus connection and fixed wiring . . . . . . . 189

4.4.5 Replacing switch elements/button elements of control panel PAN . . . . . . . 193

4.4.6 Replacing Peripheral Interface Module housing with motherboard . . . . . . . 195

4.4.7 Replacing the processor assembly of a Peripheral Interface Module . . . . . 200

4.4.8 Replacing printed circuit board CIB 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

4.4.9 Replacing 24 VDC relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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FRIEDRICHSHAFEN

Table of contents (cont.)

5 Illustrated parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.2 Illustrations and tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

5.3 Cross-reference list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

A Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Reference documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

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FRIEDRICHSHAFEN

Abbreviations
a Acceleration

BR Baureihe, series (in this case: engine series)

CAN Controller Area Network (bus designation)


CB Connection Box

ECS Engine Control System, MTU engine management system


ECU Engine Control Unit
ESI Engine System Interface (connection box)

f Formula for frequency


fL Limit frequency
FPP Fixed Pitch Propeller

g Acceleration due to gravity

I/O Input/Output
I Formula for electrical current
IIn Input current
IEC International Electrotechnical Commission
IP International Protection

LED Light Emitting Diode


LOP Local Operating Panel

mA Milliampere
min Minute
mV Millivolt
MCS Monitoring and Control System, MTU control and monitoring system
MCS-PO Main Control Station
MTU Motoren- und Turbinen-Union

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Abbreviations (cont.)

n Speed

p Pressure
PIM Peripheral Interface Module
PP Plant personnel
PPS Programmable Process Station

R Formula for electrical resistance


RAM Random Access Memory
RCS Remote Control System
RS422 Recommended Standard (interface standard)

s Second
SISY Sicherheitssystem, safety system
SDAF Shut down air flaps
STn Connector designation

T Temperature

U Voltage
UOut Output voltage
UB Ship’s voltage (+24 V)
UIn Input voltage

V Volt
VCC Operating voltage
VDC Voltage Direct Current
Vpp Voltage value from peak to peak

xpp Vibration test deflection, peak – peak value

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Guide Page IX
FRIEDRICHSHAFEN

General information about documentation

Documentation structure

Documentation Title/contents Target group


Part
1 Structure and function Operating personnel, plant personnel

2 Operation Operating personnel

3 Maintenance and Operating personnel, plant personnel


repair
(Plant personnel)
4 Maintenance and Electronics service personnel
repair familiar with the plant
(Service personnel)
5 Illustrated Operating, service and logistics personnel
parts catalog
6 Order-specific Electronics service personnel
adaptation
7 Installation Electromechanical specialists

Note: Not all documentation parts are written for every product!

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

Reference numbers and reference lines


Details in figures are provided with reference numbers and reference lines if necessary.
If reference is made in the text to a detail provided with a reference number, the figure
number and, separated by an oblique, the reference number of the detail are written in
brackets. Example: (5/2) means fig. 5, reference number 2.

A point at the end of the reference line means that the detail is visible in the
figure.
An arrow at the end of the reference line indicates that the detail cannot be
seen in the figure.

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Symbols

Rectification of a fault marked with this symbol either requires the


customer’s service personnel or service personnel provided by MTU.
The affected assembly can be sent to MTU for repairs.
Such a fault cannot be repaired by ship’s personnel.

Further troubleshooting or fault rectification requires work to be performed


on the engine with reference to the engine documentation.

Further troubleshooting or fault rectification requires mechanical work to be per-


formed on other assemblies or equipment with reference to the relevant
documentation.

Refer to other MTU manuals for more information.

 Fig. X Refer to fig. X for more information (cross reference to another figure).

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Structure and function
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Part 1

Structure and function

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1 Structure and function

1.1 Use and structure

1.1.1 Use of Local Operating Panel LOP 1

Fig. 1: Local Operating Panel LOP 1

The Local Operating Panel LOP 1 is the central interface in the Propulsion Control System
of the ship’s main drive, and in the ECS-5 engine-management system of the on-board
equipment. Its main tasks include:
 Propulsion side or engine side
– Connection of the following via the shared field bus of the Propulsion Con-
trol System: ECU 1 or ECU 4 Engine Control Unit; EMU Engine Monitoring
Unit; GCU 1 Gear Control Unit or GCU/GMU 1 Gear Control Unit and Gear
Monitoring Unit
– Power supply to the corresponding assemblies

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 Plant side:
– Feeding supply voltage(s)
– Connecting additional sensors (measuring points in the engine room, e.g.
start air pressure, exhaust back pressure, water level in primary fuel filter)
– Connecting alarm equipment (horn, beacon etc.)
– Connecting start devices (e.g. starter motor, priming etc.)
– Interfaces (CAN bus) for further monitoring and/or control systems (MTU or
other systems)
 Operator side:
– Indicating propulsion plant operating states on a flat-screen display
– Indicating fault messages
– Operating the propulsion plant in Local mode via luminous pushbutton:
Input of start and stop commands, clutch control
– Tripping an emergency stop via a luminous pushbutton with protective flap

One Local Operating Panel LOP 1 is used per engine.

Local Operating Panel LOP 1 is located in the engine room near the engine to which it is
assigned. A pre-cut cable set connects it to the other assemblies in the Propulsion Control
System.

Reference Documentation:
The integration of the Local Operating Panel LOP 1 into the entire system of
ship main drives is documented in the system description of the ”Propulsion
Control System, MTU/DDC Series 4000, Ship Usage, doc. no. E 531 693”
drive-management system.The following documentation applies to the 2000
series:
”DDC/MTU Series 2000, Ship Usage”, doc. no. E 531 730. The system
descriptions of the ”Engine Control System ECS-5, MTU/DDC Series 4000,
On-board Equipment Usage” doc. no. E 531 989 and DDC/MTU Series 2000,
On-board Usage, doc. no. E 532 025 apply to on-board equipment.

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1.1.2 Structure of Local Operating Panel LOP 1

1.1.2.1 External structure

1
10

14
3

4
13

12

6
11

10
9

Fig. 2: Local Operating Panel LOP 1 – external structure

1 Front door 8 Ready for operation controls, Local mode,


2 Flat-screen display start, stop, emergency stop
3 Flat-screen display controls 9 Grounding screw
4 Connector X11 (EMU) 10 Door lock
5 Dimmer controls and test functions 11 Connector X5 (ECU, supply)
6 Gear controls, speed 12 Door handle
7 Connector X21 (GCU or GCU/GMU) 13 Connector X1 (ECU, signals)
14 Socket for X31 dialog unit

The underside of the Local Operating Panel includes a removable flange plate
for ship’s cable entries (this flange plate is not installed on the amagnetic ver-
sion with a stainless steel housing; the cable entries are installed directly in the
bottom of the housing).

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Display panel DIS

LC-Display

function keys

cast housing

Fig. 3: Display panel on the LOP 1 Local Operating Panel

The display panel is a plug-in version and comprises the following assemblies and compo-
nents:
 Fine cast aluminium housing
 LCD screen
 5 function keys
 LED for operating state display
 Terminal block ST 1
 Terminal block CAN 2
 Terminal block CAN 1
 Sub-D-pin connector COM 1
 PC Basic display unit
 Module plug connector for MEM
 Strain relief device for connecting cable
 Cover

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The TFT-based LCD screen has its own control logic which functions as a driver for the
liquid crystal display and luminous background.

Reference Documentation:
A detailed functional description of the display panel is included in the docu-
mentation entitled “Display panel DIS, Documentation Part 1 – 7”,
document no. E 531 900.

Screen pages

A screen page is divided into the following three areas:


 Status bar
 Central display area
 Key assignment display (operating levels)

Status bar

3000

Central display area


1500 (Example: Graphic page)

1500 60 5.0 60 400 400


Key assignment display

Fig. 4: Screen page structure (sample contents)

The display panel has 5 function keys (F1 to F5) for operation. The function keys (F1 to
F5) are assigned various functions depending on the page selected on-screen.

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Status bar

The status bar indicates the page designation and the display fields for the number of
alarms, safety system override, combined alarm and system status. Appropriate message
texts are displayed when safety system override is active or if a combined alarm or sys-
tem status is applied, otherwise the display fields are blank.

Page designation Number of alarms display Safety system override display field
field
3

Combined alarm display field System status display field

Fig. 5: Status bar structure (sample contents)

The following messages are displayed in the system status display field:
 Initialization
 Bus error
 Bootup Sys. (operating software and system data are loaded.)
 Download Sys. (system data are updated.)
 Bootup Proj. (job–specific data are loaded.)
 Download Proj. (job–specific data are updated.)
 BDM OK (normal operation with BDM functionality is active.)
 BDM receipt (BDM service operation is active.)
 BDM PPS error

Central display area

The central display area is used to display the following pages:


 Overview page
 Graphic pages
– Measured values in graphic representation
 Measured value list
– Measured values in alphanumeric representation
 Alarm page
– Alarm messages in alphanumeric representation

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 Contrast page
– LCD display setting
 Help pages
– Explanation of the system errors and abbreviations at alarm messages
 Configuration page
– Display and modification of date, time and printer settings
 Service page
– Display and modification of system settings
 Status page
– System status in alphanumeric representation
 System page
– System status and software version in alphanumeric representation
 BDM page
– Display and operation of the software download or upload

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Function key assignment display

The display panel is equipped with five function keys (F1 to F5) with which the panel is
operated on all levels.

The function keys (F1 to F5) are assigned various functions depending on the page
selected on-screen.

Overview page

Graphic page
Measured value list
Help page

Alarm page

Contrast page

Service page in display mode


BDM page in display mode

Configuration page
Service page in edit mode
BDM page in edit mode

Status page
System page

Fig. 6: Function key assignment

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Symbol Key Description

F2 Opens the Alarm page

F3 Scroll up to select a menu option on the Overview page.


Scroll up page-by-page on graphic screen pages, measurand list,
Help page and Alarm page.
The function key is inactive when the arrow is dotted.

F4 Scroll down to select a menu option on the Overview page.


Scroll down page-by-page on graphic screen pages, measurand list,
Help page and Alarm page.
The function key is inactive when the arrow is dotted.

F5 Opens the selected menu option on the Overview page.


F2 On the Service page in edit mode:
Accepts the entered value and selects the input fields. The selected input
field is represented inversely. This indicates that the input value has been
activated for processing.

F5 Opens the Overview page

F2 Opens the Help page

F5 Returns to the previously selected page from the Alarm page.

F1 Increase brightness
Brightness of LCD background illumination, illumination of function keys F1
to F5 and the operating status LED is increased in stages.

F2 Decrease brightness
Brightness of LCD background illumination, illumination of function keys F1
to F5 and the operating status LED is decreased in stages.

F3 Increase contrast
LC display contrast is increased in stages.

F4 Decrease contrast
LC display contrast is decreased in stages.

F1 Saves the old value of activated variables and exits the input field.

>>

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Symbol Key Description

>>

F3 Increases the input value

F4 Decreases the input value

F3 Text language switching (e.g. German/English)


Texts are stored in two languages

F4 Horn off
Switches off the horn connected to the relay output when sounding.

Overview page

Drive ECU EMU Measuring Contrast Help Configuration Service Status System BDM
overview overview point list page pages page page page page page

ECU EMU
Status Exhaust A

ECU EMU
Pressure Exhaust B

ECU
Temp.

Fig. 7: Screen page hierarchy (sample contents)

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Graphic page symbols

The following elements and/or symbols may be used on screen pages which graphically
represent measuring values and operating states in the main display section.
 Bar graph displays
 Graphic representation of the propulsion arrangement

Bar graph displays are used to represent analog data. These bar graphs are used for:
 Speeds (rpm)
 Fuel injection quantity
 Temperatures
 Pressures

Bar graphs have the following features:

Measured variable
P-Lube T-
Oil Bar graph Coolant 1st upper limit value

30 Unit 120 2nd upper limit value

bar Scale C

1st lower limit value


15 50
2nd lower limit value

Alphanumerical display of
measuring value
0 0
Unit
bar C

Fig. 8: Bar graph displays (using pressure and temperature as an example)

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Graphic symbols are used to indicate the state of the propulsion components. This dia-
grammatic representation can include the following information:
 Engine running
 Cylinder cutout
 Exhaust turbocharger activated
 Engine operating hours
 Clutch state
 Gear state

This information is displayed in one of two forms as illustrated in figures 9 and 10.

Control mode: Remote mode active: Remote


Control Mode: Remote Local mode active: Local
Engine
Engine state: Light: Engine standing still
Dark: Engine running
Cylinder cutout: Light: Cylinder switched off
Dark: Cylinder switched on
(all cylinders active)

Exhaust turbocharger
1 2 ETC1: Dark: connected
(always connected)
Exhaust turbocharger
ETC2: Dark: connected
Light: Switched off
Total operating hours
Operating Hours
99999 h

Fig. 9: Engine operating state display incorporating operating mode display and operating hours
display

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Engine state: Light: Engine standing still


Dark: Engine running
Cylinder cutout: Light: Cylinder switched off
Dark: Cylinder switched on
(all cylinders active)

Exhaust turbocharger
ETC1: Dark: connected
(always connected)
Exhaust turbocharger
ETC2: Dark: Switched on
Light: Switched off
Trolling on: Direct display
Trolling
Clutch Astern Clutch position: On reversing gear:
↑ Clutch Ahead
Neutral
↓ Clutch Astern

On reduction gear:
Clutch engaged
Clutch disengaged

Fig. 10 : Engine operating state display incorporating gear status display

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PAN control panels

Fig. 11 : Control panels for Local Operating Panel LOP 1

1 Dimmer and test function control panel


2 Gear control and speed/rpm adjustment control panel
3 Engine and general function control panel

Two different types of PAN control panel are used in the Local Operating Panel:
 The first two panels illustrated (11/1 and 11/2) have an internal COP8 processor
with integral CAN sensor/actuator bus interface; the states can only be evalu-
ated by the bus while the lamps are activated in the same way via the CAN bus
 The third panel illustrated (11/3) also includes a connection for a contact level
(changeover connection) per luminous switch to enable wiring of certain func-
tions (in this instance start, stop, emergency stop)

Reference Documentation:
A detailed functional description for the control panel can be found in the docu-
mentation entitled “Control panel PAN, Documentation Parts 1, 2, 3, 5, 7”,
document no. E 531 649.

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Control inscriptions

2
21

20 F1 F2 F3 F4 F5
3

19 4

5
18
DIMMER DIMMER OVER-
21 ALARM LAMP
SPEED
ACKN. TEST 6
17 TEST
7

16

15 INCREASE DECREASE
8
CLUTCH CLUTCH CLUTCH

21 AHEAD NEUTRAL* ASTERN


ENGINE ENGINE 9
SPEED SPEED

14
10

13 11
READY 12
LOCAL EMERG.
FOR START STOP
21 MODE STOP
OPERATION

Fig. 12 : Control arrangement


* Depending on gear version, see text and fig. 13

Item Type Colour Assignment Inscription/function meaning Signal path

12/1  White Display panel Function keys F1 to F5 for operating the Internal processing
DIS screen interface,
interface functions change and in display panel DIS
12/2  White are indicated on the display

12/3  White

12/4  White

12/5  White

>>

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Item Type Colour Assignment Inscription/function meaning Signal path

>>

12/6  White Local Oper- Luminous pushbutton: Conversion on sen-


ating Panel Trips the lamp test function; whilst this sor/actuator bus,
button remains depressed, all control processing and out-
fields light up along with all spots on the put in corresponding
luminous pushbutton PAN control panels
Display (spot):
Lamp test is active

12/7  Red Engine Luminous pushbutton: Conversion on sen-


Trips the overspeed test function (only sor/actuator bus,
possible if Local mode is activated): processing and out-
1. Overspeed protection test for ECU put through ECU or
Engine Control Unit: through EMU via
Start engine. Engine running. The requi- field bus of Propul-
rements and activities are different for the sion Control System
ship main drive usage and the on-board
equipment (see 2.13.1). Press and hold
the ”Overspeed test” illuminating push-
button. Press the ”Increase speed” illumi-
nating pushbutton to approach the swit-
ching threshold. The ECU Engine Control
Unit is switched without power and the
”Overspeed” and ”Emergency stop”
alarms are sounded.

2. Overspeed protection test for EMU


Engine Monitoring Unit (only with Propul-
sion Control System, monitoring II availa-
ble):
Pressing the button when the engine is at
a standstill, immediately cuts off the
power to the ECU

Display (spot):
Spot lights up as soon as the overspeed
test is executed

12/8  White Engine Luminous pushbutton: Conversion on sen-


The speed is increased continually for as sor/actuator bus,
long as the button is held down (provided processing and out-
Local mode is activated) put ECU via field
Display (spot): bus of Propulsion
Lights up for as long as the button is held Control System
down (runs on)

>>

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Item Type Colour Assignment Inscription/function meaning Signal path

>>

12/9  White Engine Luminous pushbutton: Conversion on sen-


The speed is continually decreased for as sor/actuator bus,
long as the button remains pressed (pro- processing and out-
viding Local mode is activated) put ECU via field
Display (spot): bus of Propulsion
Lights up for as long as the button is held Control System
down (runs on)

12/10  White Engine Luminous pushbutton: Feedback from


Trips an engine start (provided that Local CIB 3 to PIM via
mode and ready for operation are acti- LCU (conversion on
vated and all start conditions are fulfilled) sensor/actuator
Display (spot): bus).
Lights up for as long as the start is Parallel wiring of
executed button contact at
start input of PCB
CIB 3

12/11  White Engine Luminous pushbutton: Feedback from


Trips an engine stop (provided Local CIB 3 to PIM via
mode is activated) LCU (conversion on
Display (spot): sensor/actuator
Lights up for as long as the stop signal is bus).
available (also via Remote control in the Parallel wiring of
event of emergency stop or stop) button contact at
stop input of CIB 3
PCB, activation of
ECU stop input

12/12  Red Engine Luminous pushbutton: Parallel wiring of the


with Trips an emergency engine stop; ECU de- button contact on
protec- energized or shut down air flaps tripped emergency stop
tive flap (depending on engine equipment), emer- input of CIB 3 PCB,
gency stop alarm tripped interruption of power
Display (spot): supply to ECU or
Flashes once the emergency stop has SDAF trip. Feed-
been tripped, goes out once the alarm has back from CIB 3 to
been acknowledged PAN via LCU (con-
version on sensor/
actuator bus)

>>

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Item Type Colour Assignment Inscription/function meaning Signal path

>>

12/13  Green System Luminous switch: Conversion on sen-


Pressing the switch informs the system sor/actuator bus,
that the operator has made the propul- processing and out-
sion system ready for operation; the put LCU via S/A
system can only trip an engine start once field bus, parallel
this switch is activated wiring of button con-
Display (spot): tact on ready for
Indicates the current switch status operation input of
CIB 3 PCB

12/14  Green System Luminous switch: Conversion on sen-


Pressing the switch activates Local sor/actuator bus,
mode; the luminous pushbuttons on the processing and out-
Local Operating Panel used to operate put ECU and GCU
the engine and the gear are activated as or GCU/GMU via
a result; control signals from a Remote field bus of Propul-
Control System as well as start and stop sion Control Sy-
commands from a Monitoring and Control stem. Parallel wiring
System are not evaluated in this ope- of button contact at
rating mode; pressing the button while Local mode input on
the engine is running triggers automatic CIB 3 PCB.
disengage Feedback from ECU
Display (spot): and GCU or GCU/
Indicates the current system status; lights GMU through LCU
up when the switch is switched to Local on PAN via field bus
mode. Flashes when changeover to of Propulsion Con-
Remote control mode occurs, provided trol System
that the output (switch position is Remote
control) does not yet match the feedback
from the ECU Engine Control Unit and
the GCU Gear Control Unit or GCU/GMU
Gear Control and Monitoring Unit. Goes
out once the system has changed over to
Remote control mode.

12/15  Green Gear See text under fig. 13 for luminous push- Conversion on sen-
button and display function sor/actuator bus,
processing and out-
put GCU 1 or GCU/
GMU 1 via i field
fi ld bus
b
12/16  Green Gear of Propulsion Con-
trol System.
Feedback from ECU
and GCU or GCU/
12/17  Green Gear GMU through LCU
on PAN via field bus
of Propulsion Con-
trol System

>>

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Item Type Colour Assignment Inscription/function meaning Signal path

>>

12/18  White System Luminous pushbutton: Conversion on sen-


Acknowledges an active alarm: If a “new” sor/actuator bus,
alarm is active, the horn and beacon are processing and out-
switched off when the button is pushed to put LCU via field
the first time. Pressing the button a bus of Propulsion
second time acknowledges the alarm and Control System
resets the emergency stop memory
Display (spot):
Indicates that a new alarm has been trig-
gered and, therefore, that the horn/
beacon or alarm need to be acknow-
ledged

12/19  White Local Oper- Luminous pushbutton: Conversion on sen-


ating Panel The intensity of the background illumina- sor/actuator bus,
tion and the spots continues to increase processing through
for as long as the button is held down (12 LCU and the corres-
levels) ponding PAN control
Display (spot): panels
Lights up for as long as the button is held
down

12/20  White Local Oper- Luminous pushbutton: Conversion on sen-


ating Panel The intensity of the background illumina- sor/actuator bus,
tion and the spots continues to decrease processing through
for as long as the button is held down (12 LCU and the corres-
levels) ponding PAN control
Display (spot): panels
Lights up for as long as the button is held
down

12/21 – – Corres- Status LEDs for the CAN bus


ponding panel

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1
Reversing gear with Fixed
2
Pitch Propeller:
CLUTCH CLUTCH CLUTCH
AHEAD NEUTRAL ASTERN
3

4
Reduction gear with Con-
trollable Pitch Propeller or 5
waterjet: CLUTCH CLUTCH
ENGAGE DISENGAGE

7
Reversing gear with water-
jet incorporating flush 8
function: CLUTCH CLUTCH
FLUSH
ENGAGE DISENGAGE
9

Fig. 13 : Luminous pushbuttons for controlling various types of gears

The luminous gear control pushbuttons (12/15, 12/16 and 12/17) are assigned depending
on the type of gear and propulsion system involved:
 Reversing gear:
All three luminous pushbuttons are assigned in this instance:
CLUTCH AHEAD (13/1) engages gear ahead;
CLUTCH NEUTRAL (13/2) disengages the clutch;
CLUTCH ASTERN (13/3) engages gear astern
 Reduction gear:
Only two of the luminous pushbuttons are assigned in this instance:
CLUTCH ENGAGE (13/4) engages the clutch;
CLUTCH DISENGAGE (13/5) disengages the clutch;
the propulsion system (e.g. controllable-pitch propeller or waterjet) changes the
direction of thrust

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 Reversing gear with waterjet propulsion:


In this special case, a reversing gear is used so that the waterjet can be oper-
ated in reverse to flush foreign matter out of the intake channel. It is activated
via the luminous pushbutton FLUSH (13/9), provided that this luminous push-
button FLUSH is held down;
CLUTCH ENGAGE (13/7) engages ahead;
CLUTCH DISENGAGE (13/8) disengages the clutch

The display (spot):


 Lights up when the corresponding feedback is active
 Flashes when the corresponding clutch command is available, provided the
feedback is not yet active
 Goes out when the corresponding feedback is active

The clutch commands are stored in the GCU or GCU/GMU Gear Control Unit.

For on-board equipment and ship main drives without shift transmissions, the
three illuminating pushbuttons for transmission control are not assigned to a
function and do not operate.

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Structure and function
FRIEDRICHSHAFEN Page 23

1.1.2.2 Internal structure

2
17

16 3

5
15
6
14
7
7

13
12
11
10
9

Fig. 14 : Local Operating Panel LOP 1 – internal structure

1 Mounting plate 11 Decoupling diodes


2 Bracket for wiring harness 12 Relay
3 Socket outlet for dialog unit (CAN) 13 Power circuit breaker
4 CIB 3 PCB 14 End piece
5 Peripheral Interface Module PIM (LCU) 15 Peripheral Interface Module PIM (LMU)
6 DIN rail 16 CIB 3 screw terminals
7 Grounding for PIM 17 Bracket for spare fuses
8 Power supply connection terminals, starter
9 Grounding cable
10 Input/output connection terminals, field bus

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Peripheral Interface Modules PIM

Two type 2 Peripheral Interface Modules are used in the Local Operating Panel. They are
equipped with the printed circuit boards shown in fig. 15.

MPU 23 + CCB 1

BOB 1
AIB 1

MPU 23 + CCB 1

BIB 1
BIB 1

1
COB 3

SAB 1

IIB 1
COB 3

Fig. 15 : Peripheral Interface Modules in LOP 1 Local Operating Panel

The functions of the two PIM Peripheral Interface Modules can be summarized as follows:
 =21.X+A001–A010: LCU
Local Control Unit; this PIM Peripheral Interface Module predominantly records
and processes signals for controlling the system
 =21.X+A001–A020: LMU
Local Monitoring Unit; this PIM Peripheral Interface Module predominantly
records and processes signals for additional system monitoring; in addition, it
contains the interface to the superordinate MCS Monitoring and Control System

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Structure and function
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The actual Local Operating Panel functions are realized via display DIS, the
control panels PAN and the LCU PIM. The other assemblies form the auxiliary
monitoring system.

Signal processing in the PIM Peripheral Interface Module

The following table describes the Peripheral Interface Module inputs and outputs:

Item No. PCB Functions Remarks

15/1 =21.X+LOP–A010 MPU 23 Outputs: –


LCU BIB 1  Safety system reset by Local Operating
SAB 1 Panel LOP
IIB 1
 External start interlock
 Engine speed (signal from Engine Con-
trol Unit ECU)
 Engine speed (signal from Engine Moni-
toring Unit EMU)
 Injection quantity/engine loading
 Charge air pressure
 Local Operating Panel LOP combined
alarm
 Horn and beacon in engine room
Inputs:
 PCS and MCS voltage failure
 Engine start, engine stop, emergency
engine stop feedback
 External starter interlock
 Emergency stop signal feedback from:
– Engine Control Unit ECU
– Engine Monitoring Unit EMU*
– External emergency stop
 Combined stop signal feedback, safety
system
 Shut down air flap position
 Message or power reduction request via
Engine Control Unit ECU and Engine
Monitoring Unit EMU
 Horn signal from display panel DIS
 Combined alarm acknowledgement, LOP
Serial interfaces:
 Sensor/actuator bus for PAN control
panels
 Field bus of Propulsion Control System
>>

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Item No. PCB Functions Remarks


>>

15/2 =21.X+LOP–A020 MPU 23 Outputs: –


LMU BOB 1  Start and stop signal from MCS
AIB 1
BIB 1  Safety system reset from MCS
 Safety system override (from MCS)
Inputs:
 Propulsion Control System power failure
 Start device signals:
Pump error*
Charge error*
Ignition plug error*
 Safety system override (fixed wiring
optional)
 Feedback from engine room: Safety
system override
 Additional sensors in engine room:
– Water level in primary fuel filter
– Start air pressure*
– Exhaust backpressure*
Serial interfaces:
 Field bus of Propulsion Control System

*Depending on the type of Propulsion Control System:

 With/without priming pump


 With/without flame start device
 With/without generator
 With/without Engine Monitoring Unit EMU
 With/without pneumatic start
 With/without exhaust backpressure monitoring

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CIB 3 PCB

The CIB 3 PCB performs the following functions:


 Feeding main and emergency supply voltage for control and basic monitoring,
filtering voltages and distributing to other Propulsion Control System assem-
blies
 Monitoring supply voltages for ECU, EMU, GCU, GCU/GMU, LOP (PAN, DIS,
LCU), emergency functions and control voltages
 Recording the PAN control signals (fixed wiring)
 Activating starting devices (priming for flame start, pneumatic start, electric
start, depending on system)
 Monitoring of the generator (if fitted)
 Controlling the start sequence via PAL-programmed program

The CIB 3 PCB has six fuses to safeguard the assemblies inside the Local Operating
Panel.

CIB 3 PCB

1 2 3 4 5 6

Fig. 16 : CIB 3 PCB with fuses

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The CIB 3 PCB fuses are assigned as follows:

Item No. Value Assignment Remarks

16/1 =21.X+A002–F1 30 A (green)  Engine Control Unit ECU


16/2 =21.X+A002–F2 4 A (pink)  Gear Control Unit GCU
16/3 =21.X+A002–F3 3 A (purple)  PIM LCU Local Operating Panel
Display panel DIS
Control panel PAN

16/4 =21.X+A002–F4 3 A (purple)  Emergency functions (emergency


stop, shut down air flaps)

16/5 =21.X+A002–F5 2 A (grey)  External contact supply


16/6 =21.X+A002–F6 1 A (black)  External contact supply

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Power circuit breakers, decoupling diodes, varistors and relays

The discrete circuit incorporating the power circuit breakers, decoupling diodes, varistors
and relays realizes the following functions:
 Feeding the main and emergency supply for auxiliary monitoring and dialog
unit, filtering the voltage and distributing to the other MCS-5 or Propulsion Con-
trol System assemblies
 Monitoring the supply voltages for EMU, GMU, LOP (LMU), MCS-5 compo-
nents in main and slave control stations.

