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Quick User Guide


Alphatronic 2000
Propulsion Control System

'rif^r

Alphatronic 2000 PCS

MAN B&W Diesel

Alphatronic 2000 propulsion control system


AT2000 - PCS

Quick user guide

Alphatronic 2000 PCS

Alphatronic 2000 PCS

MAN B&W Diesel

Introduction
The Alphatronic 2000 Propulsion Control
System - AT2000 PCS Is used for remote
control of the ships propulsion line, including
a diesel engine connected to a controllable
pitch propeller (CPP) through an optional reduction gearbox, with optional clutch control
for the main engine clutch. The system may
also be interfaced to a shaft generator.

The AT2000 PCS is operated by means of


setpoint handles and standard AT2000 PCS
panels with build in four lines display.
The overall structure of the system can be
seen on fig 1.

Figl
Main Control Station
(Center)

Bridge Wing
Krw

Bridge Wing

nicn

L^
Operator
Panel (*)

Operator
Panel

ES

TK:

Ship's
Alarm
System

Diagnosis

nrtA

>|

iES

rncT

Operator
Panel

Engine Control R o o m

Slart/Slop Remote/Local

Remote
Control
System

Clutch In/Out, Remote/l-ocal


Pitch Set
Operator
Par
'anel

Aloha =cmm
Monitnnng
(ACM-E)

MJJuphcated

Alptiacomm
Safety
(ACS)

TKliifl

Netjrork

d
Shaft Generator
/PMS

Mr Press.

Sei lal

Handles
Interface

Bridge

Operator
Panel (*)

ES: Emergency Stop


BU: Back-Up Control

-U nmk

Auxiliary Control
Equipment

Coordinated
Control
System

Propeller Pitch
Closed Loop
Control Box
I Back-up
Pitch

m i

Alphacomm
Momtonng
(ACM-GP)

tJL^
Engine R o o m

Serial

Propulsion Control System, AT2000 PCS layout


for a four-stroke engine using AT2000-LMCS

Release Intro

page 3

Alphatronic 2000 PCS


The AT2000 PCS may be serially connected
to the engine mounted system called Alphatronic 2000 LMCS (Local Monitoring, Control and Safety system). This system is
transferring information about shut down
conditions to the PCS. Values from sensors
for load reduction are also transferred via
the serial connection.

Main engine load reduction


Combinator control from a single
handle in the ECR and on the bridge
Controllable pitch propeller (CPP) setpoint (combinator curves)
Control transfer between the bridge
and the ECR

Alternative hard-wired or serial connection


to the engines safety system may apply.

Propulsion mode selection (combinator, constant rpm and separate mode)

The AT2000 PCS will take care of the following functions:

Clutch engage and disengage (if a


clutch is fitted)

Main engine start and stop

Main engine setpoint (combinator,


constant rpm and separate mode)

Main engine load control (load control


limitations)

Interface to PTO connected shaft generator


Bridge wing control using follow-up
control on the manoeuvring handles

page 4

Release Intro

Alphatronic 2000 PCS

MAN B&W Diesel

Manoeuvring panels for remote control of engine


and propeller
For operation of the ships propulsion line,
the PCS is connected to PCS operator panels on the bridge and in the engine control
room (ECR). The manoeuvring panels include a handle for thrust commands, the
propulsion control panel (PCP), instruments
for propeller rpm and pitch indication and in
addition an emergency stop push button.

stopping is independent of the remote control system.


The instruments showing propeller rpm and
pitch are independent of the remote control
system.
A light dimmer is fitted in the instrument unit.
This will control the intensity of the illumination inside the manoeuvring handle, the instruments and the push buttons below the
manoeuvring handle.

The emergency stop push button will immediately stop the main engine. This way of
Fig 2
Propeller indicator panel
PIP

'
r

a
\

PROPELLER

STOP

'

PROPELLER

>

^ \
/

<

* ^Z

~ "E
Propulsion Control System

Alphatronic2000

0 ^=

DDD

=- -=

rrnn
ir ir in

DO
Propulsion control panel
PCP

DHD
DSD

(
V
\

'

y
^

BACKUP
CONTROL
ONfOFF

CONTROL

TAKE
COMTROL

Manoeuvre handle panel


MHP

PCS panel common for all control locations

Release Description

page 5

Alphatronic 2000 PCS


Manoeuvring handle panel operations

General operation at the propulsion control panels

Once the engine is running and clutched in,


a movement of the manoeuvring handle will
result in a corresponding thrust on the ship.

The propulsion control panel (PCP) is the


operator's interface when interacting with
the engine, the clutch and the propeller.

Normally, the propeller pitch is controlled via


the remote control system (Alphatronic
2000 PCS), and thereby offering an optimized propulsion using different combinator
curves and limitation functions.

A normal sequence before sailing, would be


that the engine staff will prepare the engine
for operation, start the engine and then
transfer the responsibility to the operator on
the bridge. The operator on the bridge will
then clutch-in the propeller and move the
manoeuvring handle in orderte start moving
the ship.

However, should the remote control system


be out of order, it will still be possible for the
operator on the bridge to control the propeller thrust by pushing the push button
"BACK-UP CONTROL ON/OFF". This will
immediately by-pass the remote control
system, without a significant change in the
propeller thrust. The control can be given
back to the remote control system by pushing the same push button again.

Starting of the engine can be done by two


keystrokes. First activate "MACHINERY
CONTROL" and then the soft-key "START
ENGINE". If the engine does not start, this
may be caused by a start blocking, preventing the engine from starting if not all condition are fulfilled to start. The engineer will
then investigate the problem, using the display and the keys of the PCP. For operations
possible at the PCP, please refer to the following chapter.

Fig 3
Propulsion Control System

WAINTENAHCE

STOP
HORN

Alphatronic 2000

ACCEPT

LOAD
REDUC

S1

CANCEL

s;

LOAD
REDUC.

LOAD
RESTRICT
CANCEL

SHUT
DOWN

S2

ENCINE
CONinOL
ROOM

SEPARATE

LOCAL
CONTROL

BRIOCE

CONST.
SPEED

1
i

COMBINATOR

CANCEL
SHUT
DOWN

RESET
SHUT
DOWN

ACHINERV
CONTRO

RESET
LOAD
REDUC

Propulsion control panel

page 6

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

AT2000 PCS operator panel


The PCS operation from ECR and bridge
panels is similar, and made by means of
softkeys, where the function is displayed on
the 4-line display, and operated by means
of four keys [ S1 ] - [ S2 ] - [ S3 ] - [ S4 ].
Control right for PCS control functions
It is always possible to view the information
on the display, independent of the present
control location.
The softkeys on the different PCS control
functions are only working on the PCS panels, which are in control. Activation of the
softkeys, for a PCS control function on a
panel, which is not in control, will activate the
buzzer for a short time, to tell the operator
that the operation, which he is trying to execute, is not allowed at the moment.
Basic mode overview display on PCS
panel
The basic mode overview display shows the
status for the available, requested and
actual power, for the propulsion system.
Basic mode is the display selected, when
the [ESC] key is pressed one or more times
from another display, until the outermost
level is reached.