1 2 3 4

Fig. 17 : Power circuit breakers in Local Operating Panel LOP 1

The power circuit breakers are located next to the terminal strip and perform the following
functions:

Item No. Value Assignment Remarks

17/1 F010 8A  Supplying voltage to the main control station moni-


toring system, supply voltage to PIM LMU (monitoring)

17/2 F011 8A  Supplying voltage to slave control station monitoring


system

17/3 F012 2A  Supplying voltage to Engine Monitoring Unit EMU


17/4 F013 2A  Supplying voltage to Gear Monitoring and Control Unit Depending on
GMU system con-
figuration

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Dialog unit connection

Fig. 18 : Dialog unit connection

There is a multi-pole socket outlet located on the right-hand side of the housing for con-
necting the dialog unit. The field bus of the Propulsion Control System runs via this socket
outlet and is therefore accessible from outside. There is a dust cap on this socket outlet
for normal operating conditions.

This socket outlet may only be used for the corresponding cable set (MTU
accessories) together with the MTU dialog unit.

The MTU dialog unit can be powered if a voltage is supplied to this socket outlet. This
supply voltage is protected by a self-restoring fuse (4 A) which is plugged on the COB 9
PCB. The COB 9 PCB is located on the rear end of the socket outlet inside the housing.

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1.2 Function

1.2.1 General notes on Local Operating Panel LOP 1 functions

Local Operating Panel LOP 1 (with integral emergency control station function) for propul-
sion systems and on-board electricity-generation systems with MTU/DDC series 4000 or
DDC/MTU series 2000 engines and the ECU Engine Control Unit form the basic engine
monitoring system.The inclusion of interfaces to superordinate Monitoring and Control
Systems (e.g. MCS-5) and Remote Control Systems (e.g. RCS-5) make it possible to
create an entire propulsion monitoring and control system and to integrate it into the
on-board electrical system (via interface modules).

Dialog unit

Engine Monitoring Unit


Engine Control Unit EMU
ECU

Gear Control Unit GCU 1 or


MCS-5 Gear Control and Monitoring Unit
or interface modules GCU/GMU 1

Starter motor
RCS-5

Generator
24 VDC supply
Main supply MTU system cable
Emergency supply
Horn/beacon, Yard cabling
sensors in engine room

Fig. 19 : Interfaces between Local Operating Panel and environment

The system cables supplied by MTU form the link between Local Operating Panel LOP 1
and Engine Control Unit ECU as well as Engine Monitoring Unit EMU (optional) and Gear
Control Unit GCU 1 or Gear Control and Monitoring Unit GCU/GMU 1 (optional).

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Refer to the ship’s wiring diagram for the Yard cabling specifications.

Local Operating Panel LOP 1 functions can be split up into the following (independently
operating) domains:
 Control and display unit (actual Local Operating Panel) comprising
 Monitoring unit
 Sequence control for engine start and engine stop sequences
 Power supply, distribution and monitoring

Redundant field bus of the Propulsion Control System

Dialog unit
Display panel connection
DIS

ÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇ
3 x control ÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇ
Start, stop, emergency stop
Ready for operation, Local mode

ÇÇÇÇÇÇÇ
PAN
Sensor/actuator bus

ÇÇÇÇÇÇÇ Printed circuit board

ÇÇÇÇÇÇÇ
CIB 3

Peripheral Interface Module Peripheral Interface Module


PIM LMU PIM LCU

Remote control Engine Monitoring Unit Gear Control Unit Engine Control Unit Starting devices
and monitoring EMU GCU or GCU/GMU ECU 4
systems (optional) (optional)
(optional)

Sensors in the Combined alarm


engine room (horn and beacon
in engine room)

Fig. 20 : Local Operating Panel LOP 1 block diagram

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The function domains comprise the following assemblies:


 Control and display unit:
– 2 PAN control panels with connection for sensor/actuator bus
– 1 PAN control panel with connection for sensor/actuator bus as well as
parallel connection of luminous pushbuttons and luminous switches
– DIS display panel
– The PIM LCU Peripheral Interface Module with the PCBs
SAB 1 for connecting the sensor/actuator bus, for outputting switch signals
(including for the alarm devices in the engine room),
BIB 1 for acquiring switch signals (see chap. 1.1.2.2, page 25),
IIB 1 for activating analog display instruments and recording switch signals
 Monitoring unit:
– The PIM LMU Peripheral Interface Module with the PCBs
BOB 1 for outputting switch signals,
BIB 1 for acquiring switch signals (see chap. 1.1.2.2, page 26),
AIB 1 for acquiring analog signals
 Sequence control for engine start and engine stop sequences (PCB CIB 3):
– PAL-programmed sequences
– Relay interlocks
– Evaluation of control signals for starting devices (if fitted)
– Start repeat circuit
 Power supply, distribution and monitoring
– F10 to F13 power reduction switches
– K1 to K3 relays: Voltage monitoring system
– CIB 3 PCB: Fuses
– CIB 3 PCB: Voltage monitoring circuit

1.2.2 Central tasks of Local Operating Panel LOP 1

The function domains indicated allow the realization of the following functional features:
 Start/stop/emergency stop control logic
– Engine start from Local Operating Panel LOP1 (in Local mode) and from
MCS–5 or via interface modules (remotely)
– Start locks

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– Emergency stop via ECU power cut-off and/or activation of the shut down
air flaps on the engine (depending on the engine equipment)
– Control of starting devices for pneumatic start, flame start or electric start
(depending on the engine equipment) and priming (if available)
– Manual stop (on-site operation), emergency stop from the Local Operating
Panel LOP 1 (possible at any time) and from the MCS-5 or via an interface
module (remotely). Remote emergency stop is possible at any time
– Automatic stop/emergency stop via integral safety system
 Emergency control stations function
– Ready for operation
– Changeover between Local mode and Remote control mode
– Engine start/engine stop in Local mode
– Engine emergency stop
– Engine speed control via up/down keys in Local mode
– Gear control (depending on gear and propulsion version) in Local mode,
not possible with on-board electricity-generation systems.
Function is realized via Gear Control Unit GCU 1 or Gear Control and Moni-
toring Unit GCU/GMU 1, (signals are sent to the relevant assembly via CAN
bus)
– Reset safety system (by acknowledging alarm)
– Execute overspeed test
 Two CAN bus interfaces for Remote Control Systems and Monitoring and
Control Systems, or interface modules
 Power supply for all assemblies in Propulsion Control System PCS-5 as well as
for components in Monitoring and Control System MCS-5, or the Engine Con-
trol System ECS-5 and the interface modules
 Input and output voltage monitoring
 Interface between propulsion plant and Engine Control Unit ECU

Local Operating Panel LOP 1 is the central link between the Propulsion Control System/
ECS-5 for MTU/DDC series 4000 or DDC/MTU series 2000 and superordinate systems.
Local Operating Panel LOP 1 has a defined interface for all systems on the plant side.

Peripheral equipment and starting devices, e.g. starter motor, priming device with priming
pump, flame start device etc., are directly activated by Local Operating Panel LOP 1.

Signals such as start, stop or emergency stop, which stem from various sources, are
linked via logic circuits. The corresponding actions are subsequently performed.

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1.2.3 Bus system of the Local Operating Panel

CAN bus technology is used for data transmission in Propulsion Control System or Engine
Control System ECS-5. This also applies to both buses in the Local Operating Panel:
 Sensor/actuator bus “Local Operating Panel”
 Field bus of Propulsion Control System (for connecting the assemblies on the
propulsion side)

Both are multi-master buses.

Each Propulsion Control System/ECS-5 unit with bus connection has a location-specific
device identifier. The device identifier contains all specific information such as node name,
baud rate and other configuration data. This device identifier is permanently stored.

The sensor/actuator bus and field bus of the Propulsion Control System use different
transmission protocols.

1.2.3.1 Redundant field bus of the Propulsion Control System

Field bus of the Propulsion Control System


MCS and Further
RCS (optional) Propulsion
 Fig. 20 Control System
devices
 Fig. 20

=21.X+A001–A010 =21.X+A001–A020 =21.X+A001–A001


PIM 2: FBG MPU23 PIM 2: FBG MPU23
LCU BIB 1 LMU BOB 1 Display panel DIS

ÉÉÉÉ
SAB 1 AIB 1
IIB 1 BIB 1

ÉÉÉÉ
ÉÉÉÉ
Sensor/actuator bus
PAN control panels
 Fig. 15
Engine operating data
 Fig. 15
Override functions
 Fig. 22 Combined alarm functions Safety system functions
LMU voltage monitoring LCU voltage monitoring

Fig. 21 : Field bus of the Propulsion Control System in Local Operating Panel (internal)

The redundant field bus of the Propulsion Control System is routed to display panel DIS
and both PIMs (LMU and LCU) in the Local Operating Panel one after the other.

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If no further systems or devices are connected to the redundant field bus of the
Propulsion Control System, both buses can be closed off by using two resis-
tors, each 121 Ω between terminals X010 terminals 17 and 18, as well as ter-
minals 67 and 68. It is terminated on the other end of the Propulsion Control
System equipment by two resistors integrated in the W004 system cable (X1
connector of ECU).

1.2.3.2 Sensor/actuator bus

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
É É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
É É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
É É
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
É É
SAB 1

=21.X+A001–A011 =21.X+A001–A012 =21.X+A001–A013


PIM LCU Control panel Control panel Control panel
Dimmer, Gear control, Engine, general
test functions speed adjustment
acknowledgement
=21.X+A001–A010

Fig. 22 : Sensor/actuator bus (internal)

The sensor/actuator bus represents an extension of the Local Control Unit. In this respect,
this functional domain of Local Operating Panel LOP 1 is supplemented by three PAN
control panels.

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1.2.4 Function of the various assemblies

1.2.4.1 Control panel PAN

The control panels are of plug-in design. Two types are used in Local Operating Panel
LOP 1:
 Electronic panel (control panel for acknowledgement, dimmer, test functions;
gear control and speed adjustment control panel)
 Hard-wired panel (engine control panel, general)

The following sections describe the structure of the 2 control panel types.

Electronic panel

The PAN control panel (electronic panel) fulfills the following functions:
 Alarm handling (flashing, acknowledgement)
 Signal lamps (background illumination, spot, dimming)
 Pushbutton/switch function
 Adjustable node address via jumper
 Integral self-test functions with LED display
 Lamp test

The 5 luminous switches are pushbutton design. Their function (buttons, signal lamp only,
cap colour and cap texts) is described in chap. 1.1.2.1.

There is a green LED to the left of the luminous pushbuttons which provides information
regarding the operating state of the control panel. The LED indicates the following:
 LED dark: No operating voltage
 LED lit: Normal mode, no errors detected (PAN active in
CAN network)
 LED flashes slowly (2 Hz): CAN bus communication fault or failure
(CAN timeout)
In the case of the redundant CAN bus, the LED
only flashes if both buses have failed.
 LED flashes rapidly (8 Hz): Watchdog has responded (hardware defect)

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Node
address COP8 PWM

Multi-LEDs 24 VDC/
100 mA
Driver/ Power
dimming supply
Spots 5 VDC/
180 mA

ÈÈÈÈ
18 VDC
to

ÈÈÈÈ
32 VDC
BUS
driver
S/A-Bus
Keys
2nd contact level
1b 2b 3b 4b 5b

Watch-
dog

Connection terminals
Only on hard-wired panel version

Fig. 23 : Control panel PAN block diagram

The logic functions of control panel PAN are realized with the Local Control Unit LCU. A
sensor/actuator bus connects both control panels to the system via the LCU with printed
circuit board SAB 1.

Hard-wired panel

The hard-wired panel functions are the same as the electronic panel functions (see fig.
23); however, it has two additional wired 2nd contact levels. All the operating elements are
assigned switches or buttons. Their function (switches, buttons, display function only, cap
colour and cap texts are described in chap. 1.1.2.1).

Reference Documentation:
A detailed functional description of the control panel can be found in the docu-
mentation entitled “Control panel PAN, Documentation Parts 1, 2, 3, 5, 7”,
document no. E 531 649.

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1.2.4.2 Display DIS

Display DIS fulfills the following functions:


 Self–test functions with operating state display
 Display functions
– Measured– or limit values are displayed as a bar graph or as a numerical
value.
– Binary values are displayed as text or graphics (e.g. inverse display of the
motor block, if the motor is running).
 Operating functions
– Side control
– Horn handling
– Brightness and contrast adjustment
– 2 languages available for switching
– Setting of parameters
 BDM functions (see Part 3)
 Acoustic warning by means of internal horn
 Clock

The DIS display panel CAN bus is redundant. Data are received and transmitted from
both CAN interfaces. Communication is active when one of the two interfaces receives
valid data.

Timeout

Data transmission is monitored and, after a 6-second communication interruption, the fol-
lowing actions are tripped:
 Horn activated (evaluated by LCU)
 All process data marked “Missing Data” (MD)
 System page activated
 Operating level 4 activated (to acknowledge the horn output)

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Function keys and operating state display

The function keys F1 to F5 are the user interfaces for the process visualization system
realized by the control panel. Its function is described in chap. 1.1.2.1.

There is a green LED to the left of the function keys which provides information on the
operating state of the display panel. The LED indicates the following:

 LED dark: Operating voltage not present.

 LED lights up Normal operation, planning data loaded,


no fault recognized.

 LED flashes slowly (with approx. 2 Hz):


Communication via field bus faulty or failed (CAN
timeout),
Display panel does not have planning data.
In the case of a redundant field bus the LED only
flashes if both busses have failed.

 LED flashes rapidly (with approx. 8 Hz):


Watchdog has been triggered.
System is in a hardware reset state.

Reference Documentation:
A detailed functional description of the display panel can be found in the docu-
mentation entitled “Display panel DIS, Documentation Parts 1, 2, 3, 4, 5, 7”,
document no. E 531 900.

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1.2.4.3 Peripheral Interface Module PIM

Type 2 PIMs are used in Local Operating Panel LOP 1. They are characterized by the fol-
lowing features:
 Basic module 2 (64 terminals) with
– Two module cassettes (module cassette 1 and module cassette 2)
– A COB 3 connection PCB
 A processor PCB MPU 23 (with additional PCB CCB 1 for 2nd CAN interface)
 Up to three PIM PCBs

PIM modules have integral processor control and are equipped with PIM PCBs for the
various input and output signals (see fig. 15).

They acquire signals from the sensors and transmit signals for the actuators. Input signals
are checked for sensor defect criteria (if possible) (e.g. no measuring value in the event of
cable breakage or measuring value out of measuring range).

Signal inputs/outputs
Interface PCB
Processor
SAB 1
PCB One of the AIB 1
MPU 23 following BIB 1
with CCB 1 PCBs BOB 1
Field bus of the Propulsion Control System

IIB 1

Signal inputs/outputs
Interface PCB
SAB 1
One of the AIB 1
following BIB 1
PCBs BOB 1
IIB 1

Signal inputs/outputs
Interface PCB
SAB 1
One of the AIB 1
following BIB 1
PCBs BOB 1
IIB 1
PIM 2

Fig. 24 : Block diagram highlighting data acquisition and signal output with one PIM

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Various PCBs are used in the PIMs for data recording and output:

PCB Function

MPU 23 Processor assembly and additional PCB


CCB 1 1 x CAN interface (field bus 1)

AIB 1 Analog input


4 x Analog input
(PT1000, 4 mA … 20 mA, 0 V … 10 V,
NiCr-Ni, potentiometer)

BIB 1 Binary input,


electrical isolation
8 x binary input supplied from external source

BOB 1 Relay outputs


3 x floating relay contacts
1 x floating relay contacts, two levels

IIB 1 Instrument outputs


4 x analog voltage outputs for operating instruments
Binary inputs
4 x electrically isolated binary channels (two-wire design)

SAB 1 CAN interface (sensor/actuator bus), relay outputs, transistor output, binary input

COB 3 Motherboard

The processor PCB and the PIM PCBs are equipped with LEDs for local fault
and status monitoring. These are described in chap. 1.2.9.2.

Reference Documentation:
More detailed information can be found in the documentation entitled “Process
level assembly catalog”, Documentation Part 1, Structure and function, docu-
ment no. E 531 439.

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1.2.5 Engine start and engine stop sequences

1.2.5.1 Engine start

The start sequence is predominantly controlled by the CIB 3 PCB integrated in Local
Operating Panel LOP 1.

Engine Control Unit ECU starts the injection sequence as soon as the engine has been
run up to a defined speed threshold on the starter and no stop commands have been re-
ceived from the plant.

Manual starts
Local
&
LOP Start LOP
Local 1
& &
MCS Start MCS
Gear neutral

SDAFs closed (option) 1 Start sequence

External starter interlock 1 Note: If the override


signal is active, the gear
neutral and SDAF closed
Ready for operation signals are ignored.

Fig. 25 : Logic diagram for start conditions (simplified)

Engine start may be tripped by the


 Monitoring and Control System MCS or via interface modules (via CAN telegram)
in Remote control mode
 Local Operating Panel LOP 1 in Local mode (if the Local signal is active)
If necessary, further signals are checked as a precondition for initiating the start sequence
in Local Operating Panel LOP 1:
 Gear/clutch must be in neutral position (disengaged)
 Shut down air flaps (if fitted) must not be closed
 External start interlock not activated
 The signal “Ready for operation” must be applied

Depending on the plant equipment, engine start has to be interlocked, e.g. if the engine
room vent flaps are closed. An “External starter interlock” input is provided for this purpose.
Depending on the engine model, the engine will be also be cut off if a cover is removed
from the location where the engine racing mechanism is attached. The missing cover is
detected by a limit switch. The signal is also connected to the ”external start cut–off” input.

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An electrical, pneumatic or flame start can be set by outputting a signal (see chap. 1.2.5.3,
1.2.5.4 and 1.2.5.2). It is also possible to activate a priming device (see chap. 1.2.5.5).

1.2.5.2 Electrical start

A jumper is required between terminals X004–53 and X004–54 to set an electric start. If
the starter motor does not respond, a component integrated on the CIB 3 PCB controls
the start repeat sequence.

Up to two starter motors can be activated at the same time for electric starts. In this case
also, the CIB 3 PCB controls the start repeat sequence if one of the starter motors does
not respond.

The starter motors are only switched on once the feedback indicating that both
starter motors have responded is received. If none or only one of the starter
motors respond, the start sequence is repeated automatically.

In the case of electric start with one or two starter motors, Local Operating Panel LOP 1
controls the start sequence:
 Activation of priming device (if fitted)
 Activation of flame start device (if fitted)
 Activation of starter motor (with starter motor monitoring and repeat function)

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Start sequence

START

Priming
(option)
PRIMING_FINISHED
Flame start device (optional)
Flame start
required Y FLAME_ON

N
Glowing
Start
t > t1

n > 300 rpm

Injection
Starter off
Priming off
t > t2

Glowing/injection off
Engine running at
idling speed FLAME_FINISHED

Fig. 26 : Electric start sequence (simplified)

The start control sends the priming lubrication command to the priming device (option);
this feeds back PRIMING_FINISHED and/or PUMP_ERROR. If PRIMING_FINISHED is
fed back, the start sequence is continued; if PUMP_ERROR is fed back, an alarm is out-
put (providing no priming device is connected, see chap. 1.2.5.5). A start request is saved
in the Local Operating Panel LOP 1 in connection with the PPC Prelubrication Pump Con-
trol.

If the optional flame start device is activated, the FLAME_FINISHED signal is interrogated
in order to continue the start sequence. If the PLUG_ERROR signal is sent instead, the
start sequence is interrupted and an alarm is output (provided no flame start device is
connected, see chap. 1.2.5.3). A start can be aborted by pressing the STOP button.

The gear and the clutch (if available) are automatically disengaged during the
start sequence. This function is controlled by Gear Control Unit GCU 1 or Gear
Control and Monitoring Unit GCU/GMU 1.

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1.2.5.3 Flame start (optional)

Two jumpers on terminal strip X004 (on CIB 3 PCB) must be removed to allow integration
of a flame start device in the system:
 Terminal X004–66 on X004–67
Always simulates “Flame finished” without flame start device connection
 Terminal X004–64 on X004–65
Always simulates plug error, without flame start device connection

1.2.5.4 Pneumatic start (optional)

For pneumatic starts, only a start request is transmitted to the pneumatic start unit (e.g.
Compressed-air starting motor). The pneumatic start unit controls the engine start
sequence.

In this case, a jumper needs to be removed:


 Terminal X004–53 on X004–54
Interrupts electric starter activation

The following jumper also needs removing:


 Terminal X004–53 on X004–55
Forwards the start signal to the pneumatic start unit connection terminals.

If an external changeover contact (selector switch) is connected to terminals X004–53 (C),


X004–54 (NC) and X004–55 (NO), it is also possible to switch the start devices from elec-
tric start to pneumatic start (depending on engine equipment).
Depending on the engine model, different cabling may be necessary. Details are available
in the cabling schematic of the pneumatic starting mechanism.

1.2.5.5 Priming (optional)

If a priming device is connected, two jumpers need to be removed on the X004 terminal
strip (on CIB 3 PCB):
 Terminal X004–60 on X004–61
Simulates “Priming finished” without connection of a priming device
 Terminal X004–62 on X004–63
Simulates that there are no pump errors without connection of a priming device

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1.2.5.6 Emergency start

An emergency start function is integrated in Propulsion Control System or Engine Control


System ECS-5 by Local Operating Panel LOP 1. It starts the engine in emergencies
without taking certain start conditions into account. Exception: Ready for operation signal
must be available and external start interlock not activated.

The emergency start function is activated by an external button or key-operated switch


(optional).

This button is directly connected on the CIB 3 PCB, terminal X004–111 and
X004–112 (NO contacts).

Manual emergency start

LOP Emergency start &

External starter interlock 1 Emergency start sequence

Ready for operation

Fig. 27 : Logic diagram highlighting emergency start conditions (simplified)

The gear and the clutch are also automatically disengaged if necessary during an emer-
gency start. Error feedback from the priming and flame start device (if fitted) is ignored.

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1.2.6 Engine stop

Following an external stop command or an automatic shutdown the engine is stopped by


reducing feeding to zero and switching off the high-pressure pump (MTU/DDC series
4000 only).

Manual stops

Local
&
LOP Stop LOP
Local 1
&
MCS Stop MCS

Automatic stops

EMU Stop

11
GCU Stop

GMU Stop

ECU Stop

SDAFs closed (option)


Engine stop and
& disengage clutch
Override 1

Fig. 28 : Logic diagram highlighting stop conditions (simplified)

A manual signal from Local Operating Panel LOP 1 or Monitoring and Control System
MCS or interface modules (via CAN telegram) is accepted depending on the Local signal.

Manual stop commands from Local Operating Panel LOP 1 or Monitoring and Control
System MCS or interface modules are always executed. All other stop commands from
other sources (Engine Control Unit ECU, Engine Monitoring Unit EMU, Gear Control Unit
GCU 1 or Gear Control and Monitoring Unit GCU/GMU 1) are only executed when safety
system override is not activated (see chap. 1.2.7).

A stop command is output if the shut down air flap is closed (depending on engine equip-
ment).

The stop command is output to Engine Control Unit ECU which, in turn, switches off fuel
injection. A clutch disengage command is sent to the Remote Control System via Gear
Control Unit GCU or Gear Control and Monitoring Unit GCU/GMU (if available) at the
same time the stop command is sent to Engine Control Unit ECU.

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1.2.6.1 Engine emergency stop

Emergency engine stop is executed whenever an emergency stop signal is detected,


regardless of conditions. This applies to manual emergency stop commands from Local
Operating Panel LOP 1 or from Monitoring and Control System MCS-5 or from emergen-
cy-stop buttons (ancillary to the interface modules) as well as for automatic emergency stop
commands from the assemblies near the engine Engine Control Unit ECU (or Engine Moni-
toring Unit EMU) or externally supplied emergency stop commands.

Depending on the plant equipment, engine emergency shutdown has to take place if the
engine room vent flaps begin to close for example. An “External emergency stop” input is
available for this purpose.

Local Operating Panel LOP 1 controls the emergency shutdown. If automatic emergency
shutdown occurs (in the event of overspeed), Engine Control Unit ECU sends an emer-
gency stop signal (plant signal TAA 1) to Local Operating Panel LOP 1 which, in turn, acti-
vates emergency shutdown.

Depending on the engine equipment, the emergency stop occurs as a result of the following:
 ECU de-energization
 Shut down air flap(s) activation

Manual emergency stops

MCS Manual emergency stop 


11
LOP Manual emergency stop
Stop and disengage clutch

Automatic emergency stops Emergency stop


 SDAF activation or
ECU ECU emergency stop  ECU de-energization

EMU EMU emergency stop

Extern Emergency stop

Fig. 29 : Logic diagram highlighting emergency stop conditions (simplified)

An engine stop and clutch disengage signal is sent at the same time as the emergency
stop signal.

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1.2.7 Safety system override

The override function is activated on the main or slave control stations via Monitoring and
Control System MCS-5. The “SAFETY SYSTEM OVERRIDE” signal is transmitted to the
Propulsion Control System/ECS-5 either by pressing a button on control panel PAN or via
a serial interface (RS422/CAN) on a non-MTU monitoring system. The signal is trans-
mitted to the Local Operating Panel via a CAN telegram.

The override function prevents an automatic engine stop. This may be important if man-
oeuvrability is crucial in certain situations. Stop commands from the Engine Monitoring
Unit or Gear Monitoring Unit are not executed as long as safety system override remains
activated.

If the engine is started when override is active, the start interlocks “Gear not in
neutral” and “SDAF closed” are ignored.

The override function does not have any influence on the emergency stop function (emer-
gency stop buttons, overspeed).

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1.2.8 Power supply

+24 VDC +24 VDC


Main supply Emergency supply

Key-operated switch*

LOP 1
DIS LCU GND LMU
Local Local
PAN Control Monitoring
PAN Unit Unit
PAN

CIB 3  K30 K4 
F3
F4 F010 MCS Main control station
UEM.STOP F5 F011
UControl 1 MCS Slave control stations
F6 Power circuit breakers
UControl 2 F2 F013
Self-restoring
F1 fuse F012
Fuses
COB 9 F1 Dialog unit

ECU Engine EMU*

GCU 1 Gear GMU 1**

Fig. 30 : Propulsion Control System supply concept for an engine system

* Optional (depending on Monitoring and Control System version)


** Optional (depending on Monitoring and Control System version), located in the same housing as the GCU 1

Key-operated switch (supplied depending on Monitoring and Control System


version). The key-operated switch is connected to the following terminals:
X010 – 52 on X010 – 2: K4 for monitoring side (NO contact)
X010 – 51 on X010 – 1: K30 for control side (NO contact)
If no key-operated switch is used, the above terminals require jumpers (condi-
tion as supplied).

The power supply and monitoring concept is based on two independent supply voltages:
Main supply and emergency supply.

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Both power supplies are linked via decoupling diodes, i.e. if one of the power supplies
fails, the system immediately switches to the second supply without interruption.

The power supplies for individual units are split between the control side and the moni-
toring side; fuses are fitted in both instances (normal fuses on the control side, power cir-
cuit breakers on the monitoring side).

All of the supply voltages, including main and emergency supply, are monitored by elec-
tronic circuits or relays and auxiliary contacts in the power circuit breakers. Each moni-
toring system is evaluated by the other meaning that, even if total failure occurs in one of
the supply systems, an alarm message is sent to the operator.

The relay contacts  and  for monitoring the supply voltages are drawn in the operating
position, i.e. all voltages OK. If voltage errors occur, the contact opens. A binary input in
the partner system reads in the switch state.

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1.2.9 Internal status indicators

Various operating states are indicated inside Local Operating Panel LOP 1 by means of
LEDs on the CIB 3 PCB and relays K1 to K3 and on the PCBs of both PIM Peripheral
Interface Modules.