Line 3:
Indicating actual power output to the propeller. Bargraph and digital value.
Line 4:
Showing the oldest unacknowledged alarm,
or the number of alarms when all are acknowledged. In addition showing if any
alarm channels are suppressed.
Setpoint system alignment
When the operators are changing the control position between ECR and bridge, this
bargraph display for aligning the setpoint
levers is automatically displayed.
ALIGN BRIDGE AND ECR HANDLE
BRIDGE CDM:
X HI
ECR CDM:
X

90 %
0%

If the operator want to remove this display,


because eg an alarm shows up, this can be
done by pressing the [ESC] key, or by activating any other hardkey, which when activated will change the display.
Flashing when unacknowledged alarms are
present in the PCS, steady light indicates
that all present alarms are acknowledged.
Extinguished when all alarms are gone.

DISPLAY (Shown in basic mode)


nuniLPiGLE
llllllllllllllllllll
POUER DEMRND l l l l l l l l l l l l l l l l l
nCTUflL POUER l l l l l l l l l l l l l l l l
OLDEST UNflCKNOULESED RLflRM

ioo^
83^:
^''

Line 1:
Indicating available power. Bargraph and
digital value.

Connected to mechanical over-load switch


on the fuel rack. This indicator is operating
independently of the propulsion control system.
Indicates that there is a fault inside the panel
itself or in the communication to it.

Line 2:
Indicating power demand from active
handle. Bargraph and digital value.

Release Description

page?

Alphatronic 2000 PCS


BUZZER SOUND inside panel
Steady:
A new alarm has appeared in the PCS.
2 beeps:
Indicates that a Bridge / ECR change-over
is in progress.
1 beep:
Indicates a wrong operation, ie the l<ey
pressed is not allowed in the present condition.

Press the up, down, left and right arrows to


move the cursor on the display to select a
specific function.

Press the ENTkey to select/accept a choice


Press the key to stop the buzzer.

Press the key to acknowledge new alarms.


Only alarms visible in the display can be acknowledge.

Press ESCape to discard a choice or to


move one level out in the menu / soft key
structure. Push several times to get to the
outermost level (Basic mode on the display).

Press the appropriate key to activate the


soft-key function on line 3 & 4 on the display.
Lamp: Indicates that the maintenance function is active.
Key:

Press to activate the maintenance


function. Used for troubleshooting
and advanced adjustments. A list of
pending alarms is also found under
this key.

Light dimming, down and up. Collective


function for lamp indicators, background
light in keys and backlight in display. Individual adjustment (balancing of the three
groups) is possible under the maintenance
key.

page 8

ENGINE
CONTROL
ROOM

Lamp: Flashing when change-over to ECR


control is requested from the bridge
panel. The flashing continues until
acknowledgement has taken place
and the handles on the bridge and in
the ECR are aligned. Changes to
steady light indication that ECR control is active.
Key:

Press the key to request or to acknowledge ECR control. The request must be acknowledged with
the corresponding key on the receiving panel.

Release Description

Alphatronic 2000 PCS

Lamp; Flashing when changeover to bridge


control is requested from the bridge
panel. The flashing continues until
acknowledgement has taken place
and the handles on the bridge and in
the ECR are aligned. Changes to
steady light indicating that bridge
control is active.
Key:

Press the key to request bridge control. A request must be acknowledged with the corresponding key
on the receiving panel.

LOCAL
i CONTROL

Lamp: On the bridge panel, the local indication is flashing if the control position
is taken from bridge control to local
control. Steady light indicates that
local control is active.
Key:

On the bridge panel, the key must be


pressed to accept the Bridge to local
take-over.

Lamp: On when separate mode is selected


Key:

MAN B&W Diesel

Lamp: On when combinator mode is selected


Key:

Press to select combinator mode.


Not possible if running in constant
speed mode with a shaft generator
connected.

Lamp: Steady light indicates that a shut


down is active. Flashing light indicates that a cancellable shut down
sensor has exceeded its limit, but
that the shut down is presently suppressed.
Key:

Press to display the shut down


status list.

Lamp: Flashing during the prewaming time


for a cancellable shut down to indicate that it can be cancelled. Steady
light indicates that the automatic
shut down function is cancelled.
Key:

Press to select separate mode. Not


possible if running in constant speed
mode with a shaft generator connected.

Press the key to cancel shut down.


Press it again to remove.

Lamp: Flashing when reset is possible.


Key:
Lamp: On when constant speed mode is
selected
Key:

Press to reset the shut down memory. It is necessary to reset all shut
downs before the engine can be restarted.

Press to select constant speed


mode.

Release Description

page 9

Alphatronic 2000 PCS

LOAD
: RESTRICT
CANCEL

Lamp: Indicates that a load reduction is active.


Key:

Press the load reduction key to display the load reduction status list.

Lamp: Flashing indicates that a load restriction in the PCS is active. Steady light
indicates that the load restrictions
are cancelled.
Key:

Lamp: Flashing during the prewarning time


for a cancellable load reduction to
indicate that it can be cancelled.
Steady light indicates that the automatic load reduction function has
been cancelled.
Key:

Press the key to cancel a load reduction. Press it again to remove.

Press to activate the load restrictions cancel function. Press it again


to remove.

MACHINERY
1 CONTROL

Lamp: Indicates that the machinery control


function is selected.
Key:

Press to activate the machinery control function and use the soft-keys
S1 - S4 for continued operation.
Please refer to fig 4.

Lamp: Flashing when it is possible to reset


the load reduction memory.
Key:

Press to reset the load reduction


memory.

page 10

Depending on options for the actual plant,


some softl<eys and the corresponding functions, may be missing.

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Machinery control softkeys


Fig 4
o
MACHINERY
CONTROL

SELECT DIRECT COMMAND:


|S|CLUTCH
111 OUT

|S|CLUTCH
|2|IN

|S| START
|3| ME

|S| MORE
|4|

SELECT CONTROL GROUP:


|S|SEPERAT
|1|RP^SET

|S|START/
|2|ST0^

|S|GEAR &
|3|CLUTC

|S| MORE

See page 12

See page 16 for


optional gear and
clutch functions

SELECT CONTROL FUNCTION:


|S|
111

SG
IF_

|S(THRUST
jZICLUICH

THRUST CLUTCH
<Mode>
<Feedbacl<>
|S|DIS|SI ENGAGE
|1|ENGAGE
|2|

ME SG INTERFACE

|S|
|4|

SG PTO STATUS
CONSTANT SG REQUEST
CONSTANT SG FEEDBACK
DG STANDBY START
MAINTAIN SPEED REQ

ME START/STOP
<Mode
> <Runstat>
|S| STOP
|S| START
1
ME
2 ME
|S|CANCEL
JSICANCEL
|2|STR.BLK
HI OFF

<Interlnk>
|S| RESET
|3|

STANDBY
OFF
OFF
OFF
OFF

800 rpm
|S|CANCEL
|S| MORE
3 SLOWTRN. 4
RESET
MORE

SET SEPERATE RPM


SEPARATE RPM SETPT.