1.2.9.1 Printed circuit board CIB 3

The CIB 3 PCB (see fig. 31 for arrangement) has indicators for the following functions:
 Voltages available:
– 5 VDC missing (internal voltage controller, CIB 3 PCB)
– 24 VDC available on Local Operating Panel
 Defective fuse:
One of the fuses on the CIB 3 PCB is defective
 Status indicators (start enable signals):
– Gear state
– Ready for operation, stop signals, starter interlock
– Position of the shut down air flaps

red
green 5 V voltage defect
24 V voltage OK
24 V fuse defect
Gear in neutral position
Ready for operation signal available
No stop/emergency stop signal active
No external starter interlock active
SDAF open

CIB 3

Fig. 31 : LEDs in the Local Operating Panel LOP 1, CIB 3 PCB

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1.2.9.2 Printed circuit boards in the Peripheral Interface Module

The PCBs explained in chap. 1.2.4.3 are used in the PIM Peripheral Interface Modules in
Local Operating Panel LOP 1:

The LEDs of these PCBs indicate the following function states:

PCB LED displays LED status display under normal


operating conditions
MPU 23 (LMU and LCU)
LED 1 LED 1 Power supply LED 1 On
LED 2 green available LED 2 Off
LED 3
LED 4 LED 2 The microprocessor LED 3 Flashes irregularly
red is in RESET state and
is not currently oper- LED 4 Flashes irregularly
ating (switched on
during initialization
and if supply voltage
is too low)
LED 3 Data exchange on
yellow MPU 23 CAN inter-
face
LED 4 Data exchange on
yellow MPU 23 second CAN
interface

BIB 1 LMU
LED 1 LED 1 Channel 1 active Odd LEDs:
LED 2 yellow Chan. 1, LED 1: Water level OFF
LED 3 Primary fuel filter
LED 4 LED 2 Line breakage
red Channel 1 Chan. 2, LED 3: – OFF
Chan. 3, LED 5: Override OFF
LED 5 Odd: Chan. 4, LED 7: Safety system OFF
LED 6 See LED 1 overridden
LED 7 (channels 2 … 8) Chan. 5, LED 9: Ignition plug error OFF
LED 8
Even: Chan. 6, LED 11: Pump error OFF
LED 9 See LED 2 Chan. 7, LED 13: Charging error OFF
LED 10
LED 11 (channels 2 … 8) Chan. 8, LED 15: Power failure OFF
LED 12 PCS

LED 13 Even LEDs:


LED 14 All off
LED 15
LED 16

>>

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PCB LED displays LED status display under normal


operating conditions
>>

BIB 1 LCU
LED 1 LED 1 Channel 1 active Odd LEDs:
LED 2
LED 3
yellow Chan. 1, LED 1: ECU emerg. stop OFF
LED 4 LED 2 Line breakage Chan. 2, LED 3: EMU emerg. stop OFF
red Channel 1 Chan. 3, LED 5: External emerg. stop OFF
Chan. 4, LED 6: Safety system stop OFF
LED 5 Odd:
LED 6
Chan. 5, LED 9: SDAF closed OFF
LED 7 See LED 1 Chan. 6, LED 11: Power reduction OFF
LED 8 (channels 2 … 8) required
Even: Chan. 7, LED 13: Horn output OFF
LED 9
LED 10 See LED 2 Display panel DIS
LED 11 (channels 2 … 8) Chan. 8, LED 15: Power failure OFF
LED 12 PCS/MCS

LED 13 Even LEDs:


LED 14 All off
LED 15
LED 16

BOB 1 LMU

LED 1 LED 1 Status of LED 1: Start via MCS OFF


LED 2 yellow channel 1 LED 2: Stop via MCS OFF
LED 3
LED 4 LED 2 Status of LED 3: Safety system override OFF
yellow channel 2
LED 4: Safety system reset by MCS OFF
LED 5 LED 3 Status of
yellow channel 3 LED 5: OFF
LED 4 Status of
yellow channel 4
LED 5 Error
red

>>

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PCB LED displays LED status display under normal


operating conditions
>>

IIB 1 LCU
LED 1 Ready for operation LED 1 ON
green LED 2 OFF
LED 2 Error LED 3: Feedback start OFF
red
LED 4: Feedback stop OFF
LED 3 Status of
yellow channel 1 LED 5: Feedback emergency stop OFF
LED 4 Status of LED 6: No external start interlock active ON
yellow channel 2

LED 1
LED 5 Status of
LED 2 yellow channel 3
LED 6 Status of
yellow channel 4
LED 3
LED 4
LED 5
LED 6

AIB 1 LMU
The AIB 1 PCB does not have
any LEDs for displaying op-
erating states

SAB 1 LCU
LED 1 Cable breakage LED 1: OFF
red binary input LED 2: Acknowledgement LOP OFF
LED 2 Switch condition LED 3: External start interlock active OFF
yellow binary input
LED 4: Beacon on, horn on OFF
LED 3 Status
yellow transistor output LED 5: Combined alarm OFF
LED 4 Status of LED 6: Safety system reset by LOP OFF
yellow relay output
Channel 1
LED 1
LED 2 LED 5 Status of
yellow relay output
Channel 2
LED 3 LED 6 Status of
LED 4
LED 5 yellow relay output
LED 6 Channel 3

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1.3 Technical data

Dimensions (W x H x D) 400 mm x 500 mm x 240 mm


Lateral space: +135 mm

Operating voltage 24 VDC, –20 %/+30 %


Residual ripple less than 5 %

Operating temperature range –0 °C … +55 °C

Storage temperature range –10 °C … +70 °C

Vibration 2 Hz … 13 Hz: xpp = ± 3.0 mm


13 Hz … 100 Hz: a = ±1 g

Shock 10 g/11 ms semi-sinusoidal shock

Relative humidity Max. 95 %, condensing

EMI/EMC protection IEC 801

Degree of protection IP 54 DIN 40 050

Power consumption 3 A ... 8 A permanent,


20 A max.
(depending on operating state)

Weight 26 kg

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Part 2
Operation
FRIEDRICHSHAFEN Page 59

Part 2

Operation

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Operation
Page 60 FRIEDRICHSHAFEN

2 Operation

The safety requirements in chap. 2.1 must be read before taking any steps for
operating the system. The safety requirements shall be observed at all times.

These system operating instructions primarily consist of function-oriented tables.

The “PRE-REQUISITES” column lists all requirements necessary for the execution of the
operating step before the operating step in the “ACTIVITIES” column may be performed.
Only those messages necessary for the execution of the operating step are described at
this point. It is also possible that other messages are displayed depending on the oper-
ating state which, however, have no influence on the operating procedure.

The “ACTIVITIES” column lists the manual activities necessary for operation.

The “EFFECTS” column lists the effects resulting from the execution of the operating step.

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Operation
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2.1 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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Safety requirements for commissioning


Before first using the electronic product, it must be installed in accordance with the instruc-
tions and approved to MTU specifications.
Whenever the device or system is taken into operation
 All maintenance and repair work must have been completed
 Any loose parts must have been removed from rotating machine components
 All personnel must be clear of the danger zone represented by moving parts
Immediately after taking the device or system into operation, the control and display ele-
ments as well as the monitoring, signalling and alarm systems must be tested for proper
operation.

Safety requirements for operation


The emergency procedures must be practiced on a regular basis.
The operator must be familiar with the control and display elements.
The operator must know the effects of any action he/she performs.
The operator must proceed with the individual steps as specified in the documentation.
During operation, the display elements and monitoring assemblies must be supervised
with respect to current operating states, violation of limit values as well as warnings and
alarm messages.
If a fault in the system is detected or signalled by the system, the appropriate steps must
be taken immediately and the fault reported to the person in charge.
Every message must be evaluated immediately. Emergency countermeasures shall be
taken immediately as required, e.g. emergency engine stopping.

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Operation
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2.2 User interface on Local Operating Panel LOP 1

The operating and display elements on Local Operating Panel LOP 1 comprise:
 Three PAN control panels
– Operating elements for acknowledgement, dimmer and test functions (32/3)
– Operating elements for gear control and speed adjustment (32/4)
– Operating elements for engine, general (32/5)
 One DIS display panel (32/1) with its own operating buttons (32/2)

Fig. 32 : Display and operating elements on Local Operating Panel LOP

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Display panel DIS

Engine operating data are represented graphically on the display panel with the help of
bar graphs. Operation of the display and the meaning of the bar graphs are explained in
chap. 2.16.

Operating elements on control panel PAN

The operating elements are located beneath display panel DIS. The operating elements
have the following functions (the luminous pushbuttons for gear operation are explained in
chap. 2.10):

Item Text Colour Assignment Meaning of text/function

12/6 White Local Oper- Luminous pushbutton:


ating Panel Tripping the lamp test function; all operating element
LAMP
fields light up whilst this button is pressed, all spots on
TEST
the luminous pushbuttons light up and all segments of
the display are dark
Display (spot):
Lamp test is active

12/7 Red Engine Luminous pushbutton:


OVER- Tripping the overspeed test function (only possible if
SPEED Local mode is activated):
TEST 1. Testing overspeed protection in Engine Control Unit
ECU:
Start engine. Engine running. The requirements and
activities are different for the ship main drive usage
and the on-board equipment (see 2.13.1). Press and
hold the ”Overspeed test” illuminating pushbutton.
Press the ”Increase speed” illuminating pushbutton to
approach the switching threshold. The ECU Engine
Control Unit is switched without power and the ”Over-
speed” and ”Emergency stop” alarms are sounded.

2. Overspeed protection test for Engine Monitoring


Unit EMU (only with Propulsion Control System,
monitoring II available):
Pressing the button when the engine is at a standstill,
immediately de-energizes the ECU

Display (spot):
Spot lights up as soon as the overspeed test is
executed

>>

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Operation
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Item Text Colour Assignment Meaning of text/function

>>

12/8 White Engine Luminous pushbutton:


INCREASE The speed is increased continually for as long as the
ENGINE button is held down (provided Local mode is activated)
SPEED Display (spot):
Lights up for as long as the button is held down

12/9 White Engine Luminous pushbutton:


DECREASE The speed is continually decreased for as long as the
ENGINE button remains pressed (providing Local mode is acti-
SPEED vated)
Display (spot):
Lights up for as long as the button is held down

12/10 White Engine Luminous pushbutton:


Trips an engine start (provided that Local mode and
START ready for operation are activated and all start condi-
tions are fulfilled)
Display (spot):
Lights up for as long as the start is executed

12/11 White Engine Luminous pushbutton:


Trips an engine stop (provided Local mode is acti-
STOP vated)
Display (spot):
Lights up for as long as the stop signal is applied

12/12 Red Engine Luminous pushbutton:


Trips an emergency engine stop; ECU de-energized or
EMERG. shut down air flaps tripped (depending on engine equip-
STOP ment), emergency stop alarm tripped
Display (spot):
Flashes once the emergency stop has been tripped,
goes out once the alarm has been acknowledged

12/13 Green System Luminous switch:


READY Pressing the switch informs the system that the opera-
FOR tor has made the propulsion system ready for opera-
OPERATION tion; the system can only trip an engine start once this
switch has been actuated
Display (spot):
Indicates the current switch status

>>

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Item Text Colour Assignment Meaning of text/function

>>

12/14 Green System Luminous switch:


LOCAL
Pressing the switch activates Local mode; the lumi-
MODE
nous pushbuttons on the Local Operating Panel used
to operate the engine and the gear are activated as a
result; control signals from a Remote Control System
as well as start and stop commands from a Monitoring
and Control System are not evaluated in this operating
mode
Display (spot):
Indicates the current system status; lights up when the
switch is switched to Local mode. Flashes when
changeover to Remote control mode occurs, provided
that the output (switch position is Remote control)
does not yet match the feedback from Engine Control
Unit ECU and Gear Control Unit GCU or Gear Control
and Monitoring Unit GCU/GMU. Goes out once the
system has changed over to Remote control mode.

12/18 White System Luminous pushbutton:


Acknowledges an active alarm: If a “new” alarm is
ALARM
active, the horn and beacon are switched off when the
ACKN.
button is pushed to the first time. Pressing the button a
second time acknowledges the alarm and resets the
emergency stop memory
Display (spot):
Indicates that a new alarm has been triggered and,
therefore, that the horn or alarm need to be ac-
knowledged

12/19 White Local Oper- Luminous pushbutton:


DIMMER ating Panel The intensity of the background illumination and the
spots continues to increase for as long as the button is
held down (12 levels)
Display (spot):
Lights up for as long as the button is held down

12/20 White Local Oper- Luminous pushbutton:


DIMMER ating Panel The intensity of the background illumination and the
spots continues to decrease for as long as the button
is held down (12 levels)
Display (spot):
Lights up for as long as the button is held down

>>

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Item Text Colour Assignment Meaning of text/function

>>

12/15 White Gear  Reversing gear:


CLUTCH
All three luminous pushbuttons are assigned in
AHEAD
this application:
CLUTCH AHEAD (13/1) engages ahead;
CLUTCH NEUTRAL (13/2) disengages the clutch;
CLUTCH CLUTCH ASTERN (13/3) engages astern
NEUTRAL
 Reduction gear:
Only two of the luminous pushbuttons are as-
signed in this instance:
CLUTCH
CLUTCH ENGAGE (13/4) engages the clutch;
ASTERN
CLUTCH DISENGAGE (13/5) disengages the
clutch;
clutch
12/16 White Gear the propulsion system changes the direction of
thrust (e.g. via Controllable Pitch Propeller or
waterjet)
CLUTCH
ENGAGE
 Reversing gear with waterjet drive:
In this special instance, a reversing gear is used
so that the waterjet can be operated in reverse to
CLUTCH
flush foreign matter out of the intake channel; this
DISENGAGE
is activated by the FLUSH luminous pushbutton
(13/9) provided that the FLUSH pushbutton is
held down;
CLUTCH ENGAGE (13/7) engages ahead;
CLUTCH DISENGAGE (13/8) disengages the
clutch
12/17 White Gear
CLUTCH The display (spot):
ENGAGE
 Lights up when the corresponding feedback is
active

CLUTCH
 Flashes when the corresponding clutch command
DISENGAGE
is available but the feedback is not yet active
 Goes out when the corresponding feedback is
active

FLUSH

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2.3 Taking into operation

The operating functions used to switch on the entire system depend on how the
system has been incorporated in the ship. They are either activated by switch-
ing on the ship’s voltage on the main switchboard or they have their own key-
operated switches (option).

The table below assumes that the system has its own switch.

Pre-requisites Activities Effects


 System is switched off → Turn Propulsion Control ♦ Propulsion Control
System/MCS-5 key-op- System (and Monitoring
erated switch and Control System MCS
if connected) switched on
♦ Local Operating Panel
LOP 1 luminous pushbut-
tons light up (basic
brightness setting)
♦ System is ready for op-
eration
 Switch positions of –– ♦ The state of Remote con-
 LOCAL MODE trol/Local switching and
(12/14) ready for operation
and depends on the state of
 READY FOR the system before it was
OPERATION (12/13) last switched off
when the system was
last switched off

Pressing the LOCAL MODE and READY FOR OPERATION buttons when the
system is switched off affects the state of the system when it is switched back
on again.

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Operation
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2.4 Switching off the system

Pre-requisites Activities Effects


 Engine at a standstill → Turn the Propulsion Con- ♦ Propulsion Control
trol System/MCS-5 key- System (and connected
operated switch Monitoring and Control
System MCS if applica-
ble) switched off

The position of the LOCAL MODE and READY FOR OPERATION luminous
pushbuttons is stored when the system is switched off. This state is reactivated
when the system is switched back on.

2.5 Lamp test

The background illumination is visible at all times since all the LEDs remain dimmly lit.
Proceed as follows to check the function of the spots and the display light active functions.

Pre-requisites Activities Effects


 System is switched on → Press luminous pushbut- ♦ Provided the luminous
ton pushbutton
 LAMP TEST (12/6)  LAMP TEST (12/6)
is pressed and held, all of
the
 Display elements
 Operating elements
 Spots
light up brightly

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2.6 Changing between Local mode and Remote mode

Monitoring and Control System function is restricted and


Remote Control System function is disabled in Local mode!
With the exception of emergency stop (always possible, anywhere)
and safety system override, the control functions are disabled on the
DANGER main and slave control stations following changeover to Local mode.

It is only possible to change between Local mode and Remote mode on Local Operating
Panel LOP 1.

Pre-requisites Activities Effects


 System operative → Press luminous switch ♦ Luminous switch
 Local mode active,  LOCAL MODE (12/14)  LOCAL MODE (12/14)
luminous switch flashes provided that the
 LOCAL MODE (12/14) output (switch in Remote
brightly lit mode position) does not
 Gear disengaged correspond to the ECU
and GCU feedback
 Engine at a standstill or
idling ♦ Luminous switch
 LOCAL MODE (12/14)
lights up in basic bright-
ness once the system
has switched over to
Remote mode
♦ Remote Control System
active
♦ The engine can only be
controlled by the Remote
Control System. “Ready
for operation” must be
confirmed at LOP for
engine start on MCS
♦ Emergency stop is possi-
ble at all control locations
>>

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>>
 System operative → Press luminous switch ♦ Luminous switch
 Remote Control System  LOCAL MODE (12/14)  LOCAL MODE (12/14)
active, lights up brightly
luminous switch ♦ Local mode active
 LOCAL MODE (12/14) ♦ Engine and gear can only
lit in basic brightness be controlled at LOP
 Gear disengaged ♦ “Ready for operation”
 Engine at a standstill or must be confirmed at
idling LOP for engine start
♦ Emergency stop is possi-
ble at any control location

If changeover inadvertently takes place whilst the gear is engaged, Local mode
remains active. In this instance, the LOCAL MODE display (12/14) flashes for
as long as the RCS Remote Control System outputs “NEUTRAL” clutch position
or the same clutch and gear position as currently available at the propulsion
system.
The speed is set to the nominal speed specified by the RCS following change-
over from Local to Remote mode. When a change from Remote to Local mode
takes place, the speed remains constant and can be increased or decreased
using the buttons.
The switch remains in the same position when the system is switched off.

If changeover takes place in combination with the PPC Prelubrication Pump


Control during an active start, the saving of the start request is reset and the
start sequence aborted.

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2.7 Engine ready for operation

Before confirming “Ready for operation”, ensure that the engine


actually is ready for operation.

CAUTION

Pre-requisites Activities Effects


 Engine ready for opera- → Press luminous switch ♦ Luminous switch
tion  READY FOR  READY FOR
 “Ready for operation” not OPERATION (12/13) OPERATION (12/13)
confirmed, lights up brightly
luminous switch ♦ “Ready for operation”
 READY FOR confirmed
OPERATION (12/13) ♦ The engine can be
lit in basic brightness started provided no other
starting requirements
remain unfulfilled
 “Ready for operation” → Press luminous switch ♦ Luminous switch
confirmed,  READY FOR  READY FOR
luminous switch OPERATION (12/13) OPERATION (12/13)
 READY FOR lit in basic brightness
OPERATION (12/13) ♦ Engine cannot be started
brightly lit

The switch remains in the same position after the system has been switched off.

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2.8 Engine start

Ensure that the engine is ready for operation before starting the
engine.

CAUTION

Pre-requisites Activities Effects


 System switched on → Press and hold down ♦ Luminous pushbutton
 “Ready for operation” luminous pushbutton  START (12/10)
confirmed,  START (12/10) lights up brightly when all
luminous switch start conditions have
 READY FOR been fulfilled
OPERATION (12/13) ♦ Start device(s) is (are)
brightly lit activated*
 Local mode active, ♦ Engine starts
luminous switch ♦ Speed is shown on bar
 LOCAL MODE (12/14) graph display
brightly lit ♦ Operating hours counter
 Gear disengaged, running (at n > 300 rpm,
luminous pushbutton internal function, in-
 GEAR NEUTRAL dicated on display page)
brightly lit ♦ Starter motor disengages
and start system com-
pletes start sequence*
 Engine running → Release luminous push- ♦ Luminous pushbutton
button  START (12/10)
 START (12/10) reverts to basic bright-
ness
* Depending on starter variant (see chap. 1.2.5)

Pressing the ENGINE START luminous pushbutton again has no effect whatsoever when
the engine is running.
Start with safety system override active:
The start is executed even if the “Gear neutral” signal is not applied and the
“SDAF closed” signal is applied.
A start request is saved in the Local Operating Panel LOP 1 in connection with
the PPC Prelubrication Pump Control. The START illuminating pushbutton must
therefore not be pressed while it is illuminated, i.e. all starting conditions have
been met.
A start can be aborted by pressing the STOP illuminating pushbutton.

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2.9 Changing speed

The maximum speed specified by the gear and propulsion system


manufacturer (propeller, waterjet, etc.) must be complied with in all
operating modes.

CAUTION

Pre-requisites Activities Effects


 System switched on → Press and hold down ♦ Depressed luminous
 Local mode active, luminous pushbutton pushbutton lights up
luminous switch  INCREASE brightly
 LOCAL MODE (12/14) SPEED (12/8) ♦ Engine speed is adjusted
brightly lit or at a speed specified by
 Engine running  DECREASE the engine controller
SPEED (12/9) ♦ Speed is indicated on
display (switch to rele-
vant page beforehand)
→ Luminous pushbutton → Release luminous push- ♦ Luminous pushbutton
 INCREASE button reverts to basic bright-
SPEED (12/8) ness
or ♦ Engine speed remains
 DECREASE constant
SPEED (12/9)
is depressed

Briefly pressing the luminous pushbutton typically alters the engine speed by
1 rpm.
The speed can be controlled over the entire speed range.

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2.10 Clutch control

The maximum speeds specified by the gear and drive manufac-


turers (propeller, waterjet etc.) must be complied with in all oper-
ating modes (including the waterjet flush function).

CAUTION

Gear operation depends on the type of gear used:


 Reversing gear with Fixed Pitch Propeller
 Reduction gear with Controllable Pitch Propeller or waterjet
 Reversing gear with waterjet incorporating flush function

The text on the three gear control luminous pushbuttons varies depending on the above
gear types and propulsion systems. These variants are listed in fig. 13 (see page 21).

For on-board equipment and ship main drives without shift transmissions, the
three illuminating pushbuttons for transmission control are not assigned to a
function and do not operate.

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2.10.1 Reversing gear with Fixed Pitch Propeller

Pre-requisites Activities Effects


 Local mode active, → Press luminous pushbut- ♦ Clutch command output
luminous switch ton ♦ Corresponding luminous
 LOCAL MODE (12/14)  CLUTCH pushbutton
brightly lit AHEAD (13/1)  CLUTCH
 Engine running, engine or AHEAD (13/1)
speed inside a clutch  CLUTCH or
engage speed window ASTERN (13/3)  CLUTCH
(typ. idling 150 rpm)* ASTERN (13/3)
 Gear disengaged, lights up brightly when
luminous pushbutton feedback is active (other-
 CLUTCH wise the luminous push-
NEUTRAL (13/2) button flashes, provided
brightly lit the corresponding feed-
back is not yet active)
♦ Luminous pushbutton
 CLUTCH
NEUTRAL (13/2)
reverts to basic bright-
ness
>>

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Pre-requisites Activities Effects


>>
 Local mode active, → Press luminous pushbut- ♦ Disengage command
luminous switch ton output
 LOCAL MODE (12/14)  CLUTCH ♦ Corresponding luminous
brightly lit NEUTRAL (13/2) pushbutton
 Engine running, engine  CLUTCH
speed below clutch dis- AHEAD (13/1)
engagement speed limit  CLUTCH
(typ. idling 150 rpm)* ASTERN (13/3)
♦ Gear engaged, reverts to basic bright-
luminous pushbutton ness
 CLUTCH ♦ Luminous pushbutton
AHEAD (13/1)  CLUTCH
or NEUTRAL (13/2)
 CLUTCH lights up brightly when
ASTERN (13/3) feedback is active (other-
brightly lit wise, luminous pushbut-
ton flashes, provided that
corresponding feedback
is not yet active)

* The values indicated are standard values; they may vary depending on the order and can be changed
using the dialog unit.

Direction can only be changed by going through the CLUTCH NEUTRAL posi-
tion.

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2.10.2 Reduction gear with Controllable Pitch Propeller or waterjet


The CLUTCH ENGAGE (13/4) and CLUTCH DISENGAGE (13/4) luminous pushbuttons
are provided on plants not equipped with reversing gears. The other luminous pushbutton
has no function and is sealed off to prevent it from being inadvertently pressed.

Pre-requisites Activities Effects


 Local mode active, → Press luminous pushbut- ♦ Clutch command output
luminous switch ton ♦ Luminous pushbutton
 LOCAL MODE (12/14)  CLUTCH  CLUTCH
brightly lit ENGAGE (13/5) ENGAGE (13/5)
 Engine running, engine lights up brightly when
speed inside a clutch feedback is active (other-
engage speed window wise, the luminous push-
(typ. idling 150 rpm)* button flashes provided
 Gear disengaged, that the corresponding
luminous pushbutton feedback is not yet
 CLUTCH active)
DISENGAGE (13/4) ♦ Luminous pushbutton
brightly lit  CLUTCH
DISENGAGE (13/4)
reverts to basic bright-
ness
 Local mode active, → Press luminous pushbut- ♦ Clutch disengage com-
luminous switch ton mand output
 LOCAL MODE (12/14)  CLUTCH ♦ Luminous pushbutton
brightly lit DISENGAGE (13/4)  CLUTCH
 Engine running, engine DISENGAGE (13/4)
speed below a clutch dis- lights up brightly when
engagement speed limit feedback is active (other-
(typ. idling 150 rpm)* wise the luminous push-
 Gear engaged, button flashes provided
luminous pushbutton that the corresponding
 CLUTCH feedback is not yet
ENGAGE (13/5) active)
brightly lit ♦ Luminous pushbutton
 CLUTCH
ENGAGE (13/5)
reverts to basic bright-
ness
* The values indicated are standard values; they may vary depending on the order and can be changed
using the dialog unit.
In this instance, it is only possible to change the direction using the Controllable
Pitch Propeller or waterjet.

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2.10.3 Reversing gear with waterjet incorporating flush function

The gear can be engaged in reverse to flush foreign matter out of the intake channel of the
waterjet drive in systems which operate using a waterjet drive. For this purpose, the
FLUSH luminous pushbutton (13/9) is located on the LOP 1 Local Operating Panel control
panel.

2.10.3.1 Engaging and disengaging the clutch

Pre-requisites Activities Effects


 Local mode active, → Press luminous pushbut- ♦ Clutch command output
luminous switch ton ♦ Luminous pushbutton
 LOCAL MODE (12/14)  CLUTCH  CLUTCH
brightly lit ENGAGE (13/7) ENGAGE (13/7)
 Engine running, engine lights up brightly when
speed inside a clutch feedback is active (other-
engage speed window wise the luminous push-
(typ. idling 150 rpm)* button flashes provided
 Gear disengaged, that the corresponding
luminous pushbutton feedback is not yet
 CLUTCH active)
DISENGAGE (13/8) ♦ Luminous pushbutton
brightly lit  CLUTCH
DISENGAGE (13/8)
reverts to basic bright-
ness
>>

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Pre-requisites Activities Effects


>>
 Local mode active, → Press luminous pushbut- ♦ Clutch disengagement
luminous switch ton command output
 LOCAL MODE (12/14)  CLUTCH ♦ Luminous pushbutton
brightly lit DISENGAGE (13/8)  CLUTCH
 Engine running, engine DISENGAGE (13/8)
speed below a clutch dis- lights up brightly when
engagement speed limit feedback is active (other-
(typ. idling 150 rpm)* wise the luminous push-
 Gear engaged, button flashes providing
luminous pushbutton that the corresponding
 CLUTCH feedback is not yet
ENGAGE (13/7) active)
brightly lit ♦ Luminous pushbutton
 CLUTCH
ENGAGE (13/7)
reverts to basic bright-
ness

* The values indicated are standard values; they may vary depending on the order and can be changed
using the dialog unit.

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2.10.3.2 Flushing

Pre-requisites Activities Effects


 Local mode active, → Press and hold down ♦ Clutch command output
luminous switch luminous pushbutton ♦ Luminous pushbutton
 LOCAL MODE (12/14)  FLUSH (13/9)  FLUSH (13/9)
brightly lit lights up brightly when
 Engine running, engine feedback is active (other-
speed inside a clutch wise the luminous push-
engage speed window button flashes providing
(typ. idling +150 rpm)* that the corresponding
 Gear disengaged, feedback is not yet
luminous pushbutton active)
 CLUTCH ♦ Luminous pushbutton
DISENGAGE (13/8)  CLUTCH
brightly lit DISENGAGE (13/8)
reverts to basic bright-
ness
 Local mode active, → Release luminous push- ♦ Clutch disengage com-
luminous switch button mand output
 LOCAL MODE (12/14)  FLUSH (13/9) ♦ Luminous pushbutton
brightly lit  CLUTCH
 Engine running, engine DISENGAGE (13/8)
speed below a clutch lights up brightly when
disengage speed limit feedback is active (other-
(typ. idling 150 rpm)* wise the luminous push-
 Flush sequence running, button flashes providing
luminous pushbutton that the corresponding
 FLUSH (13/9) feedback is not yet
pressed and brightly lit active)
♦ Luminous pushbutton
 FLUSH (13/9)
reverts to basic bright-
ness

* The values indicated are standard values; they may vary depending on the order and can be changed
using the dialog unit.

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2.11 Engine stop

Pre-requisites Activities Effects


 Engine running → Press luminous pushbut- ♦ Lamp in luminous push-
 Local mode active, ton button
luminous switch  STOP (12/11)  STOP (12/11)
 LOCAL MODE (12/14) lights up
brightly lit ♦ Stop signal stored in
ECU
♦ Engine is stopped
→ Release luminous push- ♦ Lamp in luminous push-
button button
 STOP (12/11)  STOP (12/11)
reverts to basic bright-
ness
♦ Engine at a standstill

The STOP illuminating pushbutton has an additional function. A start request is


saved in the Local Operating Panel LOP 1 in connection with a PPC
Prelubrication Pump Control. A start can be aborted by pressing the STOP
illuminating pushbutton.