789

SET SEPARATE RPM


ME RPM FEEDBACK
>SEPARATE RPM SETPT.
NEW VALUE:+0000789

777 RPM
789 RPM
10000]

RPM

ENT

0;

Functions under the push button "MACHINERY CONTROL'

Release Description

page 11

Alphatronic 2000 PCS


Fig 4 (continued)
MACHI-A
NERY

|S| ME
|l|CON1jtOL

| S | MORE

| S | MORE

141

14

|S|STATUS
|2|LIST,

|S| I/O
|S| MORE
|3|ADJUS'fe |4|

r^

SELECT CONTROL OBJECT:


|S|CPP INP
IllADJUST
|S|BRG PIT
|1|LEVER

|S|CPP OUT |S|60V OUT


12[ADJUST
I3IADJUST
|S|ECR PIT |S|
|2|LEVER
|3|

iSI MORE
|S| MORE

SELECT CONTROL OBJECT:

SI START
111 BLOCK
ISI LOAD
II CONTROL
|S|CH. AIR
lljCONTROL

|S|CPP
|2|CONTROL
PTI
|S|SHUT121 SOWN

|S|GOVERI3IN0R
|S| SET131 POINT
|S|LOAD
|3|REDUC.

|S| MORE
|S| MORE
141
n
|S| MORE
|4|

SELECT CONTROL FUNCTION:


|S|LOAD
IIICONTROL

|S I FINEADJ |S|TACHO
|2|RPM
|3isYSTEM

- ^ See page 13

ML

- ^ See page 14
-^-

See page 15

Seepage 17 for optional functions for


plants with PTI

HI

ME TACHO SYSTEM:
|S|SELECT
jlJTACHOl

RPM FINE ADJUST


<FadjStat>
760
|S|FINEADJ |S|FINEADJ
UILOWER
|2|RAISE

|S|SELECT
|2|TACH02

|S|AUTOSEL
|3iTACH0

765
|S| RESET
|3|

RPM
|S|

SET MAX LOAD


MAX ENGINE LOAD

100.0;

SET MAX LOAD


ACTUAL ENGINE LOAD
MAX ENGINE LOAD
NEW VALUE:+00088.0

89.3 %
100.0%
100.0]

|S| RESET
|4|

141

ENT

50.0;

Functions under the push button "MACHINERY CONTROL'

page 12

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Fig 4 (continued)
MACHI-a
NERY

MORE

[STATUS
I LIST,

MORE

|4|

SELECT CONTROL OBJECT:


|S|START
|l|BLOg(
|S|LOAC
111 CONl^OL
|S|CH. AIR
1 CONT ROL

|S|CPP
12 CONTSpL
|S|PTI

Jli
|S|SHUT
I2IS0MN

|S|G0VERI3IN0R ,
|S| SET|3|POINT
|S|LOAD
13 REDUC

|S| MORE

J4L
|S| MORE
141
|S| MORE

141

See page 14
-

GOVERNOR INTERFACE
ME RPM FEEDBAACK
GOVERNOR SETPOINT
SP.DROP COMPENSATION
GOVERNOR STOP ON
CANCEL LIMITS ON

PITCH CONTROL
CONTROL MODE
MODE
FEATHER CTRL INTRLOK
PITCH FEEDBACK
PITCH COMMAND
PITCH MIS ALIGNED
CRP BOOSTER PUMP
ZERO PITCH
FEATHER POS. INPUT
FEATHER POS. CONTROL

START BLOCKINGS
READY TO START
START BLOCKED
START BLOCKED CANCELLED
LOCAL CONTROL
SHUT DOWN
START/FAIL
SLOWTURNING FAIL
TURNING GEAR ENGAGED
ENG. LOCAL CONTROL
CPP oil press low
CPP pitch not ZERO
Shaft locking device
Start air press low
Main start valve
Control air press
Safety air press
Exh. valve Ctrl air
Aux. blowers ready
Disconnecting device
Gear lub oil press.

See page 15

799 RPM
800 RPM
22 RPM
OFF/ON
OFF/ON

REMOTE
ONLINE
<Interlk;>
100%
100%
NORMAL
STOPPED/STARTED
ON/OFF
OFF/ON
NORMAL/ALARM

ON/OFF
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON

Functions under the push button "MACHINERY CONTROL'


Status lists

Release Description

page 13

Alphatronic 2000 PCS


Fig 4 (continued)
o
MACHI-<
NERY

|S|

MORE

|S|STATUS
|2|LIST.

MORE

SELECT CONTROL OBJECT:


|SISTART
111 BLOCK
|S|LOAD
|1|C0N1R0L
ISICH. AIR
IIICONIROL

|S|CPP
|2[CONTROL
|S|PTI
|2| m
|S|SHUT
I2IS0WN

|S|GOVER|3|N0R
|S| SET|3|P0INT
|S|L0AD
I3IREDUC

|S| MORE

ML
|S| MORE
|4|
|S| MORE

SETPOINT SYSTEM
BRIDGE PITCH SETPNT.
ECR PITCH SETPOINT
BRIDGE RPM SETPOINT
ECR RPM SETPOINT
SELECTED SETPOINT
ADJUSTED SETPOINT
ME MAINTAIN SPEED
ME FIXED SPEED REQ.
ME SG CONNECTED
Bridge centre
Bridge wing port
Bridge wing starboard
Bridge aft

PTI CONTROL
PTI LOAD CONTROL
PITCH REQUEST
LOAD CTRL. PITCH OUT
SG MOTOR LOAD LIMIT
SG MOTOR MAX LOAD
SG MOTOR ACTUAL LOAD
DG LOAD LIMIT
MAX DG LOAD
DGl ACTUAL LOAD
DG2 ACTUAL LOAD
DG3 ACTUAL LOAD
DG4 ACTUAL LOAD
DG5 ACTUAL LOAD
PTI CONTROL MODE
PTI CONTROL MODE
LOAD CONTROL
STATUS
PITCH REQUEST
LOAD CTRL. PITCH OUT
MAX ENGINE LOAD
ACTUAL ENGINE LOAD
ACTUAL FUEL INDEX
SEL. LOAD PROGRAM
LOAD PROGRAM STATUS
LOAD PROGRAM OUTPUT
RPM LIMITER STATE
RPM LIMITER OUTPUT
ME RPM
CHARGE AIR LIM STATE
CHARGE AIR LIM OUTP
CHARGE AIR PRESSURE
LOAD REDUCTION STATE
LOAD REDUCTION LIMIT

See page 15

100.0%
100.0%
0-800 RPM
0-800 RPM
0-800 RPM
0-840 RPM
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON

NO LIMIT/SG/DGx LIMIT
+/- 100 %
+/- 100 %
NO LIMIT/LIMITED
0-100.0 %/A/kW
0-100.0 %/A/kW
NO LIMIT/DGx LIMIT
0-100.0 % of max
0-100.0 %/A/kW
0-100.0 %/A/kW
0-100.0 %/A/kW
0-100.0 %/A/kW
0-100.0 %/A/kW
<MODE>
<STATUS>

NO LIMIT
100.0%
100.0%
0-110.0%
0-110.0%
0-100.0%
NORMAL

MIN
60-100.0%
LIMIT OFF/ON
0-100.0%
0-800 RPM
LIMIT OFF/ON
0-100.0%
0-3.20 bar
OFF/ON
40.0%

Functions under the push button "MACHINERY CONTROL'


Status lists

page 14

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Fig 4 (continued)
o

MORE

MACHI-a
NERY
CONTROL

|S| MORE
|4|

|S|STATUS
|4|LIST

SELECT CONTROL OBJECT:


|SISTART
111 BLOCK
SI LOAD
|1|C0NTR0L
|S|CH. AIR
111 CONTROL

|S|CPP
12[CONTROL
|S|PTI
|S|SHUT
21 SOWN

|S|GOVER|3|N0R
|S| SET|3|POINT
|S|LOAD
I3IREDUC

|S| MORE
|S| MORE

Mi
|S| MORE
141

LOAD REDUCTION
LOAD RED. PREWARNING
LOAD REDUCT. ACTIVE
LOAD RED. CANCELLED
L.O. TEMP INLET
H.T. C.W. TEMP INLET
H.T. C.W. TEMP OUTL
THRUST BEARING TEMP
MAIN BEARINGS TEMP
EXH. GAS DEVIATION