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2.12 Emergency engine stop

Emergency stop involves a high degree of mechanical wear and


tear on the engine.
Emergency stops may only be executed in real emergencies.
CAUTION

Pre-requisites Activities Effects


 Engine running → Open the cover flap on ♦ Engine stopped by ECU
luminous pushbutton de-energization or shut
 EMERG. STOP down air flap actuation
(12/12) ♦ Alarm is tripped and
→ Press luminous pushbut- stored
ton ♦ Lamp in luminous push-
 EMERG. STOP button
(12/12)  EMERG. STOP
(12/12)
flashes until the alarm
has been acknowledged
 Engine at a standstill → Press luminous pushbut- ♦ Engine is ready to start
ton
 ALARM ACKN.
(12/18)
twice
→ Open the shut down air
flaps (if necessary)

Before restarting the engine, the shut down air flaps (fitted depending on engine equip-
ment) must be opened manually.

The stored alarm must be acknowledged using ALARM ACKNOWLEDGE (12/18) before
power is restored to Engine Control Unit ECU.

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2.13 Overspeed test

The overspeed test checks operation of the components involved in an emergency stop.
Depending on the design of the overall Propulsion Control System or Engine Control
System ECS-5, an overspeed test may be executed when the engine is either at a stand-
still or running. In both instances, various functional domains of the system are tested:
 When the engine is running, overspeed is stopped by the components of
Engine Control Unit ECU
 When the engine is at a standstill, Engine Control Unit ECU power is switched
off via the components of the optional Engine Monitoring Unit EMU or the shut
down air flaps are actuated.

2.13.1 Overspeed test with engine running

The requirements and activities for the main ship drive and the on-board
aggregate applications differ. However, the results are identical.

Pre-requisites Activities Effects


For the ship main drive: → Press and hold down ♦ Engine is stopped by
 Engine running at idling luminous pushbutton safety system which de-
speed (tolerance  OVERSPEED energizes ECU or actua-
+100 rpm) TEST (12/7) tes shut down air flaps
→ Press and hold down ♦ Corresponding alarms
For the on-board equipment: luminous pushbutton are tripped and stored
 Engine running; speed at  INCREASE ♦ Lamp in luminous push-
lower limit of preset SPEED (12/8) button
speed range (tolerance until speed reaches  EMERG. STOP
is dependent upon the (12/12)
programming of the en- For the ship main drive: flashes until the alarm
gine control unit, but has approx. 5/8 of the preset has been acknowledged
a minimum of +25 rpm) overspeed has been ♦ Luminous pushbutton
 Local mode active, reached (fallen limiting value  ALARM ACKN.
luminous switch and engine speed can be (12/18)
 LOCAL MODE (12/14) observed in the display). lights up brightly
brightly lit
For the on-board equipment: ♦ Shut down air flaps are
approx. nominal speed (syn- closed (if applicable)
chronous speed) is achieved
(fallen limiting value and en-
gine speed can be observed
in the display).
>>

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Pre-requisites Activities Effects


>>
 Engine at a standstill → Press luminous pushbut- ♦ Engine ready to start
ton
 ALARM ACKN.
(12/18)
→ Open shut down air flaps
(if applicable)

Before restarting the engine, the shut down air flaps (fitted depending on engine
version) must be opened manually.

The stored alarm must be acknowledged using ALARM ACKN. (12/18) before power is
restored to Engine Control Unit ECU.

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2.13.2 Overspeed test with engine at a standstill

This overspeed test may only be executed if the engine is equipped with an
Engine Monitoring Unit EMU.

Pre-requisites Activities Effects


 Engine at a standstill → Press luminous pushbut- ♦ Engine Control Unit ECU
 Local mode active, ton is de-energized by safety
luminous switch  OVERSPEED system or shut down air
 LOCAL MODE (12/14) TEST (12/7) flaps are actuated
brightly lit (limit value and simulated ♦ Corresponding alarms
EMU engine speed can are tripped and stored
be seen on the display) ♦ Lamp in luminous push-
button
 EMERG. STOP
(12/12)
flashes until the alarm
has been acknowledged
♦ Luminous pushbutton
 ALARM ACKN.
(12/18)
lights up brightly
♦ Shut down air flaps are
closed (if applicable)
 Engine still at a standstill → Press luminous pushbut- ♦ Engine ready for start
ton
 ALARM ACKN.
(12/18)
→ Open shut down air flaps
(if applicable)

Before the engine is restarted, the shut down air flaps (fitted depending on
engine version) must be opened manually.

The stored alarm must be acknowledged using ALARM ACKN. (12/18) before power is
restored to Engine Control Unit ECU.

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2.14 Alarm handling

Immediately rectify the cause of the fault if an alarm is tripped by


Local Operating Panel LOP 1 and/or the monitoring unit.

CAUTION

Local Operating Panel LOP 1 indicates engine shutdown by the safety system as well as
alarms for all limit value violation and system errors.

Pre-requisites Activities Effects


 Emergency engine stop, → Press luminous pushbut- ♦ Horn and beacon in
limit value violation or ton engine room are
system error trips alarm  ALARM ACKN. switched off
 Horn and beacon in (12/18) ♦ Luminous pushbutton
engine room are  ALARM ACKN.
switched on (12/18)
 Luminous pushbutton remains brightly lit
 ALARM ACKN. ♦ Corresponding alarm is
(12/18) indicated on the display
brightly lit by flashing “UNACK”
♦ The lamp in the luminous
pushbutton
 EMERG. STOP
(12/12)
also flashes following an
emergency stop
 Luminous pushbutton → Rectify the cause of the ♦ Stored alarm is cleared; if
 ALARM ACKN. engine stop the cause of the alarm
(12/18) → Press luminous pushbut- has not been rectified,
brightly lit ton the display switches over
 ALARM ACKN. to “ACK”
(12/18) again

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2.15 Safety system override

The safety system override function deactives the engine stop criteria with the exception
of overspeed.

In addition, the following start criteria are ignored due to the safety system override:
 Gear neutral start requirement
 SDAF open start requirement

Override can only be activated via the Monitoring and Control System on the main or slave
control station, providing Local or Remote mode is activated.

Overriding safety functions:


The engine is no longer automatically protected if override is acti-
vated. The corresponding operating values must be monitored by
the operator.
CAUTION If inadmissible operating values occur, the engine must be stop-
ped manually using engine stop or engine EMERG. STOP.

Overspeed monitoring and, if necessary, overspeed shutdown remain active.

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2.16 Using display panel DIS

2.16.1 General information

The operating instructions for display panel DIS 5.01/V5.10 assume that the panel itself is
operating normally, i.e. power is applied, project data is loaded and no fault has been
detected.

Normal operation is indicated by steady green illumination LED.

Function keys F1 to F5 control all functions of display panel DIS 5.01/V5.10.

The function keys (F1 to F5) are assigned various functions depending on the page which
is selected.

2.16.2 Page selection

2.16.2.1 Opening the Overview page

The Overview page can be opened from all pages, with the exception of the Alarm page,
by pressing function key F5 .

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2.16.2.2 Opening Graphic pages

The example below assumes that Graphic page Group ECU comprises graphic pages
ECU Overview and ECU Status.

Opening a graphic page (in this case: ECU Overview ) from the Overview page

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option ECU Overview
F3 Up until menu option ECU is represented inversely
Overview is activated
→ Press function key F5 Enter ♦ Graphic page ECU
Overview is open

If the key F4 or F3 is kept pressed, the menu bar moves downwards or up-
wards menu–item–by–menu–item. If a subsequent or previous page exists, the
program jumps automatically to the next or previous page after the lowest or
uppermost line has been reached.

Scrolling down

Pre-requisites Activities Effects

 Graphic page → Press function key F4 Down ♦ Graphic page ECU Status
ECU Overview is open is opened

Scrolling up

Pre-requisites Activities Effects


 Graphic page → Press function key F3 Up ♦ Graphic page
ECU Status is open ECU Overview is opened

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2.16.2.3 Opening the Measured value list

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option


F3 Up until menu option Measuring point list is
Measuring point list is represented inversely
activated
→ Press function key F5 Enter ♦ Measured value list is
opened

Press function keys F3 and F4 to scroll up or down respectively if the measured value list
comprises several pages.

2.16.2.4 Opening the Alarm page

The Alarm page can be opened from any page, with the exception of the Contrast page,
by pressing function key F2.

Pre-requisites Activities Effects

 Contrast page is not open → Press function key F2 Alarm ♦ Alarm page is opened

Press function keys F3 and F4 to scroll up or down respectively if the Alarm page com-
prises several pages.

2.16.2.5 Opening the Help page

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option Help page is
F3 Up until menu option represented inversely
Help page is activated
→ Press function key F5 Enter ♦ Help page is opened

The Help page can be opened from the Alarm page by pressing function key F2.

Press function keys F3 and F4 to scroll up or down respectively if the Help page com-
prises several pages.

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2.16.3 Adjusting brightness and contrast

2.16.3.1 Adjusting brightness

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option Contrast
F3 Up until menu option page is represented in-
Contrast page is activated versely
→ Press function key F5 Enter ♦ Contrast page is opened
 Contrast page is open → Press function key F1 ♦ Brightness of LCD back-
Increase brightness ground illumination, key illu-
mination and operating status
LED is increased one stage
→ Press function key F2 ♦ Brightness of LCD back-
Decrease brightness ground illumination, key illu-
mination and operating status
LED is decreased one stage

Holding down the F2 or F3 key automatically adjusts brightness to the maxi-


mum or minimum value.

Unfavourable contrast and brightness (background illumination) settings may


result in the information on the LC display becoming totally invisible.

For this case it is possible to toggle between the works settings for the bright-
ness or contrast values, namely ”Minimum”, ”Middle” and ”Maximum”, by pres-
sing the function keys F1 and F5 simultaneously. This is possible from any
page.

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2.16.3.2 Adjusting contrast

Pre-requisites Activities Effects

 Contrast page is open → Press function key F3 ♦ LCD contrast is increased


Increase contrast one stage
→ Press function key F4 ♦ LCD contrast is decreased
Decrease contrast one stage

Holding down the F3 or F4 key automatically adjusts contrast to the maximum


or minimum value.

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2.16.4 Language switching

All the text variables of the screens on the display panel DIS 5.01/V5.10 are stored in two
languages (e.g. German/English). It is possible to switch between these two languages
without interrupting operation.

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option System page
F3 Up until menu option is represented inversely
System page is activated

→ Press function key F5 Enter ♦ System page is opened

 System page is open → Press function key F3 ♦ Display texts toggle between
Language the two stored languages
(e.g. German and English)

The language changeover can also be activated from the Status page.

2.16.5 Horn acknowledgement

When the horn is activated and the System page opens automatically, the horn can be
acknowledged as follows:

Pre-requisites Activities Effects

 Horn sounding → Press function key F4 Horn ♦ Horn is silenced


off
 System page is open

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2.16.6 System settings

System settings can only be made when the Service page is open in edit mode. The Ser-
vice page must be opened within 10 seconds of booting in this case. The Service page is
opened in display mode if this period has expired.

Making system settings is explained using date setting and printer driver setting as exam-
ples below.

Never change the settings for CAN baud rate, CAN node
number and node monitoring as this leads to failure of display
panel DIS 5.01/V5.10.
CAUTION

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2.16.6.1 Setting the date

Pre-requisites Activities Effects

 Overview page is open → Press function key F4 Down or ♦ Menu option Configura-
F3 Up until menu option tion page is represented
Service page is activated inversely
→ Press function key F5 Enter ♦ Configuration page is opened
→ Press function key F2 Enter ♦ Input field year is activated
(inverse representation)
 Configuration page is open → Press function key F3 + or F4 − ♦ Set year is displayed
until the year of the date to be
set has been reached
→ Press function key F2 Enter ♦ Set year is stored and the
input field “month” is acti-
vated (inverse representa-
tion)
→ Press function key F3 + or F4 − ♦ Set month is displayed
until the month of the date to be
set has been reached
→ Press function key F2 Enter ♦ Set month is stored and the
input field “day” is activated
(inverse representation)
→ Press function key F3 + or F4 − ♦ Set day is displayed
until the day of the date to be
set has been reached
→ Press function key F2 Enter ♦ Set day is stored and the
input field “hours” is activated
(inverse representation)

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2.16.6.2 Setting a printer driver and “Setting printer baud rate”

The settings described below are necessary when a printer is connected.

Pre-requisites Activities Effects

 Overview page is open. → Press function key F4 Down or ♦ Menu option


F3 Up until Menu option Con- Configuration page is
figuration page is activated. represented inversely.
→ Press function key F5 Enter. ♦ Configuration page is
opened.
 Configuration page is open. → Press function key F2 Enter ♦ Input field Printer driver
until the input field Printer is represented inversely.
 Printer driver display in-
driver is activated
dicates “Off”
Off i.e. no printer
rinter
driver is activated. → Press function key F3 + until ♦ System variable input value
• Printer baud rate dis- the required printer driver is increases from 0 to the set
play indicates “Off” i.e. trans- selected. value.
mission is not possible. ♦ Display for Printer
driver changes from “Off”
to the set printer
→ Press function key F2 Enter. ♦ The printer driver for the
printer is activated and the
setting stored
♦ Input field Printer baud
rate is activated
(represented inversely)
→ Press function key F3 +. ♦ System variable input value
increases from 0 to 1.
♦ Display for Printer baud
rate changes from “Off” to
“9600 baud”.
→ Press function key F2 Enter. ♦ Printer baud rate 9600 baud
is activated and the setting
stored.

The printer may fail to operate correctly if the values for printer driver or printer
baud rate are set incorrectly.

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2.16.7 Special functions


 Simultaneously pressing F1, F2 and F3 (for 3 seconds) restarts the software.
 Pressing the function keys F1 and F5 simultaneously effects an automatic tog-
gle between the works settings for the brightness or contrast values, namely
”Minimum”, ”Middle” and ”Maximum”.
 Simultaneously pressing all function keys for 10 seconds exits the program for
the operating system.

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Part 3

Maintenance and repair


(Plant personnel)

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(This page intentionally blanc)

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3 Maintenance and repair (Plant personnel)

3.1 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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Safety requirements for maintenance and repair


Maintenance and repair work shall be performed exactly and on schedule to ensure con-
stant readiness and reliability of the product.
Authorization must be obtained from the person in charge prior to commencing mainte-
nance and repair work and switching off parts of the electronic system required for this.
Prior to working on assemblies, 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.
Maintenance and repair work shall be performed in accordance with the instructions in the
manual by authorized personnel.
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair
work.
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.
Spare parts shall be stored properly prior to replacement, i.e. particularly protected
against the ingress of moisture. Defective electronic components and assemblies must be
suitably packed when despatched for repair, i.e. particularly protected against the ingress
of moisture and impact and wrapped in antistatic foil if necessary.
Inform the MTU service department or its representative in case of damage which cannot
be rectified by plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools
etc.) remain inside the device or system.
On completion of repair work, the device or system must be subjected to apprpriate
checks to verify functionality. Separate testing of the repaired component without system
integration is inadequate.
When working on the engine, suitable measures shall be taken to prevent accidental
starting.

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3.2 Maintenance

3.2.1 General notes

This chapter lists work on Local Operating Panel LOP 1 which is required in order to main-
tain availability. This work may be performed without the use of test and measuring equip-
ment.

Maintenance work on Local Operating Panel LOP 1 predominantly involves visual checks
to detect mechanical damage or to pinpoint loose parts and connections. Defective
assemblies must be repaired or replaced immediately.

System failure

Failure to perform the following operations in compliance with


instructions and within the time interval indicated can lead to
CAUTION failure of Local Operating Panel LOP 1 or failure of the entire
Propulsion Control System/ECS-5.

If faults are detected, the cause of the fault can be determined and remedied by following
the instructions listed in the following chapters.

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Terminology and structure used in the documentation

This documentation makes a distinction between two concepts:


 Activities
An activity is the sum of all the steps which belong to part of a task (e.g. remov-
ing cover of Engine Control Unit ECU 4). Activities are assigned identification
numbers (Ident. no. or ID no.) which begin with the letter “A” (e.g.
A-P-ECU-0006)
 Task
A task is the sum of activities which bring about the desired end result (e.g.
exchanging Engine Control Unit ECU 4).
Tasks are assigned identification numbers (Ident. no. or ID no.) which begin
with the letter “T” (e.g. T-P-ECU-0003).

A summary of all maintenance tasks is included in the introduction to the description of all
scheduled maintenance work. This summary includes references to individual task
descriptions which, in turn, comprise a series of activities, each of which are described
after the task description.

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Task overview

Task description

Activity/activities

Fig. 33 : Task overview – task description – activities

All repair work is also split up into tasks and associated activities. The introduction to the
repair chapter lists a summary of all the tasks described therein.

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3.2.2 Maintenance work

3.2.2.1 Task summary for scheduled maintenance work

All work listed in the following table may be performed by plant personnel.

Maintenance work is performed at three different intervals:


 Maintenance echelon W2
 Maintenance echelon W3
 Maintenance echelon W4
The timing of these intervals is linked to the engine maintenance echelon W1 to W5 inter-
val.

Reference Documentation:
Refer to the engine documentation for details on the timing of maintenance
work within the interval.

The following tables list the maintenance work which should be performed together with
the areas affected.

All work performed on one Local Operating Panel LOP 1 (e.g. port engine or
starboard engine) must then be performed separately on all the other LOP 1
Local Operating Panels on the ship.

Inter- Quali- Dura-


Task Task ID Page Remarks
val ficat. tion

W2 Changing over oper- PP 0.1 h – 70 The operating sequences


ating mode are described in part 2 of
this manual (chap. 2.6)

W2 Performing test pro- PP 0.1 h – The operating sequences


cedures: are described in part 2 of
this manual (chap. 2.12 and
 Emergency stop 83 2.13)
(with engine at a
standstill)

 Overspeed test 84

W4 Performing visual PP 0.2 h T-P-LOP-0001 107 Errors or faults determined


inspection (internal, during the inspections must
external) be rectified immediately

W4 Cleaning Local Op- PP 0.2 h T-P-LOP-0002 113 Only to be performed if


erating Panel LOP 1 necessary

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3.2.2.2 Task overview – visual inspection


ID-No.: T-P-LOP-0001

Required assemblies/equipment from overall Propulsion Control


System
 Local Operating Panel LOP 1

Recommended tools
 Pocket torch

Reference documentation
 Engine documentation
 Local Operating Panel LOP 1 documentation,
document no. E 531 687
 Display panel DIS documentation, document no. E 531 900
 Control panel PAN documentation, document no. E 531 649

Requirements
 Engine room and Local Operating Panel LOP 1 accessible
 Engine at a standstill

Additional safety notes


 Comply with general safety requirements: Chap. 3.1
 Comply with superordinate safety instructions in the activity descrip-
tions

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List of activities ID–No.

1. Checking assemblies for firm attachment A-P-LOP-0003


Page 109
2. Checking cabling A-P-LOP-0004
Page 111
3. Checking connectors for firm seating A-P-LOP-0005
Page 110
4. Visually inspecting buttons and operating panels A-P-LOP-0007
Page 111
5. Visually inspecting the display A-P-LOP-0008
Page 112
6. Visually inspecting the internal assemblies A-P-LOP-0009
Page 112

The activities may be performed in any order.

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3.2.2.3 Checking firm attachment


ID-No.: A-P-LOP-0003

Local Operating Panel LOP 1 is fixed to one of the ship walls by means of four mounting
bolts. These are accessible from inside the housing. Check that these bolts are firmly
seated.

1. Open the front doors of the housing.


1 2
2. There is a mounting bolt in each of the
four corners of the housing; check
that these bolts are firmly seated.
3. If this is not the case, tighten the bolts
using a suitable tool (depending on
the type).

3 4

Fig. 34 : Mounting bolts for fixing Local


Operating Panel LOP 1

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3.2.2.4 Checking connectors for firm seating


ID-No.: A-P-LOP-0005

Local Operating Panel LOP 1 (35/1) is


1 2
located near the engine (in the engine
room itself or directly next to it). There are
up to four connectors (35/3 ... 35/6) on
both sides of the housing (depending on
the engine equipment).

Sockets without connectors are closed off


with a dummy plug.

Proceed as follows to check that the con-


nectors are firmly seated on Local Oper-
ating Panel LOP 1 (35/1):

1. Check that both the latches (36/1,


above and below on each plug con-
nection) are correctly clipped onto the
lugs (36/2) so that the corresponding
connector (36/3) is firmly seated in the
socket on the Local Operating Panel.
2. If this is not the case, press the
3 4 5 6 latches by hand in the direction
indicated by the arrow (see fig. 36)
Fig. 35 : Connectors on Local Operating Panel until they engage noticeably.
LOP 1
Repeat this procedure on all of the Local
1 Operating Panel connectors.

Local Operating Panel sockets


without connectors are pro-
tected by a dummy plug. This
dummy plug is attached to the
socket by means of the two
latches (36/1) in the same way
as the connector.

1 2 3

Fig. 36 : Checking connectors for firm seating

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3.2.2.5 Checking cabling


ID-No.: A-P-LOP-0004

1 Immediately insulate or remove damaged


cables (if damage is too severe).

1. If the outer insulation is damaged and


individual wires are visible (e.g. 37/1),
simply wrap insulating tape around the
cable, provided that the cable never
2 comes into contact with water and
none of the individual wires are
damaged.
2. If any of the wires are bare or broken
and the cable is subject to water spray
or moisture, replace the entire wiring
harness (or the affected section (e.g.
37/2).

Fig. 37 : Examples of damaged cabling

3.2.2.6 Visually inspecting the operating buttons and operating panels


ID-No.: A-P-LOP-0007

When inspecting the operating buttons, ensure that:


 The caps are not damaged (no cracks etc.)
 The button casing is firmly seated
 The buttons are easy to press
 The seals are not damaged
 The lamps function correctly (see part 2), replace any defective lamps (LEDs)

In the event of serious mechanical damage (function impaired, inadequate sealing etc.),
replace the corresponding button (part 4); replace any damaged seals (A-P-LOP-0013).

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3.2.2.7 Visually inspecting the display


ID-No.: A-P-LOP-0008

When inspecting the display, ensure that:


 The LCD screen is not damaged (screen not cracked or pressed in)
 The display buttons function correctly (see chap. 3.2.2.6)
 The seals are not damaged

In the event of serious mechanical damage (function impaired, inadequate sealing etc.),
replace the entire display; replace the seal if it is damaged (A-P-LOP-0012).

3.2.2.8 Checking internal assemblies for firm seating


ID-No.: A-P-LOP-0009

The modules inside Local Operating


1 7 2 Panel LOP 1 are located on a mounting
plate. Check that the mounting plate bolts
are firmly seated. Also check that the
assemblies located on this mounting plate
are firmly seated.

1. Open the front door of the housing.


2. There is a mounting bolt (38/1 ... 38/4)
on each corner of the mounting plate;
check that these bolts are firmly
seated.
3. If this is not the case, tighten the bolts
using a suitable wrench.
4. Check that the other assemblies are
also firmly seated; this applies in parti-
cular to the two Peripheral Interface
Module PIMs (38/5, 38/6) and the
CIB 3 PCB (38/7).

3 5 6 4 5. Tighten loose bolts using a suitable


tool.
Fig. 38 : Fastening the mounting plate

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3.2.2.9 Task overview – cleaning


ID-No.: T-P-LOP-0002

Required assemblies/equipment from the overall Propulsion


Control System
 Local Operating Panel LOP 1

Recommended tools
 Soft, lint-free, non-abrasive cloth
 Isopropyl alcohol

Requirements
 Engine room and Local Operating Panel LOP 1 accessible
 Engine at a standstill

Additional safety notes


 Comply with general safety requirements: Chap. 3.1
 Comply with superordinate safety instructions in the activity descrip-
tions
 Take care not to damage cables during cleaning
 If connectors are detached, ensure that the latches are correctly
re-engaged

List of activities ID–No.

1. Cleaning Local Operating Panel LOP 1 A-P-LOP-0010


Page 114

2. Cleaning connectors A-P-LOP-0010


Page 115

The activities may be performed in any order.

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3.2.2.10 Cleaning Local Operating Panel LOP 1


ID-No.: A-P-LOP-0010

Local Operating Panel LOP 1 (39/1) con-


2 sists of a steel plate housing. All electronic
assemblies belonging to Local Operating
Panel LOP 1 are integrated in this
housing.

1. Remove excessive dirt from the sur-


face of this housing (39/2) using a
cloth moistened with isopropyl alcohol.
2. Ensure that the markings on the
cables are legible; clean or replace
markings if necessary.
3. Also use a cloth moistened with iso-
propyl alcolhol to remove dirt from the
buttons (39/3).
4. It is only possible to remove any dirt
which has accumulated inside the but-
4 ton by disassembling the button; see
corresponding details in the mainte-
3 nance and repair section in this
5 regard.
1 5. Be careful when rubbing the LCD
screen (39/4); do not exert unneces-
Fig. 39 : Cleaning Local Operating Panel sary pressure under any circum-
LOP 1 stances.

Take care not to damage any components or loosen any connec-


tors on the housing (39/5) when cleaning.

CAUTION

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3.2.2.11 Cleaning connectors


ID-No.: A-P-LOP-0010

Excessive dirt on the connectors will


eventually impair operation. Such dirt
should therefore be removed (oil, grease,
fuel etc.).

1. Clean the surface of the connector


(40/1) using a cloth soaked in isopro-
pyl alcohol.
2. Remove the connector if it is ex-
tremely dirty (also see page 110).
3. Thoroughly clean the connector
housing (40/2) and the contacts using
isopropyl alcohol.
4. Also clean the plug socket (40/3) on
the Local Operating Panel LOP 1
housing thoroughly using sufficient
isopropyl alcohol.

2
1

Fig. 40 : Cleaning Local Operating Panel


LOP 1 connector

During cleaning, take care not to damage any of the components


or inadvertently loosen any of the connectors on the housing.
Proceed in accordance with the instructions on page 110 when
attaching connectors.
CAUTION

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3.3 Troubleshooting

3.3.1 Faults without fault code display

The following table lists obvious faults which are immediately apparent to the operator.

No. Fault Fault cause(s) Action See

1 Entire Propulsion Control 1. No supply voltage Check whether other Ship’s manual
System does not available parts of the electrical
respond following switch- system in the ship are
on also out of operation

Other system parts do Causes pt. 2


not function
Causes pt. 3
Only Propulsion Control
System is not operating

2. No ship voltage Switch on ship voltage Ship’s manual

3. Propulsion Control Visual inspection; reset Ship’s manual


System power supply any power circuit
shut off, corres- breakers fitted
ponding power circuit
breaker tripped

4. System key-operated Turn key counterclock- Ship’s manual


switch (if fitted) not wise, pull out, then rein-
switched on correctly sert and turn clockwise
or not engaged as far as it will go

5. Defective key-oper- Replace key-operated Ship’s manual


ated switch switch

>>

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No. Fault Fault cause(s) Action See

>>

2 Local Operating Panel 1. K30 relay defective Replace CIB 3 PCB with Part 4
LOP 1 partially out of relay
order
d ((only
l th
the control
t l
side functions) 2. Key-operated switch Replace key-operated Ship’s manual
defective or jumper switch or insert jumper
missing between
X010-51 and X010-52
and/or X010-1 and
X010-2

3 Local Operating Panel 1. K04 relay defective Replace CIB 3 PCB with Part 4
LOP 1 partially out of relay
order
d ((onlyl th
the moni-
i
toring side functions) 2. Key-operated switch Replace key-operated Ship’s manual
defective or jumper switch or insert jumper
missing between
X010-51 and X010-52
and/or X010-1 and
X010-2

4 Display blank, all control F3 fuse defective Replace F3 fuse A-P-LOP-0001


panels out of order (LED Page 149
V69 “24 V fuse defec-
tive” on CIB 3 PCB lights
up)

5 Display blank 1. Display defective Replace display Part 4

2. Wiring defective; no Check wiring, rectify A-P-LOP-0004


supply voltage availa- defects Page 111
ble

6 Display indicates missing Wiring defective; PCS-5 Check wiring, rectify A-P-LOP-0004
bus connection (display field bus connection defects Page 111
“Operating state” LED interrupted
flashes slowly)

7 All control panels out of 1. Wiring defective, SA Check wiring, rectify A-P-LOP-0004
order, all “Operating field bus connection defects Page 111
state” LEDs on the con- interrupted
trol panels flashing
slowly 2. SAB 1 PCB (in PIM Replace corresponding A-P-LOP-0028
no. SAB 1 PCB Page 162
=21.X+A001–A010)
defective

>>

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No. Fault Fault cause(s) Action See

>>

8 Start sequence cannot 1. Corresponding control Replace button element A-P-LOP-0006


be performed panel button defective Page 151

2. Wiring defective Check wiring, rectify A-P-LOP-0004


defects Page 111

3. CIB 3 PCB defective Replace CIB 3 PCB Part 4

4. BOB 1 PCB (in PIM Replace corresponding A-P-LOP-0028


no. BOB 1 PCB Page 162
=21.X+A001–A020)
defective

5. Shut down air flaps Open shut down air flaps


closed (optional)

Part 2 and
engine
description

6. K9 relay defective Replace CIB 3 PCB with Part 4


relay K9

7. One or more jumpers Check jumpers Installation


missing on Local (depending on system
Operating Panel ter- removal)
minal strip X004

8. Corresponding button Replace switch element Part 4


switch element defec-
tive

9. No “Gear in neutral If gear has neutral


position” signal switch, switch it to NEU-
TRAL position; LEDs for
start enable (inside the
LOP, see page 53) must Gear
light up documentation

>>

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No. Fault Fault cause(s) Action See

>>

8 Start sequence cannot 10.No ”External start Deactivate system-side Installation of


be performed interlock not active” start cut-off or, for en- the plant or
signal gines with limit switches
at the location where the
engine racing mecha-
nism is attached, close
the cover or check wiring
(wire break); the start re- Engine
lease LEDs (inside the description
LOP see page 53) must
illuminate.

9 Display instruments IIB 1 PCB (in PIM no. Replace corresponding A-P-LOP-0028
(optional) connected to =21.X+A001–A010) IIB 1 PCB Page 162
Local Operating Panel defective
LOP 1 do not indicate
readings

10 Emergency stop on Corresponding control Replace button element Part 4


Local Operating Panel panel button defective
cannot be executed

11 Connected Engine Con- F1 fuse on CIB 3 PCB Replace F1 fuse A-P-LOP-0001


trol Unit ECU 4 out of defective Page 149
order

12 Connected Engine Moni- F012 power circuit Reset F012 power circuit –
toring Unit EMU 1 out of breaker has tripped breaker by hand
order

13 Connected Gear Control F2 fuse on CIB 3 PCB Replace F2 fuse A-P-LOP-0001


Unit GCU 1 out of order defective Page 149

14 Connected Gear Moni- F013 power circuit Reset F013 power circuit –
toring Unit GMU 1 out of breaker has tripped breaker by hand
order

15 Connected control sta- Power circuit breaker Reset corresponding –


tions out of order F010 and/or F011 tripped power circuit breaker by
hand

16 No voltage supply from No feed from the ship’s Check ship plant Ship’s manual
main supply (relay K1 supply
LED dark)

>>

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No. Fault Fault cause(s) Action See

>>

17 No voltage supply from No feed from the ship’s Check ship plant Ship’s manual
main supply (relay K2 supply
LED dark)

18 Supply voltage distribu- 1. One of the power cir- Reset corresponding –


tion error (relay K3 lights cuit breakers has trip- power circuit breaker by
up) ped hand

2. One of the power cir- Reset corresponding A-P-LOP-0014


cuit breakers has trip- power circuit breaker by Page 171
ped hand

19 Not all operating ele- Corresponding LED Replace LED A-P-LOP-0016


ments light up during defective Page 155
lamp test

20 Complete malfunction of Control panel PAN does Insert jumper correctly A-P-LOP-0018
one PAN control panel not have correct node step 8.
(status LED on the left address Page 159
hand side of the panel
indicates error) Control panel PAN de- Replace control panel A-P-LOP-0017
fective Page 156
A-P-LOP-0018
Page 158

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3.3.2 Plain text fault messages on the display

Measuring points and fault messages are output in text form on the DIS display of Local
Operating Panel LOP 1.

Lo P-Lube oil ACK Yel


SS P-Lube oil UNACK Red
SE 10 212+A002–A040 UNACK Yel
DL 372+A310–A101 UNACK Yel
RL 372+A310–A010 UNACK Yel

F1 F2 F3 F4 F5

Fig. 41 : Fault message display

The fault messages are listed in the following table (including details of pluggable series).
The table explains the fault message and includes notes on troubleshooting and fault rec-
tification.

The operating personnel must evaluate the fault message display and, if necessary, im-
plement the necessary measures.

The entire Propulsion Control System/ECS-5 (system components ECU 4, LOP 1 and, if
applicable, EMU 1) monitors, detects and processes faults and limit violations in all ope-
rating situations (when the system is switched on).

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The fault message (see fig. 41) which appears on the DIS display simplifies diagnosis
since the problem or problems appear in plain text.

Indication of the assembly which sends the message (EMU, ECU , GCU, GMU) makes it
easier to pinpoint possible fault sources and locate the input and output channels.

When assessing the displayed fault messages, note that a fault cause may induce fol-
low-on errors which are also displayed.

The fault list explains the fault messages, indicates possible causes and includes repair
notes.

The abbreviations used have the following meanings:

Fault message classification

AL General alarm

LO Alarm under-range (Low)

HI Alarm over-range (High)

SS Safety System alarm

SD Sensor defect

TD Transmitter deviation

MG Message

LO (rear) 1st lower limit value

LOLO (rear) 2nd lower limit value

HI (rear) 1st upper limit value

HIHI (rear) 2nd upper limit value

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The table is structured as follows:


 No.
This is a serial number which enables identification of all fault messages
 Message display or measuring point text
This is an alphanumeric display text
 Meaning
This is a more exact description of the fault message
 Action or repair/maintenance level
(E – electrical,
M – mechanical)
Information of where reference documentation can be referred to, whether the
engine documentation is required and what the present manual explains with
regard to corresponding fault rectification; if the text is a pure measuring point
text or an indication of limit violations, there are no details included in this
column.
 2000
An “X” marks all fault messages which can possibly occur in the DDC/MTU
series 2000
 4000
An “X” marks all fault messages which can possibly occur in the MTU/DDC
series 4000

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Maintenance and repair
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Fault messages and measuring point texts


MTU/DDC series 4000 and DDC/MTU series 2000

Fault message display/


No. Meaning Action 2000 4000
measuring point text

1. Engine Speed (ECU) “Engine speed” meas- –


uring point recorded by
X X
the Engine Control Unit
ECU 4

2. Engine Load Measuring point –


X
“Engine load”

3. Injection Limitation Measuring point –


X
“Feeding limitation”

4. Cylinder Cutout Measuring point “Cylin- –


X
der cutout”

5. Overspeed Test Active Measuring point “Over- –


X X
speed test status”

6. Feedback Speed Demand Measuring point “Nomi- –


X X
nal speed”

7. Feedback Speed Demand Eff Measuring point “Actual –


X X
nominal speed”

8. P-Lube Oil (ECU) Measuring point –


“Engine lube oil pres- X X
sure”

9. P-Lube Oil Limit LO 1st limit value for –


X X
engine lube oil pressure

10. P-Lube Oil Limit LOLO 2nd limit value for –


X X
engine lube oil pressure

11. LO P-Lube Oil Engine lube oil pres-


sure too low
X X
Warning at p < pLimit 1
Shutdown at p < pLimit 2

12. SS P-Lube Oil Safety system meas-


ures insufficient engine X X
lube oil pressure

13. P-Crankcase Measuring point –


X
“Crankcase pressure”

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 125

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

14. P-Crankcase Limit HI 1st limit value for crank- –


X
case pressure

15. P-Crankcase Limit HIHI 2nd limit value for –


X
crankcase pressure

16. HI P-Crankcase Crankcase pressure too


high
Engine lube oil pres-
X
sure too low
Warning at p > pLimit 1
Shutdown at p > pLimit 2

17. SS P-Crankcase Safety system meas-


ures excessive crank- X
case pressure

18. P-Kuehlmittel Measuring point –


X X
“Coolant pressure”

19. P-Coolant Limit LO 1st limit value for –


X X
coolant pressure

20. P-Coolant Limit LOLO 2nd limit value for –


X X
coolant pressure

21. LO P-Coolant Coolant pressure too


low
X X
Warning at p < pLimit 1
Shutdown at p < pLimit 2

22. SS P-Coolant Safety system meas-


ures inadequate coolant X X
pressure

23. P-Fuel Measuring point “Fuel –


X
pressure”

24. LO P-Fuel Fuel pressure too low


Warning at p < pLimit 1 X
Shutdown at p < pLimit 2

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

25. SS P-Fuel Safety system meas-


ures inadequate fuel X
pressure

26. P-Charge Air Measuring point –


X X
“Charge air pressure”

27. LO P-Charge Air Charge air pressure too


low
X X
Warning at p < pLimit 1
Shutdown at p < pLimit 2

28. P-Fuel (high) Fuel pressure too high


X

29. HI P-Oil Filter Difference Difference between oil


pressure before filter
X X
and oil pressure after
filter is too great

30. LO Coolant Level Coolant level is too low


X X

31. HI Leakage Fuel Fuel leakage level is


too high X

32. ATL 1 Speed “Speed exhaust turbo- –


charger 1” measuring X X
point

33. AL Overspeed ATL 1 Speed of exhaust tur-


bocharger ETC1 is too X X
high

34. ECU Operating Seconds Operating time of –


Engine Control Unit X X
ECU 4

35. Engine Running Measuring point –


X X
“Engine operating”

36. ATL 2 Cut In Measuring point –


“Exhaust turbocharger X X
ETC2” switched on

37. Injection Quantity 0-120% Measuring point “Injec- –


X X
tion quantity”

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 127

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

38. Injection Limitation 0–120% Measuring point “Injec- –


X X
tion limitation”

39. Cylinder Cutout Measuring point “Cylin- –


X
der cutout on”

40. AL Power Amplifier Bank 1 Error message power


Failure output cylinder side A

Check wiring,
see A-P-LOP-0004,
page 111
X X

Change ECU;
see
E 531 685 (4000) or
E 531 691 (2000)

41. AL Power Amplifier Bank 2 Error message power


Failure output cylinder side B

Check wiring,
see A-P-LOP-0004,
page 111
X X

Change ECU;
see
E 531 685 (4000) or
E 531 691 (2000)

42. Status Transistor Outputs Measuring point –


“Operating state of
X X
transistor outputs
TAA1...TAA6 (ECU)”

43. ECU Power Supply Voltage Measuring point “Power –


supply of Engine Con- X X
trol Unit ECU 4”

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

44. ECU Operating Hours Measuring point –


“Operating time of
X X
Engine Control Unit
ECU 4”

45. AL ECU Defect Engine Control Unit Check wiring,


ECU 4 fault see A-P-LOP-0004,
page 111

X X

Replace ECU;
see
E 531 685 (4000) or
E 531 691 (2000)

46. Engine Speed Camshaft Measuring point –


“Engine speed, meas- X X
ured on the camshaft”

47. AL Speed Demand Defect No speed output signal Check Remote Control
System
X X
Check wiring,
see A-P-LOP-0004,
page 111

48. T-Coolant ECU Measuring point –


X X
“Coolant temperature”

49. T-Coolant Limit HI 1st limit value for –


X X
coolant temperature

50. T-Coolant Limit HIHI 2nd limit value for –


X X
coolant temperature

51. HI T-Coolant ECU Coolant temperature


too high
X X
Warning at T > TLimit 1
Shutdown at T > TLimit 2

52. SS T-Coolant ECU Safety system meas-


ures excessive coolant X X
temperature

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

53. T-Charge Air A Measuring point –


“Charge air tempera- X X
ture engine A side”

54. T-Charge Air A Limit HI Limit value for charge –


air temperature engine X X
A side

55. HI T-Charge Air A Charge air temperature


on engine A side too X X
high

56. T-Lube Oil Measuring point “Lube –


X X
oil temperature”

57. T-Lube Oil Limit HI 1st limit value for lube –


X X
oil temperature

58. T-Lube Oil LimitT HIHI 2nd limit value for lube –
X X
oil temperature

59. HI T-Lube Oil Lube oil temperature


too high
X X
Warning at T > TLimit 1
Shutdown at T > TLimit 2

60. SS T-Lube Oil Safety system meas-


ures excessive lube oil X X
temperature

61. T-Exhaust Comb. A Measuring point –


“Exhaust temperature X X
engine side A”

62. T-Exhaust Comb. A Limit HI Limit value for exhaust –


temperature engine X X
side A

63. HI T-Exhaust Comb. A Exhaust temperature


engine side A too high X X

64. T-Exhaust Comb. B Measuring point –


“Exhaust temperature X X
engine side B”

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

65. T-Exhaust Comb. B Limit HI Limit value for exhaust –


temperature engine X X
side B

66. HI T-Exhaust Comb. B Exhaust temperature


engine side B too high X X

67. T-Intake Air Measuring point “Intake –


X
air temperature”

68. T-Fuel Measuring point “Fuel –


X X
temperature”

69. P-Fuel Limit LO 1st limit value for fuel –


X
pressure

70. P-Fuel Limit LOLO 2nd limit value for fuel –


X
pressure

71. ATL 1 Speed Limit HI Limit value for ETC1 –


exhaust turbocharger X X
speed

72. Engine Speed LIMIT HI Limit value for engine –


X X
speed

73. P-Charge Air A Limit LO Limit value for charge –


air pressure engine side X X
A

74. Engine Speed (EMU) Measuring point –


“Engine speed”, ac-
X X
quired by Engine Moni-
toring Unit EMU 1

75. P-Lube Oil (EMU) Measuring point –


“Engine lube oil pres-
sure”, acquired by X X
Engine Monitoring Unit
EMU 1

76. P-Lube Oil Limit LO 1st limit value for –


X X
engine lube oil pressure

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

77. P-Lube Oil Limit LOLO 2nd limit value for –


X X
engine lube oil pressure

78. LO P-Lube Oil (EMU) Lube oil pressure too


low X X

79. SS P-Lube Oil (EMU) Safety system meas-


ures inadequate lube oil X X
pressure

80. T-Coolant (EMU) Measuring point “Engine –


coolant temperature”,
X X
acquired by Engine
Monitoring Unit EMU 1

81. T-Coolant Limit HI 1st limit value for –


engine coolant tem- X X
perature

82. T-Coolant Limit HIHI 2nd limit value for –


engine coolant tem- X X
perature

83. HI T-Coolant (EMU) Engine coolant tem-


perature too high X X

84. SS T-Coolant (EMU) Safety system meas-


ures excessive engine X X
coolant temperature

85. Engine Speed Limit HI Limit value for engine –


X X
speed

86. T-Exhaust A1 Measuring point –


“Exhaust temperature X
cylinder A1”

87. T-Exhaust A2 Measuring point –


“Exhaust temperature X
cylinder A2”

88. T-Exhaust A3 Measuring point –


“Exhaust temperature X
cylinder A3”

89. T-Exhaust A4 Measuring point –


“Exhaust temperature X
cylinder A4”

>>

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Maintenance and repair
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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

90. T-Exhaust A5 Measuring point –


X
“Exhaust temp. cyl. A5”

91. T-Exhaust A6 Measuring point –


X
“Exhaust temp. cyl. A6”

92. T-Exhaust A7 Measuring point –


X
“Exhaust temp. cyl. A7”

93. T-Exhaust A8 Measuring point –


X
“Exhaust temp. cyl. A8”

94. T-Exhaust B1 Measuring point –


X
“Exhaust temp. cyl. B1”

95. T-Exhaust B2 Measuring point –


X
“Exhaust temp. cyl. B2”

96. T-Exhaust B3 Measuring point –


X
“Exhaust temp. cyl. B3”

97. T-Exhaust B4 Measuring point –


X
“Exhaust temp. cyl. B4”

98. T-Exhaust B5 Measuring point –


X
“Exhaust temp. cyl. B5”

99. T-Exhaust B6 Measuring point –


X
“Exhaust temp. cyl. B6”

100. T-Exhaust B7 Measuring point –


X
“Exhaust temp. cyl. B7”

101. T-Exhaust B8 Measuring point –


X
“Exhaust temp. cyl. B8”

102. T-Exhaust Mean Measuring point “Mean –


X
exhaust temperature”

103. T-Exhaust Limit HI Upper limit value for –


exhaust temperature X
(applies to all cylinders)

104. T-Exhaust Limit LO Lower limit value for –


exhaust temperature X
(applies to all cylinders)

>>

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FRIEDRICHSHAFEN Page 133

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

105. HI T-Exhaust A1 Exhaust temperature


X
cylinder A1 too high

106. HI T-Exhaust A2 Exhaust temperature


X
cylinder A2 too high

107. HI T-Exhaust A3 Exhaust temperature


X
cylinder A3 too high

108. HI T-Exhaust A4 Exhaust temperature


X
cylinder A4 too high

109. HI T-Exhaust A5 Exhaust temperature


X
cylinder A5 too high

110. HI T-Exhaust A6 Exhaust temperature


X
cylinder A6 too high

111. HI T-Exhaust A7 Exhaust temperature


X
cylinder A7 too high

112. HI T-Exhaust A8 Exhaust temperature


X
cylinder A8 too high

113. HI T-Exhaust B1 Exhaust temperature


X
cylinder B1 too high

114. HI T-Exhaust B2 Exhaust temperature


X
cylinder B2 too high

115. HI T-Exhaust B3 Exhaust temperature


X
cylinder B3 too high

116. HI T-Exhaust B4 Exhaust temperature


X
cylinder B4 too high

117. HI T-Exhaust B5 Exhaust temperature


X
cylinder B5 too high

118. HI T-Exhaust B6 Exhaust temperature


X
cylinder B6 too high

119. HI T-Exhaust B7 Exhaust temperature


X
cylinder B7 too high

120. HI T-Exhaust B8 Exhaust temperature


X
cylinder B8 too high

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

121. LO T-Exhaust A1 Exhaust temperature


X
cylinder A1 too low

122. LO T-Exhaust A2 Exhaust temperature


X
cylinder A2 too low

123. LO T-Exhaust A3 Exhaust temperature


X
cylinder A3 too low

124. LO T-Exhaust A4 Exhaust temperature


X
cylinder A4 too low

125. LO T-Exhaust A5 Exhaust temperature


X
cylinder A5 too low

126. LO T-Exhaust A6 Exhaust temperature


X
cylinder A6 too low

127. LO T-Exhaust A7 Exhaust temperature


X
cylinder A7 too low

128. LO T-Exhaust A8 Exhaust temperature


X
cylinder A8 too low

129. LO T-Exhaust B1 Exhaust temperature


X
cylinder B1 too low

130. LO T-Exhaust B2 Exhaust temperature


X
cylinder B2 too low

131. LO T-Exhaust B3 Exhaust temperature


X
cylinder B3 too low

132. LO T-Exhaust B4 Exhaust temperature


X
cylinder B4 too low

133. LO T-Exhaust B5 Exhaust temperature


X
cylinder B5 too low

134. LO T-Exhaust B6 Exhaust temperature


X
cylinder B6 too low

135. LO T-Exhaust B7 Exhaust temperature


X
cylinder B7 too low

136. LO T-Exhaust B8 Exhaust temperature


X
cylinder B8 too low

137. P-Raw Water Measuring point “Raw –


X X
water pressure”

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 135

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

138. P-Raw Water Limit LO Limit value for raw –


X X
water pressure

139. LO P-Raw Water Raw water pressure too


low X X

140. P-Oil Re-Fill Measuring point “Oil –


pressure of oil refill – –
pump”

141. P-Oil Re-Fill Limit LO Limit value for oil pres- –


X X
sure of oil refill pump

142. LO P-Oil Re-Fill Oil pressure of oil refill


pump too low X X

143. AL Transistor Output 1/2 One of the transistor Replace ECU Engine
Fail. outputs TAA1 or TAA2 Control Unit;
of Engine Control Unit
ECU 4 is defective
X X

see
E 531 685 (4000) or
E 531 691 (2000)

144. AL Transistor Output 3/4 One of the transistor Replace ECU Engine
Fail. outputs TAA3 or TAA4 Control Unit;
of Engine Control Unit
ECU 4 is defective
X X

see
E 531 685 (4000) or
E 531 691 (2000)

145. AL Exhaust Monitoring Fail Exhaust temperature Replace EMU Engine


monitoring fault Monitoring Unit; X X
see E 531 686

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

146. AL Press.Monitoring Fail Pressure monitoring


(EMU) error, Engine Moni-
toring Unit EMU
X X
Replace EMU Engine
Monitoring Unit;
see E 531 686

147. SS Security Channel Defect Fault message safety


EMU system

X X
Replace EMU Engine
Monitoring Unit;
see E 531 686

148. TD T-Coolant Different measurement Check sensors


values, two sensors for Check wiring,
X X
measuring coolant tem- see A-P-LOP-0004,
perature page 111

149. TD P-Coolant Different measurement Check sensors


values, two sensors for Check wiring,
X X
measuring lube oil pres- see A-P-LOP-0004,
sure page 111

150. P-Gear C. Oil GCU Measuring point “Gear –


X X
control oil pressure”

151. P-Gear Control Oil Limit LO 1st limit value for gear –
X X
control oil pressure

152. P-Gear Control Oil Limit 2nd limit value for gear –
X X
LOLO control oil pressure

153. LO P-Gear Control Oil GCU Gear control oil pres- Gear documentation
X X
sure too low

154. SS P-Gear Control Oil GCU Safety system meas- –


ures inadequate gear X X
oil pressure

155. P-Gear Lube Oil GCU Measuring point “Gear –


X X
lube oil pressure”

>>

–08.2001– E 532 067 / 00 E


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FRIEDRICHSHAFEN Page 137

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

156. P-Gear Lube Oil Limit LO 1st limit value for gear –
X X
lube oil pressure

157. P-Gear Lube Oil Lim. LOLO 2nd limit value for gear –
X X
lube oil pressure

158. LO P-Gear Lube Oil GCU Gear lube oil pressure


too low
X X

Gear documentation

159. SS P-Gear Lube Oil GCU Safety system meas- –


ures inadequate gear X X
oil pressure

160. T-Gear Oil Measuring point “Gear –


X X
oil temperature”

161. T-Gear Oil Limit HI Limit value for gear oil –


X X
temperature

162. HI T-Gear Oil Gear oil temperature


too high
X X

Gear documentation

163. AL Gear Oil Filter Clogged Gear oil filter clogged

X X

Gear documentation

164. Feedback Astern Measuring point RCS –


X X
Remote Control System

165. Feedback Ahead/In Measuring point RCS –


X X
Remote Control System

166. Neutral/Out Measuring point RCS –


X X
Remote Control System

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

167. Ahead/In Measuring point RCS –


X X
Remote Control System

168. Astern Measuring point RCS –


X X
Remote Control System

169. RCS Command Neutral/Out Measuring point RCS –


X X
Remote Control System

170. RCS Command Ahead/In Measuring point RCS –


X X
Remote Control System

171. RCS Command Astern Measuring point RCS –


X X
Remote Control System

172. Ext. RCS Command Neutral/ Measuring point RCS –


X X
Out Remote Control System

173. Ext. RCS Command Ahead/In Measuring point RCS –


X X
Remote Control System

174. Ext. RCS Command Astern Measuring point RCS –


X X
Remote Control System

175. Valve Neutral/Out Measuring point RCS –


X X
Remote Control System

176. Valve Ahead/In Measuring point RCS –


X X
Remote Control System

177. Valve Astern Measuring point RCS –


X X
Remote Control System

178. Trolling Active Measuring point RCS –


X X
Remote Control System

179. Load Change Measuring point “Pre- –


– –
pare load change”

180. Stop Active Measuring point ”Stop” – X X

181. AL RCS/LOP Diff. Clutch Different clutch com- Part 2, standardized


Demand mand from RCS clutch command
Remote Control System
and control station X X
when changing from
Local mode to Remote
control mode

182. MG RCS Dis. Command Message RCS Remote –


X X
Requested Control System

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 139

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

183. MG RCS Ahead Command Message RCS Remote –


X X
Requested Control System

184. MG RCS Astern Command Message RCS Remote –


X X
Requested Control System

185. MG Eng. Speed High/Low Message RCS Remote –


X X
(Clutch) Control System

186. MG Disengage Message RCS Remote –


X X
Control System

187. MG Engage Failure Message RCS Remote –


X X
Control System

188. MG Disengage Failure Message RCS Remote –


X X
Control System

189. P-Gear Control Oil GMU Measuring point “Gear –


control oil pressure”,
X X
acquired by Gear Moni-
toring Unit GMU

190. P-Gear Control Oil LO 1st limit value for gear –


X X
control oil pressure

191. P-Gear Control Oil LOLO 2nd limit value for gear –
X X
control oil pressure

192. LO P-Gear Control Oil GMU Gear control oil pres-


sure too low
X X

Gear documentation

193. SS P-Gear Control Oil GMU Safety system meas-


ures inadequate gear
control oil pressure X X

Gear documentation

194. P-Gear Lube Oil GMU Measuring point “Gear –


control oil pressure”,
X X
acquired by Gear Moni-
toring Unit GMU

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

195. P-Gear Lube Oil Oel LO 1st limit value for gear –
X X
lube oil pressure

196. P-Gear Lube Oil Oel LOLO 2nd limit value for gear –
X X
lube oil pressure

197. LO P-Gear Lube Oil GMU Gear lube oil pressure


too low
X X

Gear documentation

198. SS P-Gear Lube Oil GMU Safety system meas-


ures inadequate gear
lube oil pressure X X

Gear documentation

199. Shaft Speed 1 Measuring point “Shaft –


X X
speed, sensor 1”

200. Shaft Speed 2 Measuring point “Shaft –


X X
speed, sensor 2”

201. LO Gear Oil Level Insufficient gear oil

X X

Gear documentation

202. Feedback Neutral/Out Measuring point RCS –


X X
Remote Control System

203. Trolling Active Measuring point RCS –


X X
Remote Control System

204. Stop Activated GMU Gear Monitoring Unit Determine cause of


GMU has tripped auto- shutdown and rectify
matic stop command X X
due to limit value viola-
tion

205. Emergency Stop ECU (Over- Engine Control Unit Determine cause of
speed) ECU has tripped emer- shutdown and rectify
X X
gency stop due to over-
speed

206. Emergency Stop EMU (Over- Engine Monitoring Unit Determine cause of
speed) EMU has tripped emer- shutdown and rectify
X X
gency stop due to over-
speed

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

207. SS Emergency Stop Ext. Safety system has –


executed an externally X X
tripped emergency stop

208. SS Security Shutdown Safety system has trip- Determine cause of


X X
ped a stop shutdown and rectify

209. SS SDAF Closed Safety system reports Open shut down air
closed shut down air flaps X X
flaps

210. SS Reduced Power Safety system has Determine cause of


requested power reduc- automatic power X X
tion reduction

211. AL Power Supply Fail Moni- Fault in power supply Check power circuit
X X
toring breakers and fuses

212. Feedback Start Start sequence active – X X

213. Feedback Stop Stop sequence active – X X

214. SS Emergency Stop Safety system has trip- Determine cause of


X X
ped an emergency stop shutdown and rectify

215. SS Emergency Stop Safety Safety system has trip- Determine cause of
X X
Syst. ped an emergency stop shutdown and rectify

216. LOP Demand Local Local Operating Panel –


X X
in Local mode

217. LOP Dimm Value,? LOP control element –


– –
brightness

218. Acknowledge Display Alarm acknowledge on –


X X
display

219. MG Check Start Interlocks Start conditions not ful- Check start conditions
X X
filled and fulfill if necessary

220. P-Start Air Measuring point “Start –


X X
air pressure”

>>

E 532 067 / 00 E –08.2001–


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Maintenance and repair
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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

221. P-Start Air Limit LO Limit value for start air –


X X
pressure

222. LO P-Start Air Start air pressure too


low X X

223. P-Exhaust-Back Measuring point –


– –
“Exhaust backpressure”

224. P-Exhaust-Back Limit HI Limit value for exhaust –


– –
backpressure

225. HI P-Exhaust-Back Exhaust backpressure


too high – –

226. PB Override Activated Safety system over- –


X X
ridden

227. AL Override Activated Safety system over- –


X X
ridden

228. Al Water in Fuel Prefilter Water in fuel filter


X X

229. AL Glow Plug Failure Fault on one or more


glow plugs – –

230. AL Pump Failure Priming pump has out- –


– –
put error message

231. AL Battery Charger Failure Battery not charged Check transistor


X X
controllers

232. AL Power Failure Control Control side has no Check power circuit
operating voltage breakers and fuses X X
available

233. SS Failure Safety System Safety system has –


(EMU) detected Engine Moni- X X
toring Unit error

>>

–08.2001– E 532 067 / 00 E


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Maintenance and repair
FRIEDRICHSHAFEN Page 143

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

234. AL Filure Gear Control Fault on Gear Control –


X X
(GCU) Unit GCU

235. AL Water in Fuel Prefilter Water in fuel filter


X X

236. AL Oil in Coolant Oil in coolant circuit


X

237. AL Battery Charger Failure Battery not charged Check power circuit
X X
breakers and fuses

238. AL Ext.starter interlock Cover at projection


point for racing device
missing, wiring defec-
tive (wire break) or X X
- ko l b t plant-end
r a t s or Determine and
kage activated eliminate cause of
start blockage

239. DL 211+A300-A500 Remote Control System Check wiring,


RCS with PIM no. see A-P-LOP-0004,
X X
21.X+A300–A500 not page 111
detected on default bus