SHUTDOWN
ACS: SHO PREWARNING
ACS: SHD ACTIVE
ACS: SHD CANCELLED
ACS: EMERGENCY STOP
ACS: OVERSPEED
ENG. LUB. OIL PRESS
ENG. H.T. WATER PRESS
ENG. H.T. WATER TEMP
ENG. OIL MIST DENSITY
GEAR LUB. OIL PRESS

CHARGE AIR CONTROL


CHARGE AIR PRESSURE
CHARGE AIR TEMP
TURBO CHARGER RPM

OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON

OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON

0-4.00 bar
0-150.0 deg.
0-40000 RPM

Functions under the push button "MACHINERY CONTROL"


Status lists

Release Description

page 15

Alphatronic 2000 PCS


Fig 4 (continued)

SELECT CONTROL FUNCTION:


ISIPTO
ISISG/PTO
|S|THRUST
|3|INTE^F.
|2|CLUy:H
lljCLIfCH

iS|DISCON.
UIDEVICE

DISCON. DEVICE:
<Mode>
<:Feeclbacl<>
|S|DIS|S|ENGAGE
|1|ENGAGE
|2|

PTO/SG INTERFACE
SG PTO STATUS
CONSTANT SG REQUEST
CONSTANT SG FEEDBACK
LIM.VAR SG REQUEST
LIM.VAR SG FEEDBACK
DG STANDBY START
MAINTAIN SPEED REQ

PTO CLUTCH:
<Mode>
<Feedback>
|S|DIS|S|ENGAGE
|1|ENGAGE
|2|
THRUST CLUTCH:
<Mode>
<Feedbacl<>
|S|DIS|S|ENGAGE
|1|ENGAGE
|2|

Functions

page 16

<Interlk>
|S|RESET

|3|

<Interlk>
|S|RESET

|3|

|S|
|4|

I
NOT READY
OFF
OFF
OFF
OFF
OFF

OFF

<Interll<>
|S|RESET |S|
|3|
W\

|S|
|4|

under the push button "iVIACHINERY


Optional gear and clutch functions

CONTROL'

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Fig 4 (continued)
MACHI-
NERY
CONTROL

MORE

| S | MORE
|4|

| S | ME
|l|CONTi)L

SELECT CONTROL OBJECT:


|S|LOAD
UICONTROL
|S|FINEADJ
iljCONTROL

PTI CONTROL
<Mode>
<Status>
|S|PTI
|S|PTI
jljSTOP
|2|START

|S| PTI
|2|CONyOL
|S|TACtjO
12[SYST EM

|S|PTI
|3|ADJUT

|3|

|S| MORE
|4|
|S| MORE
m

0-100.0 %
SG LOAD
|S|RESET
|S|
|3|
|4|

II

ME PTI
0-1200 kW
0-100.0 %

SG MOTUK HMA LUHU

_MAX DG

ENT

LOAD

ENT
PTI CONTROL

MAX DG LOAD
NEW VALUE:+

88.0

0-100.0%
0; 110.0]

''
PTI
SG
SG
NEW

CONTROL
MOTOR ACTUAL LOAD
MOTOR MAX LOAD
VALUE:+
1200

0;

89.3 %
100.0%
32000]

Functions under the push button "MACHINERY CONTROL'


Optional functions for plants with PTI

Release Description

page 17

Alphatronic 2000 PCS

page 18

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Troubleshooting
If you have problems with Alphatronic 2000
PCS, we ask you to write down all values in
the status list when the failure is present.
Please see pages 13 and 15 before you contact our guarantee or service department.
We can be contacted at the following address.
MAN B&W Diesel A/S
Niels Juels Vej 15
9900 Frederikshavn
Denmark
Service department:
Phone during office hours: +45 9620 4100
24 hour service: +45 2040 6059
Telefax: +45 9620 4040
Email: service.alpha@dk.manbw.com
Guarantee department:
Phone during office hours: +45 9620 4100
Telefax:+45 9620 4100
Email: guarantee.alpha@dk.manbw.com

Release Description

page 19

Alphatronic 2000 PCS


Your notes

page 20

Release Description

Alphatronic 2000 PCS

MAN B&W Diesel

Your notes

Release Description

pagG 21

Alphatronic 2000 PCS

Your notes

page 22

Release Description

MAN B&W Diesel A/S


Niels Juels Vej 15
9900 Frederikshavn
Denmark
Telephone +45 96 20 41 00
Telefax +45 96 20 40 30
Alpha@manbw.dk
www.manbw.com

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


Reproduction permitted provided source is given
Subject to modification in the interest of technical progress
xxx/x.x QB Status (January) 2005 - printing reference

Screw pumps
A Member of the
COLFAX PUMP GROUP

ACE3

l\/laintenance and Service


Instruction

This instruction is valid for all ACE pump models shown on page 2
Contents
Page

CO

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List of components
Exploded view
Ordering code/Service intervals
Sectional view
Useful tools/Shaft seal-assembly drawing
Dismantling/ reassembly
Pressure relief valve/SealGuard

2
3
4
5
6
7
11

Before commencing any work, read this instruction carefully! Failure to comply with
these instructions may cause damage and personal injury!

For more information about the pumps identification code, technical data and performance we refer to the
ACE Product description. For niore information about the pumps installation, Start-up and trouble shooting
w e refer to the IMO Installation and Start-up instruction for Low Pressure Pumps.

List of components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: D3/K3/L3/N3
V
Also valid for pump options: AlOl
N
With version codes:
T
The version code is composed of the letters in the 4 columns.
Q
Example of pump designations std: ACE 025L3 NTBP;
option: ACE 038N3 NVBP AlOl
Components included in spare parts sets:
Pos
no
1010
1020
113
122
125
201
202
351
401
416
417
418

Denomination

Power rotor
Power rotor
Key
Bail bearing
Secondary seal
Idler rotor
Idler rotor
Balancing bush
Pump body
Suction flange
Screw
Gasket to
423 suction flange
Gasket to
427 discharge flange
440 Discharge flange
451 Return valve
453 Screw
462 Screw
462A Plug
463 Sealing washer
463A Plug
501 Sealing washer
506 Front cover
509 Gasket
537 Shaft seal
537A Deaeration plug
551 Washer
556 Rear cover
557 Gasket
557A Plug
605 Washer
608 O-ring
608A Valve spindle
6120 Tension pin
613 Set screw
614 Pin
615 Valve piston
7310 Valve spring
732 Compl. Seal
Guard
Gas generator

Q-ty GOll G012 G050 G053 G054 G057 G070 G082 Notes
X

(X)
X
X
X
X

X
X

GOll: Rotor set


G012: Rotor set
G050: Shaft seal

(X)
X
X

X
X

Explanations:

G053: Minor kit


G054: Major kit

1
1
4
4
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1

G057: Joint kit

G070: Valve element


G082: Seal Guard kit
Notes:
1) Version NTBP
andNQBP

2) Version NQBP
only
3) Including
Gasgenerator

www.imo.se

2,3

CO

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Exploded view

509

xVxx
453

(605)
(608)
(6120)

125

7310

501

xQxx

xTxx, xQxx

731

xQxx

Fig.l

work carried out on the pump has to be


performed in such a manner that risks for
A All
personal injury are observed!
When handling liquids that may harm skin

A use gloves and/or protective clothing.


any maintenance work, ensure that
the driver is deenergized and the pump
A Before
hydraulically isolated.