240. DL 211+A003-ECU Engine Control Unit Check wiring,


ECU 4 not detected on see A-P-LOP-0004,
default bus page 111

X X

Replace ECU if neces-


sary; see
E 531 685 (4000) or
E 531 691 (2000)

>>

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Maintenance and repair
Page 144 FRIEDRICHSHAFEN

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

241. DL 211+A004-EMU Engine Monitoring Unit Check wiring,


EMU 1 not detected on see A-P-LOP-0004,
default bus page 111

X X

Replace ECU if neces-


sary; see
E 531 685 (4000) or
E 531 691 (2000)

242. DL 211+A001-A001 Display panel DIS not Check wiring,


detected on default bus see A-P-LOP-0004,
page 111 X X
Replace DIS if neces-
sary: see part 4

243. DL 211+A001-A010 Local Control Unit LCU Check wiring,


on Local Oper- see A-P-LOP-0004,
ating Panel LOP 1 (PIM page 111
no. 21.X+A001–A010)
X X
not detected on default Replace MPU 23 of
bus PIM no.
21.X+A001–A010 if
necessary: see part 4

244. DL 211+A001-A020 Local Monitoring Unit Check wiring,


LMU on Local Oper- see A-P-LOP-0004,
rating Panel LOP 1 page 111
(PIM no.
21.X+A001–A020) not Replace MPU 23 of X X
detected on default bus PIM no.
21.X+A001–A020
if necessary; see
part 4

245. DL 211+A002-A030 Gear Control Unit Check wiring,


GCU 1 (PIM no. see A-P-LOP-0004,
21.X+A002–A030) not page 111
detected on default bus
X X

See
E 531 689 (GCU) or
E 531 690 (GCU/GMU)

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 145

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

246. DL 211+A002-A040 Gear Monitoring Unit Check wiring,


GMU 1 (PIM no. see A-P-LOP-0004,
21.X+A002–A040) not page 111
detected on default bus
X X

See
E 531 689 (GCU) or
E 531 690 (GCU/GMU)

247. DL 211+A300-A501 Propeller Control Unit Check wiring,


PCU (PIM no. see A-P-LOP-0004,
X X
21.X+A30–A501) not page 111
detected on default bus

248. RL 211+A300-A500 Remote Control System Check wiring,


RCS with PIM no. see A-P-LOP-0004,
21.X+A300–A500 not page 111 X X
detected on redundant
bus

249. RL 211+A003-ECU Engine Control Unit Check wiring,


ECU 4 not detected on see A-P-LOP-0004,
default bus page 111

X X

Replace ECU if neces-


sary: see
E 531 685 (4000) or
E 531 691 (2000)

250. RL 211+A004-EMU Engine Monitoring Unit Check wiring,


EMU 1 not detected on see A-P-LOP-0004,
redundant bus page 111

X X

Replace EMU if neces-


sary: see
E 531 686

>>

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Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

251. RL 211+A001-A001 Display panel DIS not Check wiring,


detected on redundant see A-P-LOP-0004,
bus page 111
X X
Replace DIS if neces-
sary: see part 4

252. RL 211+A001-A010 Local Control Unit LCU Check wiring,


of Local Operating see A-P-LOP-0004,
Panel LOP 1 (PIM no. page 111
21.X+A001–A010) not
X X
detected on redundant Replace MPU 23 of
bus PIM no.
21.X+A001–A010 if
necessary: see part 4

253. RL 211+A001-A020 Local Monitoring Unit Check wiring,


LMU of Local Operating see A-P-LOP-0004,
Panel LOP 1 (PIM no. page 111
21.X+A001–A020) not
X X
detected on redundant Replace MPU 23 of
bus PIM no.
21.X+A001–A020 if
necessary; see part 4

254. RL 211+A002-A030 Gear Control Unit Check wiring,


GCU 1 (PIM no. see A-P-LOP-0004,
21.X+A002–A030) not page 111
detected on redundant
bus
X X

See
E 531 689 (GCU) or
E 531 690 (GCU/GMU)

>>

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Maintenance and repair
FRIEDRICHSHAFEN Page 147

Fault message display/


No. Meaning Action 2000 4000
measuring point text

>>

255. RL 211+A002-A040 Gear Monitoring Unit Check wiring,


GMU 1 (PIM no. see A-P-LOP-0004,
21.X+A002–A040) not page 111
detected on redundant
bus
X X

See
E 531 689 (GCU) or
E 531 690 (GCU/GMU)

256. RL 211+A300-A501 Propeller Control Unit Check wiring,


PCU (PIM no. see A-P-LOP-0004,
21.X+A30–A501) not page 111 X X
detected on redundant
bus

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3.4 Repair

The following table lists the maintenance and repair work described in this chapter.

Quali- Dura-
No. Task Task ID Page Remarks
ficat. tion

1 Replacing fuses PP 0.1 h A-P-LOP-0001 149

2 Replacing mechanical PP 0.5 h A-P-LOP-0006 151


control assemblies

3 Replacing luminous PP 0.7 h A-P-LOP-0016 155


pushbutton/luminous
switch LEDs

4 Removing control PP 0.5 h A-P-LOP-0017 156


panel PAN with bus
connection

5 Installing control PP 0.5 h A-P-LOP-0018 158


panel PAN with bus
connection

6 Replacing dialog PP 0.8 h A-P-LOP-0002 160


socket outlet

7 Replacing Peripheral PP 0.4 h A-P-LOP-0028 162


Interface Module
PCBs

8 Replacing display PP 0.4 h A-P-LOP-0012 166 Display does not need to be


panel DIS seal fully removed

9 Replacing control PP 0.4 h A-P-LOP-0013 168 Panel does not need to be


panel PAN seal fully removed

10 Replacing power cir- PP 0.2 h A-P-LOP-0014 171


cuit breakers

11 Replacing BOB 1 PP 0.1 h A-P-LOP-0015 172 PCB needs to be removed


PCB plug-in fuses from module housing

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3.4.1 Replacing fuses


ID-No.: A-P-LOP-0001

The fuses are located on the CIB 3 PCB


in the upper section of the housing. The
six fuses are assigned as follows:

Item No. Val. Assigned to

16/1 =21.X+A002–F1 30 A Engine Control


(gn) Unit ECU 4

42/2 =21.X+A002–F2 4A Gear Control


(pk) Unit GCU

42/3 =21.X+A002–F3 3A Local Operating


(vi) Panel PIM LCU
Display panel
DIS
Control panels
PAN

42/4 =21.X+A002–F4 3A Emergency


(vi) functions (shut
down air flaps)

42/5 =21.X+A002–F5 2A Supply external


1 (gr) contacts
2
42/6 =21.X+A002–F6 1 A Supply external
3 (bw) contacts
4
5
6

Fig. 42 : CIB 3 PCB fuses

1. Locate the defective fuse (recog-


nizable by the broken metal wire be-
hind the sight glass, see fig. 42).
2. Pull the defective fuse out of the sock-
et; use a small pair of pliers if neces-
sary.

Fig. 43 : Defective fuse

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3. The corresponding spare fuses (44/3)


are located on the left-hand side in the
upper section of the housing. They are
installed in a fuse holder (44/1) with a
see-through cover (44/2); take off the
cover and pull out the spare fuse
(44/3) required.
4. Insert the new fuse in the socket and
press it in as far as it will go.
5. Determine the type and item number
of the replaced fuse using the parts
catalog (see part 5 of this manual),
order the fuse and make sure the fuse
2 holder is full by installing the spare
fuse.
1

Fig. 44 : Spare fuses

Always ensure that fuses are only replaced by fuses of the same
electrical rating. Otherwise, electronic assemblies may be de-
stroyed or fire may break out.

CAUTION

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3.4.2 Replacing mechanical control assemblies


ID-No.: A-P-LOP-0006

Local Operating Panel LOP 1-01 controls


are an integral part of the following
assemblies:

 Display panel DIS (45/1)


 Control panel PAN with bus connec-
tion (45/2 and 45/3)
 Control panel PAN with bus connec-
tion and parallel contacts (45/4)

Removal and installation procedure for


the mechanical assemblies of all buttons
1
and switches is the same. Proceed as fol-
2 lows:
3
4
Fig. 45 : LOP 1 Local Operating Panel con-
trols 1. Insert the flat lug of the cap puller
(46/3) between the button cap (46/2)
and the button casing (46/1).
2. The raised part of the lug slit (46/4)
4 must face towards the button cap.

2
1
3

Fig. 46 : Attaching cap puller

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3. Use the flat lug on the cap puller


a (46/1) to pull out the button cap (46/2)
from the lower section of the button
(46/3) in the direction indicated by the
arrow A.

1 3
2

Fig. 47 : Removing cover cap

4. Remove engraved plate (48/1) from


the actuator (48/2).
5. Then remove the actuating plunger
assembly (48/2).

2
1

Fig. 48 : Remove the engraving panel

6. Unlock the plunger : Press the plunger


(49/1) down in the direction indicated
by arrow a and turn it clockwise
(direction indicated by arrow b) as far
as it will go (approx. 15°) against the
plunger body (49/2).

1 2

Fig. 49 : Removing the plunger

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7. The actuator (50/1) can now be


removed from the actuator casing
(50/2)
Proceed as follows before installing a new
actuator or if reinstalling the removed
actuator:

 Clean the inside of the button casing


2
(50/2)
 Clean and thoroughly dry the actua-
ting plunger (50/2)
1

Fig. 50 : Removing the plunger

Proceed as follows to reassemble the


button:

8. Insert the new plunger (51/1) in the


turned state evenly into the plunger
body (51/2)

a The edges of the plunger head


must be at an angle of approx.
1 15° to the corresponding edges
2 of the plunger body.

Fig. 51 : Inserting the plunger

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9. Lock the plunger (52/1): Press the


plunger down in the direction indicated
by arrow a and turn it counter-
clockwise through approx. 15°
b (direction indicated by arrow b)
against the plunger body (52/2) until
the edges of the plunger head are
parallel to the corresponding edges of
a the plunger body.

1 2

Fig. 52 : Locking the plunger

10. Insert the engraving panel (53/2) into


the plunger. Make sure that it is
positioned correctly.

The surface with the engraved


text must face the key cap.

3 11. Insert the key cap (53/1) in the


plunger body (53/3).

2 12. Firmly press the button together until


the button cap clips in.
1

Fig. 53 : Completing mounting the plunger

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Maintenance and repair
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3.4.3 Replacing a multi-LED of a function key


ID-No.: A-P-LOP-0016

1. Remove the cap as shown in Fig. 46.


2. Remove the engraving panel (46/1).
3. Remove the plunger as shown in
Fig. 49.
4. Fit the cap puller (54/1) over the
multi-LED (54/3) in the plunger body
(54/2) and pull out the multi-LED.
2 5. Note polarity of the faulty multi-LED on
3 pulling out! The new multi-LED must
be inserted in the same way!
1
6. Inserting the new multi-LED:
4

Observe polarity!
The contact marked “+” must point the
Fig. 54 : Removing multi-LED same way as determined in step 1.

7. Press the multi-LED into the key housing against light spring pressure until it snaps
into place.

8. Insert the plunger as shown in fig. 51.

9. Lock the plunger as shown in fig. 52.

10. Insert the engraving panel into the plunger body. Make sure that the text or symbol is
positioned correctly.

The surface with the engraved text must face the key cap.

8. Fit the cap in accordance with fig. 46.

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3.4.4 Removing control panel PAN with bus connection


ID-No.: A-P-LOP-0017

PAN control panels are secured at the


rear with four M4 nuts.

Control panel PAN is disassembled as


follows:

1. Open the door (55/1) of the Local


Operating Panel.
2. Pull the connector (55/2) off the rear of
the PAN control panel to be removed.

2 1

Fig. 55 : Undoing PAN control panel

3. Using a suitable screwdriver, remove


the mounting screw (56/4) for the
1 grounding cable (56/1) at the point
where the crimp connection (56/3)
2 covers the M4 mounting nut (56/2) for
the corresponding PAN control panel.

4
3

Fig. 56 : Removing grounding cable

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FRIEDRICHSHAFEN Page 157

4. Undo the four M4 mounting nuts


(57/1) using a socket wrench.
1
5. Each mounting nut has a size 4.3
1 toothed washer (57/2); carefully pull
off these washers from the threaded
pins using tweezers.

Fig. 57 : Removing mounting nuts


(and anbringen bracket if necessary)

Always ensure that none of the toothed washers fall inside the
housing; otherwise, possible short-circuits will lead to malfunc-
tioning or failure of the plant.

CAUTION

6. Carefully press out the PAN control


panel (58/1) forwards out of the door
(see fig. 58) making sure that the seal
on the housing is not damaged in the
process.

Fig. 58 : Pulling out control panel

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Maintenance and repair
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3.4.5 Installing control panel PAN with bus connection


ID-No.: A-P-LOP-0018

1. Place the control panel (59/1) onto a


flat surface with the button side facing
2 down and check that the seal is cor-
rectly seated. If the seal (59/2) is
damaged or has become hard,
replace it with a new one (observe
type and item number, see part 5 of
this manual).
2. Align the seal correctly (see fig. 59,
edges a and b must be parallel to
each other).

b
a

Fig. 59 : Fitting seal to control panel

Always ensure that none of the toothed washers fall into the
housing; otherwise possible short-circuits can lead to malfunc-
tions or failure of the plant.

CAUTION

3. Push the control panel into the correct


slot in the door from the front, en-
suring that the seal is not damaged
and lies between the mating surfaces.

Fig. 60 : Inserting control panel

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Maintenance and repair
FRIEDRICHSHAFEN Page 159

4. Slide the size 4.3 toothed washers


3 (61/2) onto the threaded pins; use a
1
pair of tweezers or small pliers to do
this if necessary.
1
5. Screw the four M4 mounting nuts
(61/1) onto the threaded pins using a
socket wrench and tighten them all
uniformly.

1 6. Screw the grounding cable to the


retaining bracket on the control panel
2 using a suitable screwdriver.

1 7. Insert the connector into the socket on


the rear of the control panel.
Fig. 61 : Fitting mounting nuts
(and connect bracket if necessary) If a new control panel has been inserted,
the CAN node setting must be checked
and, if necessary, correctly adjusted.

Proceed as follows to do this:

8. Check the position of the jumper on


the disassembled PAN control panel
(top left (61/3) on the rear of the con-
trol panel).

9. Insert the jumper (fig. 62) for the


newly installed panel in the same posi-
tion as determined above (step 8.); to
do this, use a pair of tweezers or small
pliers if necessary.

Fig. 62 : Jumper for adjusting node address


If a new panel is installed, the text labels
(example) and coloured button caps need to be
transferred from the old panel to the new
one.

Disassembly of the text labels is descri-


bed in chap. 3.4.2 (ident. no.
A-P-LOP-0006), step 1. to 4.

Installation of the text labels is described


in chap. 3.4.2 (ident. no. A-P-LOP-0006),
step 10. to 12.

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Maintenance and repair
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3.4.6 Replacing dialog socket outlet


ID-No.: A-P-LOP-0002

The dialog socket outlet (63/1) is located


on the top right hand side of the Local
Operating Panel. It is fixed to the COB 9
PCB by means of a central nut and two
bolts with spacers.

The dialog socket outlet is replaced as fol-


lows:

1. Screw off the dialog socket outlet cap.


2. Undo and unscrew the union nut on
the dialog socket outlet using a suit-
able tool.

1
3. Undo the retaining screws (64/1) on
the two green plug connectors (64/2).

Fig. 63 : COB 9 PCB

4. Pull off the three connectors (64/2


and 3) from the rear of the COB 9
PCB.
4
5. Loosen both the M4 mounting nuts
5
(64/5) using a socket wrench; use a
suitable screwdriver to hold the bolts
in position whilst doing this.
3
6. Carefully pull down the COB 9 PCB
inwards from the bolts.

2
1 1
2
Fig. 64 : Disassembling COB 9 PCB

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Maintenance and repair
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Always ensure that the two spacers on the bolts do not fall into
the housing but remain on the bolts.

CAUTION

7. Fit the new COB 9 PCB (without union


nut) onto the two bolts (65/3); hold the
bolts in position from outside.
8. Fit the two toothed washers (65/2)
onto the bolts.
9. Screw the two M4 mounting nuts
(65/1) onto the bolts using a socket
wrench and tighten them uniformly.
10. Screw on the dialog socket outlet
union nut by hand and tighten using a
1
3 suitable tool.
2 11. Fit the three connectors onto the cor-
responding COB 9 PCB socket; check
Fig. 65 : Installing COB 9 PCB
for correct cable assignment whilst
doing this.

Each plug connector has pin numbers indicated on a sticker. These numbers
are printed on the board. This ensures correct connector assignment.

12. Tighten the retaining screws for both


green plug connectors.

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3.4.7 Replacing Peripheral Interface Module printed circuit boards


ID-No.: A-P-LOP-0028

Fig. 66 shows the structure of a type 2


MPU 23 PCB Peripheral Interface Module PIM (con-
taining four PCBs). The position of the
MPU 23 PCB is the same on each PIM
PCB PCB (slot 1); the other three slots can be occu-
pied by any combination of PCBs. The
PCB slot numbering shown in fig. 66 is the
same for all PIM Peripheral Interface
Modules (fixed and binding).
Slot 1

Slot 3

Slot 2

Slot 4

Module cassette

COB 3 PCB Module housing


(Motherboard, internal)

Fig. 66 : Structure of a Peripheral Interface


Module PIM

The PIM module housing does not need to be disassembled to change a PCB.
The relevant module cassette is simply pulled out of the module housing.

PCBs must be replaced as a unit.

When changing a PCB, check whether the corresponding assem-


bly contains specific data (see appropriate instructions below).
CAUTION

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Maintenance and repair
FRIEDRICHSHAFEN Page 163

Proceed as follows to change a PCB:

1. Pull the module cassette (67/1) out of


the module housing (see fig. 66).

Fig. 67 : Module cassette

2. Open the module cassette cover as


follows:
Insert a small screwdriver into the
recess (67/2) and lever up the cover
1 (68/1);
this makes it possible to fold up the
2 cover (68/1).

Fig. 68 : Opening cover

Destruction by electrostatic charging.


(C)MOS components and assemblies equipped with (C)MOS
components may be destroyed by electrostatic charging.
Therefore:
 Ensure that personnel, tools and worktops are electrostatically
discharged by touching them with earthed metal parts before
they touch electronic components or modules.
CAUTION  Avoid touching electronic components or assemblies with non-
conductive materials.
 Do not change components or assemblies when the voltage is
switched on.

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3. Pull the relevant PCB (69/1) up out of


the module cassette (69/2).

Fig. 69 : Pulling out PCB

Preconfigured PCB

The MPU 23 PCB is factory-configured and may only be ex-


changed for a similarly configured PCB by plant personnel.

This must be stated when ordering spare parts.

CAUTION If they are to be replaced by non-configured assemblies, these


assemblies must be programmed following installation. This is a
task for service personnel and is described in part 4 of this
manual.

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Maintenance and repair
FRIEDRICHSHAFEN Page 165

4. Select the new PCB from spare parts


stocks (observe type and item num-
ber, see part 5 of this manual).
5. Insert the corresponding PCB (70/1)
into the grooves (70/3) of the module
cassette (70/2) make sure that the
1 PCB (70/1) is straight.

2 3

Fig. 70 : Inserting PCB

6. Close the module cassette cover


(71/1); ensure that it clips firmly into
the module cassette housing (71/2).
7. Reinsert the module cassette in the
correct position in the relevant module
1
housing; ensure that the module cas-
sette is straight.
2

Fig. 71 : Closing cover

Details on the allocation of PCBs to slots are included in the chapter entitled
“Internal structure” (chap. 1.1.2.2). In addition, the item numbers and types are
listed in part 5 of this manual.

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3.4.8 Replacing display panel DIS seal


ID-No.: A-P-LOP-0012

It is not necessary to completely remove


the display in order to replace the DIS dis-
play panel seal.

Proceed as follows:

1. Open the doors (72/1) of the Local


Operating Panel.
2. Undo the six M4 mounting nuts (72/2)
using a socket wrench.
3. Each mounting nut has a size 4.3
toothed washer; carefully pull off these
washers off the threaded pins using a
2
pair of tweezers.
2 1

Fig. 72 : Undoing display panel DIS

Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits can lead to malfunction
or failure of the plant.

CAUTION

4. Carefully press display panel DIS for-


wards out of the door until the thread-
ed pins become free (see fig. 73).
5. Push the damaged seal down off the
threaded pins.

Fig. 73 : Pushing display panel DIS forwards

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Maintenance and repair
FRIEDRICHSHAFEN Page 167

6. Pull the damaged seal (74/1) forwards


over the edge of the housing.
7. Guide the new seal over the edge of
the housing in the same way.
8. Slide the new seal over the threaded
pins.
9. Carefully press the display panel back
into the opening until it fully contacts
the door; whilst doing this, ensure that
the seal does not overlap the edge of
the housing at any point or is shear-ed
off on the edge of the installation
opening.
10. Slide the size 4.3 toothed washers
over the threaded pins; to do this, use
1 a pair of tweezers or small pliers if ne-
cessary.

Fig. 74 : Pulling down seal

Always ensure that none of the toothed washers fall into the hou-
sing; otherwise, possible short-circuits can lead to malfunction or
failure of the plant.

CAUTION

11. Screw the six M4 mounting nuts onto


the threaded pins using a socket
wrench and tighten all six uniformly.

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Maintenance and repair
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3.4.9 Replacing control panel PAN seal


ID-No.: A-P-LOP-0013

The panel does not need to be completely


removed to replace a seal.

Proceed as follows:

1. Open the door of the Local Operating


Panel (75/1).
2. Use a suitable screwdriver to remove
the grounding cable at the point (75/2)
where the crimp connection covers the
M4 mounting bolt of the corresponding
PAN control panel.
3. Undo the four M4 mounting bolts
(75/3) using a socket wrench.
3
2 4. Each of the mounting nuts has a size
3 1 4.3 toothed washer; carefully pull
these washers off the threaded pins
Fig. 75 : Undoing control panel PAN using a pair of tweezers.

Always ensure that none of the toothed washers fall into the hou-
sing; otherwise, possible short-circuits can lead to malfunction or
failure of the plant.

CAUTION

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5. Carefully press control panel PAN for-


wards out of the doors until the
threaded pins become free
(see fig. 76).
6. Push the damaged seal down off the
threaded pins.

Fig. 76 : Pushing control panel forwards

7. Pull the damaged seal (77/1) forwards


over the edge of the housing.
8. Guide the new seal over the edge of
the housing in the same way.
9. Slide the new seal over the threaded
pins.
10. Carefully press control panel PAN
back into the opening until it fully con-
tacts the door; whilst doing this,
ensure that no parts of the seal over-
lap the edge of the housing or shear
off on the edge of the installation
opening.
11. Slide the size 4.3 toothed washers
over the threaded pins; to do this, use
a pair of tweezers or small pliers if
necessary.
1
Fig. 77 : Pulling down seal

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Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits may lead to malfunc-
tion or failure of the plant.

CAUTION

12. Screw the four M4 mounting nuts onto


the threaded pins using a socket
wrench and tighten all four uniformly.
13. Fix the grounding cable to the control
panel retaining bracket with the screw.

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3.4.10 Replacing power circuit breaker


ID-No.: A-P-LOP-0014

The power circuit breakers (78/1) are


located on plug-in sockets.

Before removing the left-hand


power circuit breaker or a
power circuit breaker located
between the other power circuit
breakers, it is first necessary to
remove all the power circuit
breakers which are located to
the right of the defective power
circuit breaker. Only then is it
possible to push the retaining
bracket of the defective power
1 circuit breaker to one side.

Fig. 78 : Position of the power circuit


breakers

Ensure that the power circuit breakers are replaced by


ones with the same electrical ratings. Otherwise, electronic
assemblies may be destroyed or fire may break out.

CAUTION

Proceed as follows to replace a power cir-


cuit breaker:
a
1
1. Push the retaining bracket (79/1) to
one side with one hand.

2. Grasp the power circuit breaker with


thumb and forefinger (see a and b) of
the other hand and pull out of the
c
socket in the direction indicated by
arrow c.
b 3. Insert the new power circuit breaker
Fig. 79 : Disassembling power circuit breaker into the socket and clip in the retaining
bracket.

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3.4.11 Replacing plug-in fuses on BOB 1


ID-No.: A-P-LOP-0015

There are five plug-in fuses on PCB


LEDs channel status relay
LED error BOB 1.
Component side Before replacing a plug-in fuse, the BOB 1
PCB must be removed as described in
chap. 3.4.7 (ID no. A-P-LOP-0028), steps
1. to 3. The position of the BOB 1 PCB is
shown in chapter 1.

Plug-in fuses are changed as follows:

1. Grasp the defective plug-in fuse with a


pair of pointed pliers and pull it out
(see fig. 80, top view).

Plug-in fuse F5
Plug-in fuse F4
Plug-in fuse F2
Plug-in fuse F3
Plug-in fuse F1
Fig. 80 : BOB 1 plug-in fuses

2. Fit a new plug-in fuse (81/1,


3.15 A MT) onto the PCB and carefully
press it into the socket (81/2) ensuring
that none of the connection pins
become bent.
3. Reinsert the BOB 1 PCB into the cor-
responding module cassette; to do
this, proceed as described in chap.
3.4.7 (ID no. A-P-LOP-0028), steps 5.
1
2 to 7.

Fig. 81 : Changing plug-in fuse

Spare fuses used must have the correct electrical ratings:


 F1, F2, F3, F4, F5: 3.15 A medium time-lag

CAUTION

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Part 4

Maintenance and repair


(Service personnel)

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4 Maintenance and repair (Service personnel)

4.1 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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Safety requirements for maintenance and repair


Maintenance and repair work shall be performed exactly and on schedule to ensure con-
stant readiness and reliability of the product.
Authorization must be obtained from the person in charge prior to commencing mainte-
nance and repair work and switching off parts of the electronic system required for this.
Prior to working on assemblies, 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.
Maintenance and repair work shall be performed in accordance with the instructions in the
manual by authorized personnel.
Suitable tools, special MTU tools if necessary, shall be used for maintenance and repair
work.
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.
Spare parts shall be stored properly prior to replacement, i.e. particularly protected
against the ingress of moisture. Defective electronic components and assemblies must be
suitably packed when despatched for repair, i.e. particularly protected against the ingress
of moisture and impact and wrapped in antistatic foil if necessary.
Inform the MTU service department or its representative in case of damage which cannot
be rectified by plant personnel.
On completion of maintenance and repair work, ensure that no superfluous parts (tools
etc.) remain inside the device or system.
On completion of repair work, the device or system must be subjected to apprpriate
checks to verify functionality. Separate testing of the repaired component without system
integration is inadequate.
When working on the engine, suitable measures shall be taken to prevent accidental
starting.

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4.2 Maintenance

4.2.1 General notes

This chapter explains work required on Local Operating Panel LOP 1 to maintain opera-
tional readiness. This work may be performed without using test and measuring equip-
ment; however, it must be performed by trained experts.

The maintenance work on Local Operating Panel LOP 1 predominantly involves visual
checks to detect mechanical damage or pinpoint loose parts and loosened attachments.
Defective assemblies must be repaired or replaced immediately.

System failure

If the following work is not performed in accordance with the


instructions and within the intervals indicated, this may lead to
CAUTION failure of Local Operating Panel LOP 1 or the entire Propulsion
Control System/ECS-5.

If faults are detected, the fault cause can be pinpointed and the fault rectified in ac-
cordance with the instructions contained in the following chapters.

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4.2.2 Maintenance work

All scheduled maintenance work is described in part 3, chap. 3.2.2. Maintenance work as
part of maintenance echelons W5 and W6 are not applicable.

4.3 Troubleshooting

4.3.1 Faults without fault code display

The following table lists possible faults which are immediately apparent to the operator.

No. Fault Fault cause(s) Rectification See

1 Local Operating Panel Relay K30 defective Replace CIB 3 PCB with A-P-LOP-0026
LOP 1 partially out of relay Page 204
order (only the control
side functions)

2 Local Operating Panel Relay K04 defective Replace CIB 3 PCB with A-P-LOP-0026
LOP 1 partially out of relay Page 204
order (only the moni-
toring side functions)

3 No indication on display Display panel defective Replace display panel A-P-LOP-0019


panel Page 181
A-P-LOP-0020
Page 183

4 Start sequence cannot 1. CIB 3 PCB defective Replace CIB PCB A-P-LOP-0026
be executed Page 204

2. Relay K9 defective Replace CIB 3 PCB with A-P-LOP-0026


K9 relay Page 204

3. Corresponding button Replace switch element A-P-LOP-0023


switching element Page 193
defective

5 Emergency stop on 1. Corresponding control Replace button element A-P-LOP-0023


Local Operating Panel panel button defective Page 193
cannott b
be executed
t d
2. CIB 3 PCB defective Replace CIB 3 PCB A-P-LOP-0026
Page 204

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4.3.2 Faults indicated in plain text on the display

Measuring points and fault messages are output in text form on display panel DIS on Local
Operating Panel LOP 1. The form of representation is depicted in chap. 3.3.2. In addition,
this chapter includes an explanation of all abbreviations used in the messages.