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<

handling liquids which may involve


A When
fire hazards appropriate precautions to
avoid danger are to be taken.
In case of failure for a system with elevatA ing
pressure fluid jets may cause injury
and/or damage.
leakage may make the floor slippery
A Oil
and cause personal injury.

and disconnecting of electric


cables must be done only by personilel
A Connecting
authorized to do such work.

www.uno.se

Ordering code
Part numbers for pump size
Item Spare Parts sets
025
032
038
G012 Rotor set CW-rotation (std)
Low lead-L3
190486 190485
190482
Low lead-K3
Normal lead-N3
190487 190484 190483
192698
Highlead-D3
GOll Rotor set CCW-rotation
Normal lead-N3
190492 190491 190488
189964 189964 189964
G050 Shaft seal-xVxx
190495 190495 190497
Shaft seal-xTxx
190495 190495 190497
Shaft seal-xQxx
G053 Minor kit-xVxx
190501 190710 190500
Minor kit-xTxx
190503 190712 190499
Minor kit-xQxx
190503 190712 190499
G054 Major kit=G012(G011)+G053+G070
190525 190714 190522
G057 Joint kit-xVxx
190524 190713 190523
Joint kit-xTxx
190524 190713 190523
Joint kit-xQxx
189873 189873 189873
G070 Valve element
190526 190526 190527
G082 Sealguard-kit xQxx
125 Secondary seal xTxx, xQxx 190469 190469 190468
190530 190530 190530
732 Gas generator xQxx

Recommendation:
For maintenance the following spare
part sets are recommended:
Set:
To be used:
G057
Joint kit
For dismantling the pump.
G053
Minor kit
For service.
G054
Major kit
For repair after damage or greater
wear.
Ordering example:
For IMO-pump ACE 032N3 NVBP,
serial number 456789:
Shaft seal pos G050 p / n 189964
Valve element pos G070 p / n 189873

Service intervals

Inspection of shaft seal

The intervals for inspection and replacement of wear


parts vary greatiy with the properties of the pumped
Uqiiid and can only be determined by experience.
Pumping liquid which contairis abrasive materials,
or liquid that is corrosive, wiU significantly reduce
service life and call for shorter service intervals.
Wear will normally show as unnormal:
Vibration
Noise
Loss of capacity
Reduction in flow/pressure
Leakage

Excessively leaking shaft seals (more than 10 drops


per hour) should be changed without delay, as the
leakage normally wiU grow worse and cause additional damage.
In installations where unplanned shut downs must
be avoided, it is advisable to dismantle the ptunp for
a thorough inspection and thereby change out shaft
seal and ball bearing, every three years as a max
period.
It is recommended always to have the spares included in minor spare part kit available.

If the pumps operating temperature exceeds

let the pimip cool off before any service,


A 60C
maintenance or dismantling work is commenced to avoid bum injury.

Inspection of rotors
A quick inspection of the idler rotors can be made
simply by removing the rear cover. Note that the
driver must be deenergized and the pump hydraulically isolated before the rear cover is removed.
If a more thorough investigation is needed, proceed
as under "Dismantling/Reassembly".

CD

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Sectional view

451 125 (xTxx, xQxx) 113

(613)

440

501

509

506

(614) (615) (608A) 6000 (608) (6120)


122 351 (112) 401

C-C

ni

\j\

(xQxx)
CO

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Fig. 2

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www.uno.se

1020

202

556

551

Useful tools
o

"^

^
Allen key
O
tine
5 mm and
emery
3 mm
D
D= 25,5 mm Screw
Plastic
Screw
driver
mallet
spanner
16 mm

rrr

Oil can
Mounting tool kit

Tooll
Tool 2
For dimension and material,
please contact IMO AB Service.

Sliding calliper

Fig. 3

Shaft seal - assembly drawing


Shaft seal G050 (509)
Version code xVxx
51 Seat
52 O-ring
S4 Seal ring
56 O-ring
57 Spring unit
58 Stop screw

Front
cover
retaining
tab

Stationary member

S3

S2

SI

Rotating member

S4 S7

S6

S5

Seat slot

Stationary member

S8

Version code xTxx


51 Seat
52 O-ring
53 Retainer
54 Seal ring
55 Carrier
S 6 O-ring
57 Spring unit
58 Stop screw
+ Secondary seal 125

Rotating member
Version code xQxx
xTxx + Complete
SealGuard 7310

S4, S7 is one unit

Fig. 4

www.imo.se

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Dismantling

Turn the electricity OFF.

B.
^^^

Close the valves.


Remove the ptunp
from the system.
ATTENTION
Use appropriate vessels to collect oil spillage when removing and opening the pump.
Fig. 5

Note the position of the shaft coupling.


Release the stop screw.
Fig. 6

Remove the shaft


coupling.
Fig. 7

Fig. 8

E.

F.
451

to

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* Remove the
screws 451.
Fig. 9

Remove the front cover 501 and power


rotor 1020.
Fig. 10
v^rww.uno.se

G.

H. xTxx and xQxx

501-

Separate the front


cover 501 and the
power rotor 1020.

Remove the secondary seal 125 with a


suitable screw driver.
Fig. 12

Fig. 11

Place the front cover 501 on a pair of


wooden pieces.
Press out the shaft seal, stationary member
with a suitable tool.
Fig. 14

Fig. 13

K. xTxxandxQxx
Rotating
Member
Insert two suitable
screw drivers in the
carrier S5 slots and
gently push the
rotating member
S4, S7 off the rotor
shaft.
Loosen the two
stop screws S8
(3 nrni AUen key)
on the carrier S5
and pull it off.

Remove and inspect the


idler rotors 202.
O

Fig. 16

Fig. 15
8

v^rww.mio.se

8
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Reassembly

B.

A.

Un-pack a new shaft seal 509.


S8

Fig. 17

Fig. 18
Oil can

D. xTxx and xQxx

PoHsh the power rotor shaft


1020 with a fine emery and oil.
Fit the carrier S5 tight against the
ball bearing. Make sure the carrier
is not fitted upside down.
Firmly tight the two stop screws S8.
Lubricate the O-ring S6 in the rotating member with oil.
Press the rotating member S4, S7
genuy on to the rotor shaft and make
sure the driving lugs enters the slots
in the carrier S5.

Polish the power rotor shaft


1020 with a fine emery and oil.
Fit the rotating member above
the baU bearing 122 and lock it
with its stop screws S8.
Fig. 19

Fig. 20

E.

F. xTxx and xQxx

1
1020^

401

Tooll

y ^

Uo

(d

Insert the Power rotor 1020 into the pvimp


body 401.

Press the Secondary


seal 125 in place with
a suitable tool in two
steps as shown. Use a
column drill machine
as a press tool.
NOTE!
501
Tool nr 2 has
one end for sizes
025,032 and one
end for size 038

CD

S4,S7
Check that the O-ring S6 is in place.

Lubricate the idler rotors 202


and fit them into the pump body 401.
Lubrication groves tiurning downwards.

Fig. 21

xTxx, xQxx

Fig. 22

www.imo.se

Rotating
member

G. xVxx

H. xTxx and xQxx

Tooll

^
Fit the spring unit S7 in place.
Note the position for the Seat
slots and lugs.
(See fig 4.)

Fit the retainer S3


in place. Note the
position for the
retainer lugs and
cover slots.
(See fig 4.)

Lubricate the O-ring


S2 and put it on the
seat SI. Fit the seat
SI on top of the
spring unit. Watch
position of the Seat
slots and lugs.
(See fig 4.)
Press the seat gentiy into the recess in the
front cover 501 with a suitable tool as
shown.
Turn the front cover 501 up-side down. The
seat shall now remain in the cover.

Lubricate the
O-ring S2and
put it on the
seat SI. Fit the seat SI
on top of the retainer.
Watch the position of the seat
slots and lugs. (See fig 4.)
Press the seat gently into the recess in the
front cover 501 with a suitable tool as shown.
Turn the front cover 501 up-side down. The
seat shall now remain in the cover.
Fig. 24

Fig-23

/.
451

501-

506

Replace the gasket


506.
Carefully fit the
Front cover 501 on
the pump.
Fig. 25

501

506

Fit the screws


451.
Tight them crosswise,
step by step to avoid
deformation on bearing
outer ring and seal
damages.
Turn the shaft to check
that it moves without
too much force.
Fig. 26

L
Press on the shaft coupling
to its original position.
Tighten the stop screw.
Install the p u m p
back into the
system and proceed
according to insfructions under
"Start-up" in the
Installation manual.

u
Fig. 28

www.imo.se

CO

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Pressure relief valve

f-'"

553

ATTENTION |
Spring tension.

CR??
Release spring tension by turning set screw 6120
CCW as much as possible.
Loosen and rentove the screws 453.
Separate the valve element from the rear cover
551.
If necessary, replace the gasket 556 and the
O-ring 605.
Reassemble the parts in reverse order. Be careful
to tighten the screws 453 crosswise.
Readjust the valve pressure according to the
"Installation and Start-up Instruction for IMO
Low pressure pumps".

/" ' ^ N

\
^6320

^3^1

^605

/p^^S?

-556

Vig. 29

SealGuard
Version code N Q B P

Recharging
1) Discormect the pipe connector (4) from the
dispenser (2). Remove the check valve (3).
2) Remove the cover disk (10). Remove the gas
generator (9) from the dispeitser (2) with a 21
mm socket. Dispose the generator in the recycling system for batteries, where available. Push
the piston to its "filled" position, and fill the
dispenser with high-temperatiu-e resistant engine
0. Fit the check valve (3) and the cormector (4)
to the dispenser.
3) Feed o into the hose (5) and seal compartment,
for example with an oil-fiUed grease gun. Reconnect the hose (5) to the connector (4).
4) Fit a new gas generator (9) to the dispenser (2).
Tighten with approx. 2 Nm. Clip on the cover
disk (10).
5) Turn the gas generator set knob (3 mm AUen
key) to no. 6 which will make the oil last for
about 3 months.

ATTENTION
The SealGuard can be
readjusted or switched off
during operation.
Depending on temperature
and setting, it can take from
hours to a couple of days
after starting, until oil is
being dispensed.

For more information about


SealGuard, read the Installation and start-up Instruction
for SealGuard.

NOTE!
For longer periods of stand-by, the gas generator set-knob could be set to zero to avoid
unnecessary oil consumption.
/K
^^

Keep away from open fire when


removing the gas generator.
Fig. 50

ta

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<

www.imo.se

11

A Member of the
COLFAX PUMP GROUP

www.imo.se

IMG AB:

P. O. Box 42090, SE 126 14 Stockholm, Sweden


Telephone: +46 8 50 622 800, Telefax: +46 8 645 1509

Screw pumps

E4

A Member of the
COLFAX PUMP GROUP

Maintenance and Service


Instruction

This instruction is valid for aU E4 pump models shown on page 2

CO

Contents
List of components
Exploded view/Ordering code
Service intervals
Inspection of shaft seal, rotors, O-rings, ballbearing
Sectional view
List of tools/Dismantling
Reassembly

Page
2
3
4
4
5
6
9

F.

E.

509
\ 'S ^

g> W

514

1 / ^^:=:Y
\

K^

jf^^^^

\ x T ^ / ^ rJ J
^^5~YP>
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11

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Replace the retaining ring 514.

Fit a new shaft seal 509. If necessary use a


mounting sleeve.

Fig. 19

Fig. 20

^'

H.

"V
>

HV501
\^(|

^-^"^^^-S) y

Protect the edge


y ^ <^
with tape in order
not to damage the seal.

Place the p u m p body

upright.

Fit the gasket 506.

Fit the connecting frame I501 carefully in


order not to damage the i adiaJ seal 509.

Fit the screws 451/451A and tight them


carefully crosswise in several sequences.

Remove the tape.

Fit the key 113.

Fig. 21

1
^=^

506

^
^

Press the connecting frame 501 onto the


p u m p body.

Fig. 22

10

www.mio.se

Sectional view
E4
509
506

122 124

1030

501 514 124A 463 463A

401 102 202

451/451A

E4xxTE
:

E4xxJE
:

489A
382
489
025-045

E4xxBE
052-060

556 453A, 551


453

Fig. 2
CD

www.iino.se

070

G.
509
/ \

506-

Remove the shaft seal 509 as shown on the


sketch.
Remove the gasket 506.
Fig. 10

Fig. 11

K.

I.

124

/^

124A

V I V/

s
o

M/nl/'"^*/^ -^ ,'TC-

CM

PuU out the rotor set by holding one hand


vmdemeath.

Inspect the rotors and separate them.

Fig. 12

IIj)
^

Remove the retaining ring 124 and the support ring 124A.

Fig. 13
122

^^^V~5v

<
O

Remove the ball bearing 122 with a puller.

Q
tu

Fig. 14
8

www.mio.se

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Exploded view

1030

xxJE

*Excluded in size 070


Fig.l

Ordering code
Pes
no
G102

Part nuinbers, siz es


Spare part sets
Pump element CW rotation
Normal lead - p u m p N l
Low-lead
- pump K l
- pump LI

025

032

140483

140509

140491

140517

038

045

052

060

070

140525
140533

140541
140558

140566
140574

141051
141069

141077
141085

G031

Bearing element

144170

144170

144188

144188

144188

144196

144204

G050

Radial seal
Version codexRxx
"
xVxx

128009
188840

128009
188840

107680
.173690

107680
173690

107680
173690

107680
173690

107680
173690

Joint kit

144212

144212

144212

144220

144238

144246

144253

G055

Recommendation
Every shut down for service of a plant is costly. The
time for repair should therefore be limited to a minimum, ^^Jich can be accomplished by keeping a spare
pump. The changed pximp can later be repaired and
then become the spare pump.

Spare part sets:


G055 Joint kit: for dismantling of the pump.
p ^ ^ p element: for repair after^damage or greater
^
wear.

www.imo.se

. - ^ "

/lifo

Pump

A Member of the
COLFAX PUMP GROUP

www.imo.se

IMG AB:

P. O. Box 42090, SE 126 14 Stockholm, Sweden


Telephone: +46 8 50 622 800, Telefax: +46 8 645 1509

MANUAL FOR

CORROSION CONTROL

SHAFT E A R T H I N G DEVICE
With mV - meter

EDB No.: 53 950 0


Copyr.^h:: B.KC Conos:on Control .\ S
G: manualer shaft -jrouncins manual shatt aroundin

BAG CORROSION CONTROL A / S


Frvej 7 - 9 DK-4681 Herflge Danmark
telephone ^45 7026 8900 telefax ^45 7026 9700
e-mail: iP.fobacbe.''a.dk web-site: www.bacbera.dk

SHAFT EARTHING DEVICE


Without Amplifier
This system is a precautionary measure installed in
order to reduce the electrical potential between the
propeller shaft and hull to below 80 mV, and thus
prevent spark erosion damage to the main bearings
and journals of the main engine. (A reading
between 5 and 50 mV is considered as normal).
1. The system consists of the following main
components:

On haft noK, vlu*i


sanV
On haft nensat Tvla. a-8.V

,>>*-'-K<;^

A. A silver alloy slip ring is mounted on the


intermediate shaft.