Rectification/maintenance
Fault display/ echelon
No. Meaning
measuring point text message (E – electrical,
M – mechanical)

1. DL 211+A001-A001 Display panel DIS not detected E: Check wiring, replace DIS
on default bus if necessary

See A-P-LOP-0019 and


A-P-LOP-0020,
Pages 181 and 183

2. DL 211+A001-A010 Local Control Unit LCU of Local E: Check wiring, replace


Operating Panel LOP 1 (PIM MPU 23 of PIM no.
no. 21.X+A001–A010) not 21.X+A001–A010 if neces-
detected on default bus sary

See A-P-LOP-0025
Page 200

3. DL 211+A001-A020 Local Monitoring Unit LMU of E: Check wiring, replace


Local Operating Panel LOP 1 MPU 23 of PIM no.
(PIM no. 21.X+A001–A020) 21.X+A001–A020 if neces-
not detected on default bus sary

See A-P-LOP-0025
Page 200

4. RL 211+A001-A001 Display panel DIS not detected E: Check wiring, replace DIS
on redundant bus if necessary

See A-P-LOP-0019 and


A-P-LOP-0020
Pages 181 and 183

5. RL 211+A001-A010 Local Control Unit LCU of Local E: Check wiring, replace


Operating Panel LOP 1 (PIM MPU 23 of PIM no.
no. 21.X+A001–A010) not 21.X+A001–A010 if neces-
detected on redundant bus sary

See A-P-LOP-0025
Page 200

6. RL 211+A001-A020 Local Monitoring Unit LMU of E: Check wiring, replace


Local Operating Panel LOP 1 MPU 23 of PIM no.
(PIM no. 21.X+A001–A020) 21.X+A001–A020 if neces-
not detected on redundant bus sary

See A-P-LOP-0025
Page 200

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4.4 Repair

The following table summarizes the maintenance and repair work described in this chap-
ter.

Quali- Dura-
No. Task Task ID Page Remarks
ficat. tion

1 Removing display SP 0.3 h A-P-LOP-0019 181


panel DIS

2 Installing display SP 0.3 h A-P-LOP-0020 183


panel DIS

3 Removing control SP 0.7 h A-P-LOP-0021 186


panel PAN with bus
connection and fixed
wiring

4 Installing control SP 0.7 h A-P-LOP-0022 189


panel PAN with bus
connection and fixed
wiring

5 Replacing switch ele- SP 0.4 h A-P-LOP-0023 193


ments/button ele-
ments of control
panel PAN

6 Replacing housing of SP 0.7 h A-P-LOP-0024 195 Program EEPROM


Peripheral Interface
Module with mother-
board

7 Replacing processor SP 0.5 h A-P-LOP-0025 200 Pre-configured assembly or


assembly of Periphe- BDM required
ral Interface Module

8 Replacing CIB 3 PCB SP 1.5 h A-P-LOP-0026 204

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4.4.1 Removing display panel DIS


ID-No.: A-P-LOP-0019

Display panel DIS is fixed on the rear with


3
six M4 nuts.

Display DIS is disassembled as follows:

1. Open the door of the Local Operating


Panel (82/1).
2. Undo the retaining screws from the
three plug connectors (82/3) on the
rear of the housing.
3. Pull off the plug connectors (82/3).
4. Undo the six M4 mounting nuts (82/3)
2 using a socket wrench.

2 5. Each of the mounting nuts has a size


4.3 toothed washer; carefully pull off
1
these washers from the threaded pins
Fig. 82 : Undoing display panel DIS using a pair of tweezers.

Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits may lead to malfunc-
tion or failure of the plant.

CAUTION

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6. Cut open the two cable ties (83/1) on


the cable tie fastenings using cutting
1 pliers and remove the cable (83/2)
1
from the display housing.

7. Use a screwdriver to unscrew the


2
securing screws on the three connec-
tors.
8. Unplug the three connectors (83/3)
from the sockets on the rear side of
the display.

Fig. 83 : Undoing display panel DIS

Always ensure that none of the cables are snipped off.

CAUTION

9. Carefully press the display panel for-


wards (see fig. 84) out of the door
taking care not to damage the housing
seal.
10. Pull the display panel all the way out
of the door.

Fig. 84 : Pushing display panel DIS forwards


out of the cutout

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4.4.2 Installing display panel DIS


ID-No.: A-P-LOP-0020

Before the new display panel DIS can be


1 1 inserted, the two cable tie fastenings need
to be removed from the old display panel
DIS and attached to the new display panel
DIS.

1. Undo the two screws (85/1) on the old


display (85/2) using a suitable screw-
driver and take off the two cable tie
fastenings.
2. Reinsert and tighten the two screws
(85/1) without fitting the cable tie
fastenings.
2
3. Remove the same screws from the
new display and reattach them to the
Fig. 85 : Removing cable tie fastenings cable tie fastenings; align the cable tie
fastenings as shown in fig. 86.
Display panel DIS is installed as follows:

1. Place the display panel on a level sur-


face with the screen side facing down-
wards and check that the seal is cor-
rectly seated. Seals which are
damaged or have become hard must
be replaced by new ones (observe
type and item number, see part 5 of
this manual).

Fig. 86 : Aligning cable tie fastenings

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2. Align the seal (87/1) correctly.


3. Push the display panel into the door
cutout from the front ensuring that the
seal is not damaged and lies flat be-
tween the mating faces.
4. Slide the six size 4.3 toothed washers
over the threaded pins; use a pair of
tweezers or small pliers to do this if
necessary.

Fig. 87 : Aligning seal

Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits may lead to malfunc-
tion or failure of the plant.

CAUTION

5. Screw the six M4 mounting nuts (88/2)


4 3 onto the threaded pins using a socket
wrench and uniformly tighten all six.
6. Insert the three plug connectors (88/3)
into the socket on the rear of the dis-
play panel.
7. Tighten the retaining screws for the
three plug connectors.
8. Attach the wiring harness to the two
cable tie fastenings (88/4) using two
new cable ties as shown in fig. 88.

2
1
Fig. 88 : Installing complete display panel DIS

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Once a new display panel has been installed, the plant-specific


data need to be downloaded into the display panel.

CAUTION

Downloading takes place either automatically (in systems with a Programmable Process
Station PPS) or with the help of the Backup Data Module BDM.
The project data can be loaded alternatively by means of the download function of the DIS
display. For this purpose, a memory module with the corresponding data must be inserted
into the slot provided in the display.

Reference Documentation:
Downloading is explained in the MTU document ”Backup Data Module BDM,
documentation parts 1–2”, doc. no. E 531 718 and the MTU documentation for
the ”DIS Display, documentation parts 1–7, doc. no. E 531 900”.

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4.4.3 Removing control panel PAN with bus connection and fixed wiring
ID-No.: A-P-LOP-0021

PAN control panels are secured on the


rear with four M4 nuts.

The PAN control panel is disassembled as


follows:

1. Open the door (89/1) of the Local


Operating Panel.
2. Pull off the four connectors (89/2) on
the rear of the control panel PAN to be
removed.

2 1

Fig. 89 : Undoing control panel PAN

3. Cut open the two cable ties (90/1) on


the cable tie fastenings using cutting
pliers and remove the cable (90/2)
from the control panel housing.

1
1

Fig. 90 : Removing cable ties

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Always ensure that none of the cables are snipped off.

CAUTION

4. Use a suitable screwdriver to remove


the mounting screw (91/4) from the
1 grounding cable (91/1) from the point
where the crimp connection (91/3)
2 covers the M4 mounting nut (91/2) for
the corresponding control panel PAN.

4
3

Fig. 91 : Removing grounding cable

1
5. Undo the four M4 mounting bolts
(92/1) using a socket wrench.
1
6. Each of the mounting nuts has a size
4.3 toothed washer (92/2); carefully
pull off these washers from the
threaded pins using a pair of
tweezers.
7. Take off the lower retaining bracket
(92/3).
3
2

Fig. 92 : Removing mounting nuts and


retaining bracket

Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits may lead to malfunc-
tion or failure of the plant.

CAUTION

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8. Carefully push the control panel PAN


(93/1) forwards (see fig. 93) out of the
door; take care to ensure that the
housing seal is not damaged.

Fig. 93 : Pullling out control panel

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4.4.4 Installing control panel PAN with bus connection and fixed wiring
ID-No.: A-P-LOP-0022

Before the new control panel PAN can be


inserted, the two cable tie fastenings on
1 the old control panel PAN need to be
removed and attached to the new control
panel PAN.
1
1. Undo the two screws (94/1) on the old
panel (94/2) using a suitable screw-
driver and take off the two cable tie
fastenings.
2. Reinsert and tighten the two screws
(94/1) without fitting the cable tie
fastenings.
2
3. Remove the same screws from the
new display and reattach them to the
Fig. 94 : Removing cable tie fastenings cable tie fastening; align the cable tie
fastenings as shown in fig. 94 whilst
doing this.
The control panel PAN is installed as fol-
2 lows:

1. Place the control panel (95/1) on a


level surface with the button side
facing downwards and check that the
seal is correctly seated. Seals (95/2)
which are damaged or have become
hard must be replaced by new ones
(observe type and item number, see
part 5 of this manual).
2. Align the seal correctly (see fig. 95).

b
a
1

Fig. 95 : Fitting seal to control panel

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3. Push the control panel into the lower


slot in the door ensuring that the seal
is not damaged and lies flat between
the mating surfaces.

Fig. 96 : Inserting the control panel

1
4. Slide the retaining bracket (97/3) over
4
the threaded pins.
1 5. Slide the size 4.3 toothed washers
(97/2) over the threaded pins; use a
pair of tweezers or small pliers to do
this if necessary.
6. Screw the four M4 mounting nuts
(97/1) onto the threaded pins using a
socket wrench and uniformly tighten
all four.
3
2
7. Screw the grounding cable to the con-
trol panel retaining bracket using the
1 screw.

Fig. 97 : Placing mounting nuts and


bracket

Always ensure that none of the toothed washers fall into the
housing; otherwise, possible short-circuits may lead to malfunc-
tion or failure of the plant.

CAUTION

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8. Insert the three connectors (98/1) into


the corresponding sockets on the rear
of the control panel, checking for cor-
rect assignment.
9. Attach the wiring harness to the two
cable tie fastenings using two new
cable ties as shown in fig. 98.

Each plug connector has a pin


number sticker. These numbers
are also printed on the cover
plate. This ensures that the
connectors are correctly
assigned.
If a new control panel has been inserted,
the CAN node setting must be checked
and adjusted if necessary.
1

Fig. 98 : Inserting connectors

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To do this, proceed as follows:

10. Check the position of the jumper on


the removed control panel PAN (top
right on the rear of the control panel,
see fig. 97/4).
11. Insert the jumper for the newly instal-
led panel in the same position as
determined beforehand (see step 8.);
use a pair of tweezers or small pliers
to do this if necessary.
When a new panel is inserted, the text
Fig. 99 : Jumper for adjusting the node labels and coloured button caps also need
address (example)
to be transferred from the old control
panel to the new one.

Removal of the text labels is described in


chap. 3.4.2 (ident. no. A-P-LOP-0006),
steps 1. to 4.

Installation of the text labels is described


in chap. 3.4.2 (ident. no. A-P-LOP-0006),
steps 10. to 12.

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4.4.5 Replacing switch elements/button elements of control panel PAN


ID-No.: A-P-LOP-0023

It is not necessary to remove the panel to


2 replace a switch element/button element
in the control panel PAN with parallel con-
tacts.

Proceed as follows:

1. Open the door of the Local Operating


Panel.
2. Undo and remove the four screws
(100/1) on the control panel PAN
using a suitable screwdriver.
3. Pull off the lower section of the
housing (100/2).
4. Grasp the defective switch element on
two opposing sides with thumb and
1
forefinger.
5. Turn the switch element clockwise;
Fig. 100 : Inserting connector
this releases the latch.
6. Pull the switch element out to the rear.

Fig. 101 : Removing button element

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7. Fit the new switch element onto the


body of the actuator until it can be
heard to click in.

Fig. 102 : Inserting button element

8. Refit the lower section of the housing


ensuring that the contact pins of the
switch elements fit precisely into the
socket spring contacts.
9. Push on the lower section of the
housing as far as it will go.
10. Tighten the four screws (103/1) using
a suitable screwdriver.

Fig. 103 : Affixing lower housing section

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4.4.6 Replacing Peripheral Interface Module housing with motherboard


ID-No.: A-P-LOP-0024

Fig. 104 shows a type 1 Peripheral Inter-


face Module PIM. Mechanical removal
and installation is shown using this type of
module as an example. Type 2 Peripheral
Interface Modules PIM are removed and
4 installed in the same way; however, there
5
are more retaining clips (104/3). Proceed
as follows to remove the module housing
from the DIN rail:

1. Switch off the operating voltage.

2. Open the door of Local Operating


Panel LOP 1-01.

3. Locate the corresponding Peripheral


Interface Module PIM:

 =21.X+A001–A010: LCU
 =21.X+A001–A020: LMU

4. Note the terminal configuration on the


3 module to be replaced (assignment of
2
1 cable colour to terminal number,
104/1).
Fig. 104 : Removing PIM

5. Undo all the connection terminals


(screw terminals, 104/2) using a
screwdriver.

6. Pull all cables out of the terminals.

7. Lever out the retaining clip (104/3)


using a screwdriver (104/5) as shown
in fig. 104.

8. Swivel the housing (104/4) upwards


and away from the module rail (see
fig. 105).

9. Take off the housing (104/4).


Fig. 105 : Taking off Peripheral Interface
Module PIM

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Proceed as follows to mount a Peripheral


Interface Module PIM on a module rail:

10. Place the new module onto the


module rail (ensuring that the groove
in the rear of the housing is correctly
positioned on the module rail).
11. Press the module onto the module rail
until the retaining clip engages.

If the retaining clip (106/1) is


open (pulled out), push the clip
fully in before fitting the
module.

1
12. Connect cables to the terminals in
accordance with the terminal configu-
ration (see step 3); also tighten non-
Fig. 106 : Engaging retaining clip assigned terminals.

The end pieces and spacers on the module rail do not need to be undone.

Before the system is taken back into operation, the new Periph-
eral Interface Module PIM needs to be programmed with the cor-
rect node address and transmission rate. A programming printed
circuit board PAB 2-01 is required for this.
CAUTION

–08.2001– E 532 067 / 00 E


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Maintenance and repair
FRIEDRICHSHAFEN Page 197

Do not change electronic components when voltage is


applied!

De-energize the affected PIM before beginning work.


CAUTION

Set the node address and transmission


rate as follows:

13. Insert the programming cassette


SST 2-01 into the base module of the
Peripheral Interface Module PIM;
select the left slot if a PIM 2 module is
1 installed.
14. Four rotary switches on the program-
ming cassette are used to set the fol-
lowing:

2
 Node number of the PIM inside
the target system
 Baud rates for both the CAN in-
terfaces

Fig. 107 : Inserting programming cassette


SST 2-01
15. The significance and function of the
1 2 switches and LEDs of programming
cassette SST 2-01 are as follows:
(108/1) MPU 23
(108/2) Diagnostic LEDs
(108/3) S4 Baud rate 2nd CAN inter-
face
(108/4) S3 Baud rate 1st CAN inter-
face
(108/5) S5 Key “Programming start”
(108/6) S2 Node address 2nd digit
(108/7) S1 Node address 1st digit
7 6 5 4 3

Fig. 108 : Preparing programming cassette


SST 2-01

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Part 4
Maintenance and repair
Page 198 FRIEDRICHSHAFEN

16. The switches must be set depending


1 2 on the Peripheral Interface Module
PIM which has been replaced:
 LCU: =21.X+A001–A010 (109/2)
Transmission rate of both CAN inter-
faces 125 kilobaud,
node addresses must be determined
using the order-specific drawings and
adjusted accordingly
 LMU: =21.X+A001–A020 (109/1)
Transmission rate of both CAN inter-
faces 125 kilobaud,
node addresses must be determined
using the order-specific drawings and
adjusted accordingly

17. Start programming by pressing the S5


key (108/5); keep an eye on the dia-
gnosis LEDs:
If both yellow LEDs (108/2) light up,
programming has been successfully
Fig. 109 : Configuration of Peripheral
Interface Modules PIM completed.
If this is not the case, determine the
cause using the table and rectify.

LED 1 yellow
LED 2 yellow
LED 3 red
LED 4 green

Fig. 110 : Diagnostic LEDs on programming cassette SST 3-01

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Part 4
Maintenance and repair
FRIEDRICHSHAFEN Page 199

State of diagnostic LEDs Cause Rectification

LED 1 LED 2 LED 3 LED 4

During power up:

X LED 4 lit when operating voltage applied

– – X X No PAB 2 detected Check programming cassette is


correctly seated in the I/O housing

X X X Node address setting exceeds 31 Set node address as instructed

X X X Both baud rate switches set to 0 Set a valid baud rate at one of the
switches S3 or S4

X X Different baud rates set at baud rate Information only:


selector switches Identical baud rates for both
interfaces are standard on MTU
systems

On pressing the programming key:

Flash Flash – X Programming sequence running (dependent on version)

X X – X Programming executed without error

X X X X Programming could not be executed: Check settings, repeat programming


 No EEPROM inserted or hard- sequence
ware fault
Replace EEPROM if unsuccessful
 Programming error

X – LED lit
– – LED not lit
Empty field – Random LED state

This completes programming. The supply voltage now has to be switched off. The pro-
gramming cassette can be removed and the regular cassettes from the removed Periph-
eral Interface Module PIM can be inserted.

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Part 4
Maintenance and repair
Page 200 FRIEDRICHSHAFEN

4.4.7 Replacing the processor assembly of a Peripheral Interface Module


ID-No.: A-P-LOP-0025

Fig. 111 shows the structure of the two


MPU 23 PCB type 2 Peripheral Interface Modules PIM
in the Local Operating Panel with the four
PCBs. The position of the MPU 23 PCB is
the same for each PIM (slot 1); the other
three slots can be occupied by any combi-
Slot 1 nation of PCBs. The slot numbering
shown in fig. 66 is the same for all Pe-
ripheral Interface Modules PIM (fixed and
binding).

Module cassette

Fig. 111 : Position of PCB MPU 23

It is not necessary to remove the PIM module housing when changing a PCB.
Simply remove the module cassette containing the MPU 23 PCB by pulling it
out of the module housing.

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Part 4
Maintenance and repair
FRIEDRICHSHAFEN Page 201

Proceed as follows to change the MPU 23


PCB:

1. Pull the module cassette (112/1) out of


the module housing (see fig. 111).
2

Fig. 112 : Module cassette

2. Open the cover of the module cas-


sette as follows:
Insert a small screwdriver into the
recess (112/2) and lever open the
1 cover (113/1);
the cover (113/1) can then be folded
2 upwards.

Fig. 113 : Opening cover

3. Pull the MPU 23 PCB (114/1) up out


of the module cassette (114/2).

Fig. 114 : Pulling out the MPU 23 PCB

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Part 4
Maintenance and repair
Page 202 FRIEDRICHSHAFEN

Destruction by electrostatic charging.


(C)MOS components and assemblies equipped with (C)MOS
components may be destroyed by electrostatic charging.
Therefore:
 Ensure that personnel, tools and worktops are electrostatically
discharged by touching them with earthed metal parts before
they touch electronic components or modules.
CAUTION  Avoid touching electronic components or assemblies with non-
conductive materials.
 Do not change components or assemblies when the voltage is
switched on.

4. Select the new MPU 23 PCB from


spare parts stocks (observe type and
item number, see part 5 of this
manual).

1 The new MPU 23 PCB must


have been programmed using
3 the initial program loader
before it is used as a replace-
2 3 ment PCB (this is normally the
case if spare PCBs have been
ordered correctly).

5. Insert the new MPU 23 (115/1) into the


grooves (115/3) in the module cas-
sette (115/2); ensure that the PCB
(115/1) is straight.
Fig. 115 : Inserting MPU 23 PCB

6. Close the cover (116/1) of the module


cassette; ensure that it clicks correctly
into the housing of the module cas-
sette (116/2).

1 7. Reinsert the module cassette into the


corresponding module housing in the
correct position; ensure that the mod-
2 ule cassette is straight.

Fig. 116 : Closing cover

–08.2001– E 532 067 / 00 E


Part 4
Maintenance and repair
FRIEDRICHSHAFEN Page 203

The MPU 23 PCB now has to be programmed with the plant-specific data. The type and
method of programming used depends on whether the entire plant includes a PPS Pro-
grammable Process Station. If this is the case, the required data are downloaded automa-
tically after the plant operating voltage is switched on.

Reference Documentation:
In the case of plants which do not include a Programmable Process Station
PPS in the system, the data need to be manually downloaded using a BDM
Backup Data Module or a Display Panel DIS . The BDM tool and handling
instructions are described in the MTU documentation entitled “Backup Data
Module BDM for PCS-5 monitoring systems, Documentation Parts 1, 2, 5, doc-
ument no. E 531 718”. Downloading with the help of the ”DIS Display” is de-
scribed in the MTU document ”DIS Display, documentation parts 1–7, doc.
no. E 531 900”.

E 532 067 / 00 E –08.2001–


Part 4
Maintenance and repair
Page 204 FRIEDRICHSHAFEN

4.4.8 Replacing printed circuit board CIB 3


ID-No.: A-P-LOP-0026

The CIB 3 PCB is mounted on a mounting


plate in the housing using spacer pins.
Proceed as follows to remove it:
3 3 3

1. The cables (117/1 and 117/2) are con-


nected to the PCB by means of
soldered terminal strips; loosen the
1
screws with a small screwdriver and
2 pull out the cables from the two
terminal strips.
2. Pull off all the plug connectors (117/3);
some of the plug connectors do not
contain cables only jumpers; these
must also be pulled out and placed
aside for later use; these will be
required on the new CIB 3 PCB.

Fig. 117 : Cables and fixings in CIB 3 PCB

Grasp the plug connectors themselves to pull them out.


Never pull out the connectors by the cables.

CAUTION

3. Undo the fourteen hex nuts (117/3)


and remove together with the washer.

–08.2001– E 532 067 / 00 E


Part 4
Maintenance and repair
FRIEDRICHSHAFEN Page 205

Always make sure that no metallic parts (washers, nuts or similar)


fall into the housing and remain there. They may cause short-
circuits which will render the entire engine management system
inoperational.
CAUTION

4. Remove the CIB 3 PCB (118/1) from


the housing (118/2) by moving it for-
2 1 wards; to do this, first swivel the PCB
downwards and forwards (see fig.
118).
5. Insert a new CIB 3 PCB (observe item
number, see part 5 of this manual).
6. Fit the fourteen hex nuts together with
the washers and tighten them.
7. Reinsert all plug connectors with con-
nected cables into the correct (!)
sockets on the CIB 3 PCB; take parti-
cular care not to mix up the plug con-
nectors.
Each plug connector has its pin
number written on a sticker.
These numbers are also
printed on the board. This
ensures correct connector as-
signment.

Fig. 118 : Taking out CIB 3 PCB

E 532 067 / 00 E –08.2001–


Part 4
Maintenance and repair
Page 206 FRIEDRICHSHAFEN

Connectors may only be plugged in once correct assignment has


been checked.

CAUTION

8. Insert all connectors with jumpers (see


step 2.) into the corresponding
sockets on the CIB 3 PCB.
9. Insert the cables into the terminal
strips and tighten the terminals. The
cables have numbers; make sure they
are correctly assigned.

Once the CIB 3 PCB has been exchanged, the entire plant with
all connected systems (Monitoring and Control System MCS-5,
Remote Control System RCS-5) must be subjected to a compre-
hensive function check.
CAUTION

–08.2001– E 532 067 / 00 E


Part 4
Maintenance and repair
FRIEDRICHSHAFEN Page 207

4.4.9 Replacing 24 VDC relay


ID-No.: A-P-LOP-0027

24 VDC relays are replaced as follows:

1. Locate the defective relay; the arran-


gement from left to right is:
K1 – K2 – K3.
2 2. Note the colours and assignment of
the cables on the defective relay.
1 3. Undo the four cables (119/2) using the
special tool (119/1) and pull them out.
4. Insert a small screwdriver in the clip
(119/3) on the underside of the relay.
5. Move the screwdriver in the direction
indicated by the arrow and swivel the
relay away from the DIN rail.
3
6. Insert the new relay and clip it onto the
DIN rail.
Fig. 119 : Position of the relay 7. Connect the cable using the special
tool; ensure assignment is as step 2.

Risk of damage!
Opening the spring-loaded terminals on the terminal strip using
an unsuitable tool can damage the terminal in the relay.
Only use the actuating tool (119/1) !
CAUTION

When exchanging the right-hand relay (K3), ensure that the side cover plate is
removed from the old relay and fitted on the new relay.

E 532 067 / 00 E –08.2001–


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Maintenance and repair
Page 208 FRIEDRICHSHAFEN

(This page intentionally blank)

–08.2001– E 532 067 / 00 E


Part 5
Illustrated parts catalog
FRIEDRICHSHAFEN Page 209

Part 5

Illustrated parts catalog

E 532 067 / 00 E – 08.2001 –


Part 5
Illustrated parts catalog
Page 210 FRIEDRICHSHAFEN

5 Illustrated parts catalog

5.1 Introduction

This illustrated parts catalog forms the basis for spare parts orders.

This catalog consists of illustrations and their associated tables plus a cross-reference list.

The illustrations and tables in the catalog also assist when dismantling and re-assembling
the individual assemblies. The catalog therefore also includes certain parts not available
as spares.

Illustrations and tables

The headings of the illustration pages and the associated tables contain the following
information:
 EDITION (edition date)
 PAGE (page No.)
 PROJECT (project name)
 GAPL (group name in German) and
EGC (name in the foreign language)
 REFERENCE (Bill of Materials (BOM) No. for the part shown in the illustration).
 CATALOG (the parts catalog number)
 ILL. TABLE (four-digit illustration number)
 REG. NO. (six-digit registration number)

The contents of the main headings on the illustration pages and their associated table
pages differ only in their page numbers (PAGE). All other information is identical.

The row of headings on the table pages contains the following information:
 C/N Callout numbers in the illustrations crossreference to the
parts numbers and designations in the associated table.
The table’s callout numbers are in a rising numerical
sequence.
 PART NO. Use the part number for ordering spare parts.

– 08.2001 – E 532 067 / 00 E


Part 5
Illustrated parts catalog
FRIEDRICHSHAFEN Page 211

 DESIGNATION This space contains the exact part designation.


A part whose designation is intended to the right in this
column (indicated by preceding dots) is included in the
preceding part(s) (either less intended or not at all).
 Q/U Quantity required in unit at installation location.
 U/M Unit of measurement for the named part:
EA = Each KG = Kilogram MR = Meter
RL = Roll SE = Set
 FN Footnote with references for spare parts queries.
The most important footnotes are:
AB Only available as a complete assembly, repairs only possible at the
manufacturers.
KE Individual part not intended for delivery as a spare part.
KF A part that can be calibrated. When ordering, follow instructions in the
chapter, ”Ordering spare parts”).
NB Amount required by the customer.
 SUPPLEM. DES./ This column contains standardized part designations or
REMARKS manufacturer’s own designations for outsourced parts.
 ILL.-REG. This column gives the cross-reference to an illustration if
a component is illustrated separately on its own page.
 ITEM For in-house use by the manufacturer.

Cross-reference list

The cross-reference list includes all part numbers contained in the spare parts catalog.
The part numbers are sorted in a rising numerical sequence in the PART NO. column. In
addition, the DESIGNATION, ILL. TAB., REG. NO., C/N and, in some cases, the STOCK
NO. and PART NO. NEW are listed for each part number.

Modification service

No modification service is provided to inform about any part number changes taking effect
after completion of the illustrated parts catalog. We therefore recommend that you per-
sonally mark down any information about part number changes in the illustrated parts ca-
talog. This information can be found in the order confirmation and on the spare parts’ deli-
very labels.

E 532 067 / 00 E – 08.2001 –


Part 5
Illustrated parts catalog
Page 212 FRIEDRICHSHAFEN

Ordering spare parts

The following information is required in order to process a spare parts order:


 MTU order number
 Engine number and engine model (see nameplate)
 Part number
 Designation
 Quantity and unit of measurement

When ordering a calibrated part (marked by ”KF” in the ”FN” column), add the following
additional information:
 If the calibration No. is known (see part’s nameplate):
Add the calibration No., preceded by an oblique stroke, as an extension to the
part number (”/xxxxx”);
e.g.: 002 536 28 10/E1234.
Here, the extension ”E1234” would be the part’s calibration number on the
nameplate.
 If the calibration No. is not known:
Give a detailed description of the required part’s installation location by quoting
the complete Device Description code (e.g. ”= 37.1.1 + A022 – F003”) plus the
part number extension ”/77” (e.g. 500 536 28 10/77).
In this case, the calibrated spare part will be supplied under a new part number.
The Device Description is found on the nameplate at the part’s installation loca-
tion, or in the corresponding Wiring Diagram.