B. Brush holders with silver/graphite brushes.


C. Grounding wire and grounding plate.
D. Monitoring box with mV-meter and alarm
output (optional).
The silver/graphite brushes are running on the slip
ring. The two earthing brushes are connected to the
hull through the grounding wire and the grounding
plate welded to the hull. The monitoring brush is
connected to the monitoring box.
2. Functioning and checking of the
earthing/measuring device.
The meter normally reads 150 mV atfixllscale. If
readings are above 150 mV, push the bottom on
the front of the meter. The meter will now read
1500mV atfiillscale.
The meter is at rest. When the shaft is turning at
sea, a readings of between 5 and 80 mV indicates
proper grounding, although readings below 50
mV should be obtained with clean and properly
contoured brushes.

lltiPlna * ^ P*Mt* ''*d button.


Inrtrunant futt raodlng la ne
tOM i*V.
Eatlnot. taat vatua> tea-4enV.

''HW
I

SHAFT EARTHING DEVICE


Readings of "0" when the shaft is turning at sea,
indicates a defective millivoltmeter or loose or broken
cable connections.
Checking the earthing device must be done when the
shaft is rotating at sea and should be carried out once a
month.
Release the earthing brushes from their contact with
the slip ring, this should give high pulsating voltages
of 100-400 mV reading on the meter. This indicates
that the measuring circuit is in order. When the
brushes are brought back to contact with the slip ring,
the reading should fall below the 80 mV limit. You
can also read the result on the computer
It is impotant that the silver/graphite brushes are
moving correctly in the brush holders with a spring
load of 500-600 gr.
In some cases the copper lead on the brush will
corrode, so it is recommendable to coat this lead with
grease.
It is recommended that the readings of the
millivoltmeter be recorded once a day in the engine
logbook.

r
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1

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;

', TEST

;i

i
atT

rnj-i.
f :X.isxv'xsiHfTJ:

BAC Corrosion Control A/S


SHAFT-KUU, M!U.IVOI,><ET!:B

ASSV

FOR fKArrCBOUSUl.VJj
^
>?^v^,t

k*r ^\^^^

!JM.;;
.:=L-.; . t

. .

re

. o:

,:^ ...

b!u
r-- *i^
WM.

fB.4Cl
SHAFTS
OO

(iiit*f)a F rf

SLIP RING SYSTEM


General Data:
Detailed description:
A. Slip ring.
Silver alloy band, 63,5 mm wide and approx. 100 mm longer that the circumference of the shaft.
B. Holding straps.
The permanent holding straps are made of Stainless Steel.
C. Brush holder.
The cast bronze brush holder is designed to support the brushes at the right angle to the shaft.
D. Brush.
The brushes are made of Silver/Graphite.
Installation instructions.
A. The slip ring usually located about 450 mm in front of the shaft coupling.
B. Draw a line around the periphery of the shaft.
Install the two holding straps. Strap "A" next to and parallel to the scribe line and strap "B" 125
mm away and parallel to the first.
C. Sand the area on the shaft between the two straps, until a bright steel surface appears.
D. Starting with the 45 end, wrap the silver band around the shaft so that the excess overlaps the 45"
angle. Mark the edges, scribe a line between them and cut.
E. Secure the silver band loosely on the shaft, utilizing strap "C" in the center on the band. Before
tightening the clamp, put a small piece of vinyl tape under the screw clamp for protection of the
surface. Place the vinyl tape on both edges of the silver band, using the outside edge as guide.
F. Install strap "A" and "B" on the vinyl tape and tighten with a screwdriver. Remove strap "C" and
the vinyl tape from the center of the band. Apply two layers pressure sensitivity tape on each strap,
leaving an 2 'A cm wide uncovered area of silver band.
G. Construct a rigid foundation to support the brush holder shaft.
H. Assemble the brush holders and connect the wires.
I. The total resistance of the cable from the brush holder to the hull must not exceed 0,005 ohm.

MAINTENANCE OF SHAFT-GROUNDING SYSTEMS

1. Always keep the system clear of dust, grease and water.


2. When cleaning the silver bands of grease and dust, an Electrocleaner should be used.
3. When polishing the silver bands, use the glass brush, which is delivered with the system.
Never use abrasive cloth, file or other abrasives.
4. Once a month (or when needed) clean the brushes and brush boxes of dust, because the
dust can cause the brushes to stick in the brush box and thereby cause a bad connection
between the silver band and the brush.
5. The spring pressure of the brushes should be 500-600 gr.
6. Make sure that there is always a good electrical contact at all screw- and boltconnections.
7. Make sure that the earthing plate is in welded connection with the hull all the times.

Hin. 40mm

' V U-profile
120x05x7x9
or equel.

Min 96mm
Ifax 120mm
INSTAUATION INSTRUCTIONS:
1. Silver alloy band to be mounted, away from bearings, and not
exposed to water, and where it is easy to service.
3. The shaft is grinded to a clean surface, and degreased, so that the
electrical resistance is minimized as much as possible.
3. The silver alloy band is degreased on the rear aide and laid on.
4. The grounding plate is welded on the hull as close to the
brush holders as possible.
5. The shaft for brush holders is welded on, in such a way, that
the least vibrations possible will occur, and so that it is
arranged In parallel with the propeller shaft.
6. The distance between the brush holders and the silver band
alloy should be 2 - 3 mm.
7. The spring pressure on the brushes is 500-600 g.
8. The projecting ends of the shaft can be cut of.

BAC Corrosion Control A / S


ttttM. No.:

GENERAL INSTAUATION INSTRUCTIONS


FOR SHAFT GROUNDING
CAP Mo.!

S7iP4.g'

Q 0 1 0 6 l B * C >.!

gg-lQg

Iglgg.gj KSTTfT JS_

eM.vrlht SAC CrK^lor. CMtrol A/S

App. by:

(BAC

EE

WHO hr.

AvMbraboliaa M, DK-Zteo Bftdom. Phe:-)' MmMOO. Hxt

fciV. una JIL


fSTK

44F-1

M^^l^
Bfr^MN W f= 98B-g7

MTinn, t-OMtt: laioeiHMbwt.dk

ON

AvedBreholmen 86, DK-2650 Hvidovre. Phone:+45 36770600, Fax:+45^772367,

infottbacbera.dk

POS.

BAC
PAKT No.

CUENT
PAKT No.

Q'ty

DESCRIPTION

CHECK

Voltmeter lor shaft-bull potential difference


whitout amplifier for alarm.
Voltmeter for shaft-bull potential difference
incl. amplifier for alarm.

539171

1 pes.

2
3

539172

1 pes.

539170

1 pos.

539184

1 roU

El tape 33+

539185

1 roU

Pressure sensitive tape

539180

3 pes.

Pernxanent holding straps in St. steel,


12.5mm x 0,7mm x (shaft) O.D.

539182

3 pes.

Bandtlghtener in St. steel,

539264

4 pes.