When ordering a non-calibrated adjustable part (marked by ”KF” in the ”FN” column)
which should not be calibrated by the factory:
 Add extension “/76” to the part number
(e.g. 002 536 28 10/76).

To avoid errors, please confirm all telephone orders in writing.

Delivery of repaired parts

Parts sent to MTU Friedrichshafen for repair must be clearly marked with the MTU order
number and engine number.

– 08.2001 – E 532 067 / 00 E


EDITION: 08.2001 CATALOG: E532067/00ED
PAGE: 213
FRIEDRICHSHAFEN
PROJECT: M094

5.2 Bildtafeln und Tabellen


Illustrations and tables
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 214 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

45,46,59,60 8
50
70 6
71
2,58

50 37,38
13 37,38 61
3,57
7,57 45,46
21 41,42,43 4,57
44

5
39,40

9,10
11 12
1
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 215 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

000 518 530 15 85 ZB WACHSTAND LOP1–06 001 EA KF 840042


CONTROL CONSOLE
01 500 533 98 02 .ZB GEHAEUSE LOP1–01 001 EA 840044
.HOUSING
02 5105381275/S0004 .DISPLAY DIS 5–01 001 EA 840046
.DISPLAY
03 5105306662/S0001 .ZB TABLEAU PAN1–01 001 EA 840048
.PANEL
04 5105306263/S0001 .ZB TABLEAU PAN3–01 001 EA 840050
.PANEL
05 510 533 13 40 .HALTER 004 EA 840052
.RETAINER
06 510 533 16 40 .UMARBEIT HALTER 001 EA 840054
.RETAINER
07 5105306662/S0002 .ZB TABLEAU PAN1–01 001 EA 840056
.PANEL
08 000 533 04 91 .KLEBEETTIKETT 38X6,3 004 EA KE 840058
.PHOTOPLATE NB
09 910001 003100 .NIET 002 EA KE AK 3,2X 7,49 N 10001 840060
.RIVET
10 700425 000032 .SCHILD 001 EA KE 31 MMN 425 840062
.PLATE
11 518 533 15 91 .SCHILD MDEC LOP 001 EA KE 840064
.PHOTOPLATE
12 700425 000121 .SCHILD 001 EA KE 64 MMN 425 840066
.PLATE
13 000 533 07 32 .GRIFF –GEHAEUSE 001 EA 840068
.HANDLE
21 518 533 14 91 .FOTOPLATTENSATZ 001 EA KE 840070
.PHOTOPLATE
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 216 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

Notizen / Notes
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 217 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

37 000 533 35 83 .ANBAUSTECKERGEHAEUSE 002 EA 840072


.CONNECTOR HOUSING
38 000 535 00 91 .SCHUTZKAPPE GR.16 002 EA 840074
.PROTECTIVE COVER
39 000 533 38 83 .ANBAUGEH. 42–P. 001 EA 840076
.MALE CONNECTOR
40 015 531 49 83 .SCHUTZKAPPE GR.10 001 EA 840078
.MALE CONNECTOR
41 008 531 50 83 .ANBAUGEHAEUSE 001 EA 840080
.CONNECTOR HOUSING
42 015 531 48 83 .SCHUTZKAPPE GR.6 001 EA 840082
.MALE CONNECTOR
43 015 531 47 83 .BUCHSENEINSATZ 6–P. 001 EA 840084
.MALE CONNECTOR
44 207985 004100 .LINSENSCHRAUBE 002 EA M 4 X 12 DIN 7985 4.8–H DBL 8454 840086
.FILLISTER SCREW
45 200125 004301 .SCHEIBE 030 EA A 4,3 DIN 125 140 HV – A4–70 840088
.WASHER
46 000934 004013 .SECHSKANTMUTTER 038 EA M 4 DIN 934 A4–70 840090
.HEX NUT
50 910001 003103 .NIET 004 EA KE AK 3,2X 10,67 N 10001 840092
.RIVET
55 000 531 19 81 .KABELSCHNELLBINDER 050 EA 840094
.CABLE QUICK BINDER TY–23 M
56 000 531 20 81 .KABELSCHNELLBINDER 050 EA 840096
.CABLE QUICK BINDER TY–24 M
57 510 533 08 80 .DICHTUNG PAN 003 EA 840098
.GASKET
58 510 533 05 80 .DICHTUNG DIS 001 EA 840100
.GASKET
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 218 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

Notizen / Notes
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 219 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

59 200084 004105 .ZYLINDERSCHRAUBE 002 EA M 4 X 16 DIN 84 A4–70 840102


.SCREW
60 000 533 44 41 .ABSTANDSHUELSE 002 EA 840104
.SPACER SLEEVE
61 200965 004000 .SENKSCHRAUBE 002 EA M 4 X 10 DIN 965 A4–70–H 840106
.COUNTERSUNK HD SCREW
62 000125 004317 .SCHEIBE 006 EA A 4,3 DIN 125 140 HV DBL 8451.11 840108
.WASHER
70 529 530 56 12 .ZB STECKK. COB9–01/A 001 EA 840110
.PLUG–IN BOARD
71 001 533 27 31 .STAUBSCHUTZKAPPE 001 EA 840112
.CAP
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 220 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

44,46 22,91 7 51,52


94,95,96,97

32 33

40
31
58

30 60
59,61
14
30 14

99
69
84 01
E00593
98 26
84,85

70
27
84 01
E00594

12 13
51,53,54
86,87,88,89 63,64

65,90 51,53,54

18,19,54 20 24 71 73 68 8 23 72 1 74
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 221 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

01 518 533 02 36 .ZB MONTAGEPLATTE 001 EA KE 840142


.PLATE
06 517 530 22 25 .ZB KABELBAUM LOP1–06 001 EA KE 840144
.WIRING HARNESS
07 500 533 41 89 .BESCHR.SATZ LOP1 001 EA KE 840146
.IDENTIFICATION PLATE
08 000 533 11 90 .SCHUTZLEITERZEICHEN 004 EA KE 840148
.PLATE
12 000 533 40 83 .RAHMEN F.STECKERGEH. 001 EA 840150
.CONNECTOR HOUSING
13 000 533 41 83 .RAHMEN F.STECKERGEH. 001 EA 840152
.CONNECTOR HOUSING
14 000 533 42 83 .RAHMEN F.STECKERGEH. 002 EA 840154
.CONNECTOR HOUSING
18 206797 003200 .ZAHNSCHEIBE 002 EA J 3,2 DIN 6797 A2–70 840156
.TOOTHED WASHER
19 207985 003108 .LINSENSCHRAUBE 002 EA M 3 X 16 DIN 7985 A4–70–H 840158
.OVAL–HEAD SCREW
20 000 533 34 76 .ISOLIERSCHEIBE 002 EA 840160
.WASHER
22 000 531 01 40 .DIODE 1N 4004 001 EA 840162
.DIODE
23 500 530 02 26 .ZB VARISTOR M.ANSCHL 001 EA 840164
.RESISTOR
24 500 530 03 26 .ZB DIODE M.ANSCHL. 002 EA 840166
.DIODE
26 528 530 39 69 .ZB INTERF.MODUL LCU 001 EA KF 84 01 840168
.MEASURE/MONITOR MOD E00593
27 528 530 40 69 .ZB INTERF.MODUL LMU 001 EA KF 84 01 840170
.MEASURE/MONITOR MOD E00594
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 222 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

Notizen / Notes
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 223 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

30 001 531 89 86 .SICHERUNG FK2 3,0A 002 EA 840172


.FUSE
31 001 531 90 86 .SICHERUNG FK2 4,0A 001 EA 840174
.FUSE
32 001 531 84 86 .SICHERUNG FK2 30,0A 001 EA 840176
.FUSE
33 504 530 74 97 .ZB STECKK. CIB 3–01 001 EA 840178
.PLUG–IN BOARD
40 500 530 07 24 .ZB GEHAEUSE ESD–MEM 001 EA 840180
.HOUSING
44 207985 004100 .LINSENSCHRAUBE 016 EA M 4 X 12 DIN 7985 4.8–H DBL 8454 840182
.FILLISTER SCREW
46 006797 004232 .ZAHNSCHEIBE 002 EA J 4,3 DIN 6797 DBL 8451.11 840184
.TOOTHED WASHER J4.3
51 002 531 57 81 .KABELB.BEFEST.SOCKEL 043 EA 840186
.BASE
52 504 96 .BLINDNIET 022 EA KE 840188
.BLIND RIVET
52 000000 000611 .LINSENSCHRAUBE 022 EA M 3 X 6 DIN 7985 A4–70–H 840190
.OVAL–HEAD SCREW
54 000934 003002 .SECHSKANTMUTTER 025 EA M 3 DIN 934 8 DBL 8451.21 840192
.HEX NUT
58 002 531 91 60 .RELAIS 12V–150A 001 EA AB 840194
.RELAY
59 200125 005300 .SCHEIBE 002 EA A 5,3 DIN 125 140 HV – A4–70 840196
.WASHER
60 207985 005101 .LINSENSCHRAUBE 002 EA M 5 X 12 DIN 7985 A4–70–H 840198
.SCREW
61 000934 005024 .SECHSKANTMUTTER 002 EA M 5 DIN 934 A4–70 840200
.HEX NUT
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 224 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

Notizen / Notes
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 225 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

63 910001 004107 .NIET 006 EA KE AK 4 X 7,87 N 10001 840202


.RIVET
64 510 533 08 34 .UA TRAGSCHIENE 334LG 002 EA 840204
.RAIL
65 005 531 59 81 .QUERVERBINDER 2–POL. 001 EA 840206
.INSTALL ACCESSORIES
68 004 531 00 81 .DOPPELSTOCKKLEMME 029 EA 840208
.TERMINAL BLOCK
69 004 531 52 81 .ENDHALTER SCHRAUBLOS 003 EA 840210
.TERMINAL
70 004 531 80 81 .ENDHALTER SCHRAUBLOS 004 EA 840212
.TERMINAL
71 005 531 49 81 .DOPPELSTOCKKL.4QMM 016 EA 840214
.TERMINAL
72 005 531 50 81 .ABSCHLUSSPLATTE 002 EA 840216
.TERMINAL BLOCK
73 003 531 58 81 .QUERBRUECKER 012 EA 840218
.INSTALL ACCESSORIES
74 003 531 59 81 .VERTIKALBRUECKER 001 EA 840220
.INSTALL ACCESSORIES
84 004 531 53 81 .ERDUNGSKLEMME GNGE 002 EA 840222
.TERMINAL
85 004 531 41 81 .ABSCHLUSSPLATTE 002 EA 840224
.END PLATE
86 004 534 60 10 .SCHUTZSCHALTER 8,0A 002 EA 840226
.AUTOMATIC CUTOUT
87 004 534 55 10 .SCHUTZSCHALTER 2,0A 002 EA 840228
.AUTOMATIC CUTOUT
88 000 531 16 41 .STECKSOCKEL–ADAPTER 004 EA 840230
.PLUG–IN ADAPTER
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 226 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

Notizen / Notes
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 227 EGC: 84 Monitoring equipment ILL. TABLE: 84 02
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 518 530 15 85 REG. NO.: E00603

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

89 000 533 09 30 .HALTEBUEGEL BR.3600 004 EA 840232


.MOUNTING BRACKET
90 002 531 85 60 .RELAISKOPPLER 24/4A 003 EA 840234
.RELAY
91 002 531 84 60 .LEISTUNGSRELAIS 30A 001 EA 840236
.RELAY
92 000 531 80 02 .WIDST. MK 2 10K 001 EA 840238
.RESISTOR
93 001 531 87 02 .WIDST. MK 2 121R 003 EA 840240
.RESISTOR
94 001 531 92 86 .SICHERUNGSHALTER 001 EA 840242
.FUSE
95 207985 005100 .LINSENSCHRAUBE 002 EA M 5 X 12 DIN 7985 4.8–H DBL 8454 840244
.OVAL–HEAD SCREW
96 000125 005322 .SCHEIBE 002 EA A 5,3 DIN 125 140 HV DBL 8451.11 840246
.WASHER
97 000934 005004 .SECHSKANTMUTTER 002 EA M 5 DIN 934 8 DBL 8451.21 840248
.HEX NUT
98 001 531 87 86 .SICHERUNG FK2 1,0A 001 EA 840250
.FUSE
99 001 531 88 86 .SICHERUNG FK2 2,0A 001 EA 840252
.FUSE
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 228 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 528 530 39 69 REG. NO.: E00593

3,4

27 01
E00468 5

7
1,2
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 229 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 528 530 39 69 REG. NO.: E00593

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

000 528 530 39 69 ZB INTERF.MODUL LCU 001 EA KF 840010


MEASURE/MONITOR MOD
01 528 530 19 83 .ZB MODUL PIM 2–03 001 EA 840012
.MODULAR SYSTEM
02 009 531 43 48 .IC EEPROM SER 8KX 8 001 EA KF 840014
.INTEGRATED CIRCUIT
03 5295308212/S0001 .ZB STECKK.MPU 23–03 001 EA 840016
.PLUG–IN BOARD
04 504 530 78 92 .ZB STECKK. CCB 1–01 001 EA 840018
.PLUG–IN BOARD
05 529 530 89 12 .ZB STECKK. SAB 1–02 001 EA 84 01 840020
.PLUG–IN BOARD E00468
06 529 530 88 12 .ZB STECKK. BIB 1–02 001 EA 840022
.PLUG–IN BOARD
07 504 530 98 92 .ZB STECKK. IIB 1–01 001 EA 840024
.PLUG–IN BOARD
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 230 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 529 530 89 12 REG. NO.: E00468

1
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 231 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 529 530 89 12 REG. NO.: E00468

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

000 529 530 89 12 ZB STECKK. SAB 1–02 001 EA 840006


PLUG–IN BOARD
07 001 531 76 86 .SICHERUNG 3,15A/F 004 EA 840008
.FUSE
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 232 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 528 530 40 69 REG. NO.: E00594

3,4

84 01
6 E00137

7
1,2
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 233 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 528 530 40 69 REG. NO.: E00594

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

000 528 530 40 69 ZB INTERF.MODUL LMU 001 EA KF 840026


MEASURE/MONITOR MOD
01 528 530 19 83 .ZB MODUL PIM 2–03 001 EA 840028
.MODULAR SYSTEM
02 009 531 43 48 .IC EEPROM SER 8KX 8 001 EA KF 840030
.INTEGRATED CIRCUIT
03 5295308212/S0001 .ZB STECKK.MPU 23–03 001 EA 840032
.PLUG–IN BOARD
04 504 530 78 92 .ZB STECKK. CCB 1–01 001 EA 840034
.PLUG–IN BOARD
05 529 530 93 12 .ZB STECKK. AIB 1–02 001 EA 840036
.PLUG–IN BOARD
06 504 530 72 92 .ZB STECKK. BOB 1–01 001 EA 84 01 840038
.PLUG–IN BOARD E00137
07 529 530 88 12 .ZB STECKK. BIB 1–02 001 EA 840040
.PLUG–IN BOARD
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 234 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 504 530 72 92 REG. NO.: E00137

1
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 235 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 504 530 72 92 REG. NO.: E00137

ORTZ SACHNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ. / SUPPLEMENTARY DESIGNATION BILD–REG. POS.–NR.
C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ILL.–REG. ITEM

000 504 530 72 92 ZB STECKK. BOB 1–01 001 EA 840002


PLUG–IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 005 EA 840004
.FUSE
EDITION: 08.2001 GAPL: 84 Überwachungseinrichtung CATALOG: E532067/00ED
PAGE: 236 EGC: 84 Monitoring equipment ILL. TABLE: 84 01
FRIEDRICHSHAFEN PROJECT: M094 REFERENCE: 504 530 72 92 REG. NO.: E00137

Notizen / Notes
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN
EDITION: 08.2001 PAGE: 237

5.3 Querverweisliste
Cross-reference list
Querverweisliste / Cross–reference list
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN 238
EDITION: 08.2001 PAGE:

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
000000 000611 LINSENSCHRAUBE 84 02 E00603 52
OVAL–HEAD SCREW
000125 004317 SCHEIBE 84 01 E00603 62 5310–12–174–7451
WASHER
000125 005322 SCHEIBE 84 02 E00603 96 5310–12–178–2567
WASHER
000 531 01 40 DIODE 1N 4004 84 02 E00603 22 5961–12–157–5658
DIODE
000 531 16 41 STECKSOCKEL–ADAPTER 84 02 E00603 88
PLUG–IN ADAPTER
000 531 19 81 KABELSCHNELLBINDER 84 01 E00603 55
CABLE QUICK BINDER
000 531 20 81 KABELSCHNELLBINDER 84 01 E00603 56
CABLE QUICK BINDER
000 531 80 02 WIDST. MK 2 10K 84 02 E00603 92
RESISTOR
000 533 04 91 KLEBEETTIKETT 38X6,3 84 01 E00603 08
PHOTOPLATE
000 533 07 32 GRIFF –GEHAEUSE 84 01 E00603 13
HANDLE
000 533 09 30 HALTEBUEGEL BR.3600 84 02 E00603 89
MOUNTING BRACKET
000 533 11 90 SCHUTZLEITERZEICHEN 84 02 E00603 08
PLATE
000 533 34 76 ISOLIERSCHEIBE 84 02 E00603 20
WASHER
000 533 35 83 ANBAUSTECKERGEHAEUSE 84 01 E00603 37
CONNECTOR HOUSING
000 533 38 83 ANBAUGEH. 42–P. 84 01 E00603 39
MALE CONNECTOR
000 533 40 83 RAHMEN F.STECKERGEH. 84 02 E00603 12
CONNECTOR HOUSING
000 533 41 83 RAHMEN F.STECKERGEH. 84 02 E00603 13
CONNECTOR HOUSING
000 533 42 83 RAHMEN F.STECKERGEH. 84 02 E00603 14
CONNECTOR HOUSING
000 533 44 41 ABSTANDSHUELSE 84 01 E00603 60
SPACER SLEEVE
000 535 00 91 SCHUTZKAPPE GR.16 84 01 E00603 38
PROTECTIVE COVER
000934 003002 SECHSKANTMUTTER 84 02 E00603 54 5310–12–144–6201
HEX NUT
000934 004013 SECHSKANTMUTTER 84 01 E00603 46
HEX NUT
000934 005004 SECHSKANTMUTTER 84 02 E00603 97 5310–12–156–4990
HEX NUT
000934 005024 SECHSKANTMUTTER 84 02 E00603 61
HEX NUT
001 531 76 86 SICHERUNG 3,15A/F 84 01 E00137 01
FUSE 84 01 E00468 07
001 531 84 86 SICHERUNG FK2 30,0A 84 02 E00603 32
FUSE
Querverweisliste / Cross–reference list
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN 239
EDITION: 08.2001 PAGE:

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
001 531 87 02 WIDST. MK 2 121R 84 02 E00603 93
RESISTOR
001 531 87 86 SICHERUNG FK2 1,0A 84 02 E00603 98
FUSE
001 531 88 86 SICHERUNG FK2 2,0A 84 02 E00603 99
FUSE
001 531 89 86 SICHERUNG FK2 3,0A 84 02 E00603 30
FUSE
001 531 90 86 SICHERUNG FK2 4,0A 84 02 E00603 31
FUSE
001 531 92 86 SICHERUNGSHALTER 84 02 E00603 94
FUSE
001 533 27 31 STAUBSCHUTZKAPPE 84 01 E00603 71
CAP
002 531 57 81 KABELB.BEFEST.SOCKEL 84 02 E00603 51
BASE
002 531 84 60 LEISTUNGSRELAIS 30A 84 02 E00603 91
RELAY
002 531 85 60 RELAISKOPPLER 24/4A 84 02 E00603 90
RELAY
002 531 91 60 RELAIS 12V–150A 84 02 E00603 58
RELAY
003 531 58 81 QUERBRUECKER 84 02 E00603 73
INSTALL ACCESSORIES
003 531 59 81 VERTIKALBRUECKER 84 02 E00603 74
INSTALL ACCESSORIES
004 531 00 81 DOPPELSTOCKKLEMME 84 02 E00603 68
TERMINAL BLOCK
004 531 41 81 ABSCHLUSSPLATTE 84 02 E00603 85
END PLATE
004 531 52 81 ENDHALTER SCHRAUBLOS 84 02 E00603 69
TERMINAL
004 531 53 81 ERDUNGSKLEMME GNGE 84 02 E00603 84
TERMINAL
004 531 80 81 ENDHALTER SCHRAUBLOS 84 02 E00603 70
TERMINAL
004 534 55 10 SCHUTZSCHALTER 2,0A 84 02 E00603 87
AUTOMATIC CUTOUT
004 534 60 10 SCHUTZSCHALTER 8,0A 84 02 E00603 86
AUTOMATIC CUTOUT
005 531 49 81 DOPPELSTOCKKL.4QMM 84 02 E00603 71
TERMINAL
005 531 50 81 ABSCHLUSSPLATTE 84 02 E00603 72
TERMINAL BLOCK
005 531 59 81 QUERVERBINDER 2–POL. 84 02 E00603 65
INSTALL ACCESSORIES
006797 004232 ZAHNSCHEIBE 84 02 E00603 46 5310–12–143–8990
TOOTHED WASHER J4.3
008 531 50 83 ANBAUGEHAEUSE 84 01 E00603 41
CONNECTOR HOUSING
009 531 43 48 IC EEPROM SER 8KX 8 84 01 E00593 02
INTEGRATED CIRCUIT 84 01 E00594 02
Querverweisliste / Cross–reference list
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN 240
EDITION: 08.2001 PAGE:

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
015 531 47 83 BUCHSENEINSATZ 6–P. 84 01 E00603 43
MALE CONNECTOR
015 531 48 83 SCHUTZKAPPE GR.6 84 01 E00603 42
MALE CONNECTOR
015 531 49 83 SCHUTZKAPPE GR.10 84 01 E00603 40
MALE CONNECTOR
200084 004105 ZYLINDERSCHRAUBE 84 01 E00603 59
SCREW
200125 004301 SCHEIBE 84 01 E00603 45
WASHER
200125 005300 SCHEIBE 84 02 E00603 59
WASHER
200965 004000 SENKSCHRAUBE 84 01 E00603 61
COUNTERSUNK HD SCREW
206797 003200 ZAHNSCHEIBE 84 02 E00603 18
TOOTHED WASHER
207985 003108 LINSENSCHRAUBE 84 02 E00603 19
OVAL–HEAD SCREW
207985 004100 LINSENSCHRAUBE 84 01 E00603 44
FILLISTER SCREW 84 02 44
207985 005100 LINSENSCHRAUBE 84 02 E00603 95
OVAL–HEAD SCREW
207985 005101 LINSENSCHRAUBE 84 02 E00603 60
SCREW
500 530 02 26 ZB VARISTOR M.ANSCHL 84 02 E00603 23
RESISTOR
500 530 03 26 ZB DIODE M.ANSCHL. 84 02 E00603 24
DIODE
500 530 07 24 ZB GEHAEUSE ESD–MEM 84 02 E00603 40
HOUSING
500 533 41 89 BESCHR.SATZ LOP1 84 02 E00603 07
IDENTIFICATION PLATE
500 533 98 02 ZB GEHAEUSE LOP1–01 84 01 E00603 01
HOUSING
504 530 72 92 ZB STECKK. BOB 1–01 84 01 E00137 000
PLUG–IN BOARD 84 01 E00594 06
504 530 74 97 ZB STECKK. CIB 3–01 84 02 E00603 33
PLUG–IN BOARD
504 530 78 92 ZB STECKK. CCB 1–01 84 01 E00593 04
PLUG–IN BOARD 84 01 E00594 04
504 530 98 92 ZB STECKK. IIB 1–01 84 01 E00593 07
PLUG–IN BOARD
504 96 BLINDNIET 84 02 E00603 52
BLIND RIVET
5105306263/S0001 ZB TABLEAU PAN3–01 84 01 E00603 04
PANEL
5105306662/S0001 ZB TABLEAU PAN1–01 84 01 E00603 03
PANEL
5105306662/S0002 ZB TABLEAU PAN1–01 84 01 E00603 07
PANEL
510 533 05 80 DICHTUNG DIS 84 01 E00603 58
GASKET
Querverweisliste / Cross–reference list
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN 241
EDITION: 08.2001 PAGE:

SACHNUMMER BENENNUNG BILDTAF. REG.NR. ORTZ VERSORGUNGSNR. SACHNR. NEU


PART NO. DESIGNATION ILL. TAB. REG.NO. C/N STOCK NO. PART NO. NEW
510 533 08 34 UA TRAGSCHIENE 334LG 84 02 E00603 64
RAIL
510 533 08 80 DICHTUNG PAN 84 01 E00603 57
GASKET
510 533 13 40 HALTER 84 01 E00603 05
RETAINER
510 533 16 40 UMARBEIT HALTER 84 01 E00603 06
RETAINER
5105381275/S0004 DISPLAY DIS 5–01 84 01 E00603 02
DISPLAY
517 530 22 25 ZB KABELBAUM LOP1–06 84 02 E00603 06
WIRING HARNESS
518 530 15 85 ZB WACHSTAND LOP1–06 84 01 E00603 000
CONTROL CONSOLE
518 533 02 36 ZB MONTAGEPLATTE 84 02 E00603 01
PLATE
518 533 14 91 FOTOPLATTENSATZ 84 01 E00603 21
PHOTOPLATE
518 533 15 91 SCHILD MDEC LOP 84 01 E00603 11
PHOTOPLATE
528 530 19 83 ZB MODUL PIM 2–03 84 01 E00593 01
MODULAR SYSTEM 84 01 E00594 01
528 530 39 69 ZB INTERF.MODUL LCU 84 01 E00593 000
MEASURE/MONITOR MOD 84 02 E00603 26
528 530 40 69 ZB INTERF.MODUL LMU 84 01 E00594 000
MEASURE/MONITOR MOD 84 02 E00603 27
529 530 56 12 ZB STECKK. COB9–01/A 84 01 E00603 70
PLUG–IN BOARD
5295308212/S0001 ZB STECKK.MPU 23–03 84 01 E00593 03
PLUG–IN BOARD 84 01 E00594 03
529 530 88 12 ZB STECKK. BIB 1–02 84 01 E00593 06
PLUG–IN BOARD 84 01 E00594 07
529 530 89 12 ZB STECKK. SAB 1–02 84 01 E00468 000
PLUG–IN BOARD 84 01 E00593 05
529 530 93 12 ZB STECKK. AIB 1–02 84 01 E00594 05
PLUG–IN BOARD
700425 000032 SCHILD 84 01 E00603 10
PLATE
700425 000121 SCHILD 84 01 E00603 12
PLATE
910001 003100 NIET 84 01 E00603 09
RIVET
910001 003103 NIET 84 01 E00603 50
RIVET
910001 004107 NIET 84 02 E00603 63
RIVET
Querverweisliste / Cross–reference list
PROJECT: M094 CATALOG: E532067/00ED
FRIEDRICHSHAFEN 242
EDITION: 08.2001 PAGE:

Notizen / Notes
Appendix Page 243
FRIEDRICHSHAFEN

Appendix

E 532 067 / 00 E –08.2001–


Page 244 Appendix
FRIEDRICHSHAFEN

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–08.2001– E 532 067 / 00 E


Reference documentation Page 245
FRIEDRICHSHAFEN

Reference documentation

Refer to the following MTU manuals for detailed information on the individual assemblies
associated with and used in Propulsion Control System PCS:

E 531 685 Engine control unit ECU 4 (4000) Parts 1, 4, 5, 7


E 531 691 Engine control unit ECU 4 (2000) Parts 1, 4, 5, 7
E 531 686 Engine monitor EMU 1 Parts 1, 4, 5, 7
E 531 689 Gear control unit GCU 1 Parts 1, 3, 5
E 531 690 Gear control unit and monitor GCU/GMU 1 Parts 1, 3, 5
E 531 712 PCS-5 with FMEA Part 1
E 531 693 System description PCS-5 (4000, Ship main drive) Part 1
E 531 730 System description PCS-5 (2000, Ship main drive) Part 1
E 531 989 System description ECS-5 (4000, On-board equipment) Part 1
E 532 025 System description ECS-5 (2000, On-board equipment) Part 1
E 531 900 Display panel DIS 5 Parts 1, 2, 3, 4, 5, 7
E 531 649 Operator display PAN Parts 1, 2, 3, 5, 7
E 531 439 Printed circuit board catalog MCS-5 Part 1
E 531 718 Backup Data Module BDM Parts 1, 2
E 531 438 Dialog unit Part 1

E 532 067 / 00 E –08.2001–


Page 246 Reference documentation
FRIEDRICHSHAFEN

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–08.2001– E 532 067 / 00 E