St. steel shaft 12.5 x 200mm

539255

2 pes.

Brass shaft holder

10

539252

1 pes.

Brass bushing for shaft

11

539253

1 pos.

ISO bushing for shaft

12

539450

1 pes.

Bronze brush holder, single

13

539400

1 pes.

Bronze brush holder, double

14

539460

3 pes.

Brush box

15

539105

3 pes.

Silver graphite brush

16

539230

1 pes.

Grounding plate.

17

523502

2 pes.

Cable 3 5

18

526354

2 pes.

SSmm" cable socket irith 10mm. hole.

19

526352

2 pes.

35nim cable socket itith 8mm hole.

20

520600

2 pes.

Cable 6

21

526060

2 pes.
3 pes.

6min cable socket with 8nun hole.


Spare silver graphite brash (85% Ag)
Reeommende snare parts (option)
Logside

Silver aUoy band for shaft

(90% silver and 10% copper)

(85% Ag)

L=3m.

L=3m.

22

539105

23

539305

25 pes.

24

539125

1 pes.

Glass brush

25

539300

6 pes.

Manual for amplifier

26

539301

6 pes.

Manual without amplifier

BAC Corrosion Control A/S

Rev. Date: 1 0 . 0 2 . 9 4
CAD No.:

BAC No.:

00103

12.10.93

Copyright: BAC Corrosion Control A / S

-1

Drawing No.;

PART-LIST FOR
SHAFT-GROUNDING
Date;

BAC
(43-501E1)

23-103
Draw, by;

FC

App. by:
EE
Witness, by:

Rev. No.;

01

File No.:

38A-62

Scale;
1 : 1
Replacing File No.:

Avedereholmen 86. DK-2650 Hvidovre. Phone:+45 36770600, Fax:+45 36772387.E-maU; infobacbera.dk

F o r M6

Kabelsko skal vre fortinnet


Kabel skal vre tinloddet.
Cablelog to be t i n p l a t e d .
Cable to be tin soldering.

o
ru

4 m m 2 bld k o b b e r l e d e r
4 m m 2 soft

copperconductor

'
i

20

12, 5

Design c u r r e n t / b r u s h m a x lOA, or 0,04A pr. m m 2


Design b e l a s t n i n g / k u l m a x lOA, or 0,04A pr. m m 2

BAC Corrosion Control A/S


Drawing No.:

Silver graphite b r u s h
Ag 80%
Slvkul
Kev. Date: 0 6 . 0 5 . 9 6 Date:

05.07.95

CAD No.:
00107
BAC No.: 5 3 9 1 0 5
Copyright: BAC Corrosion Coatrol A/S
h^lmor, AR TtV-CRf^n

BAC
23-107

Draw, by:

FC

Rev. No.:

01

File No.:

44A-24

App. by:
EB?--, Scale:
1 : 1
jVfitness. by:
\()/ |Replaeing File No.: 4 2 A 5 5

U^riAr,-aTo Phnr>..*d?i nR77nRna

F - v + . i S nR77?.^R7

KrnniV i n f o O h a c h R r a r

Option 2
Alarm
Option 3

Option 1

m^

Monitoring b r u s h

Shp ring
Propeller

shaft

Bonding b r u s h

Option 3
Sensor m o d u l e
Main hull s t r u c t u r e

BAC Corrosion Control A / S


Principdiagram for montage
SHAFT-GROUNDING with mV/A
Date:

15.05.95

BAC

Drawing No.:

23diagram2
Rev. No.:

01

Bray, by:
FC
FUe No.:
App.
by:
E
E
Scale:
CAD No.:Diaeram2|BAC No
1 : 1
Witness, by:
Copyright: BAC Corrosion Controkl A/S
Replacing File No.:
Avedareholmen 86. DK-2650 Hvidovre. Phone:+4.5 36770600 PT:-!-4.'i :^677aryi7 F.-mftiUnfoaharhftr HV
Rev. Date:

DRAW UNE ON SHAFT


Locate a point on shaft epproz.
460saia from edge of oeupling.
Draw a lia from this point perpendicular to axis of shaft.

1.: Uount ciamps *A* and 'ET on shaft.


This edge of elamp
*A' against drwm line.
Clamps to be parallel.

2.: Clean area between clamps to


bore steel. Entire surfac to
be shiny.

F:\00\l0\101\fluft9

10

FORM SILVERBAND

1.: Starting with 45" cut end, irrap silyer


aUoy band around shaft betreen clamps
with edges perfectly aligned. Uark both
edges of band. Overlap at 45* cut aa shown.

Silver aUoy band

Remove silver alloy band, scribe a line


between the two marks and cut.

V.^

<f/
4/

/^

///

/}

/y

UOUNT SILVER ALLOY BAND


1.: Mount silver alloy band loosely on
shaft between clamps.
2.: Uount damp 'CT to center of band.

Tighten clamp, then firmly


strip of 20mm wide vinyl tape
to each edge of silver band.

Place a small piece of vinyl


tape under clamp before
tightening clamp 'CT.

Make sure silver alloy band is perpendicular to axis


of shaft, before applying tape.

11

INSTALL BAND STRAPS.


1. Assemble stainless steel
band straps.
NOTEl Right side up.

^=^^=~--~V''/^

^A

Permanent holding straps


Vinyl tape
5a,_
. .1 Vinyl tape under straps
^ ^ s i ^ a w n p A'l
\
*^

J^A^^^^^^^

2. Remove damp ' C and piece of vinyl tape


from center of silver alloy band.
3. lightly smooth skive joint vlth
One file to eliminate any
roughness.

APPLY TAPE.
Wrap two layers of S(}mm*481 pressure
Sensitive tape, coimter to shaft
rotation.

i^prox. width of flushed *t>P. Je^


25p ring.
^JUa
Shaft rotation.

12

industrial boxes
Vimen^ons
2430011
toierancM on all sides
tlmm

"24300" and safety enclosures

24310
2433)
24340

Ktotum with tid* lock with kty

182 132 107 1 lis 140


tS2 167 107 16t 153 140
232 212 13^ 2ii m l$0

95

90

ili 95

125

52

lot 77 1

aii

lOt *7 \2
157 137 t

24210
22
24230

160 no u
160 145
210 190 Ij

Ulzt

^
+ Ml.l

i\

^i_.

For Earthing device BAC No. 539500 Dimension tabel No. 24310
For Earthing device BAC No. 539600 Dimension tabel No. 24340
For Earthing device BAC No. 539700 Dimension tabel No. 24340

13

BAC NO: 539525


STANDARD SHAFT GROUNDING ASSEMBLY
This system forms connection between shaft and hull without any kind of monitoring, which
means that there is no possibility of knowing if the connection and safety of the system is
functioning correctly.

BAC NO: 539550


SHAFT GROUNDING ASSEMBLY FOR COMPUTER CONTROL
This system is identically with BAC Standard Shaft Grounding assembly, though this system
has a silver brush, which can be used for connection to an alarm computer or a measuring
instrument.
BAC NO: 539500
SHAFT GROUNDING ASSEMBLY WITH mV- METER FOR MONITORING
This system is identically with BAC Shaft Grounding for computer control, though this
system consists of a steel box with instrument for monitoring.
BAC recommends you this, as it is our most sold system.
BAC NO: 539600
SHAFT GROUNDING ASSEMBLY WITH mV- METER AND AMPLIFIER
FOR ALARM OUTPUTS
This system is identically with BAC Shaft Grounding assembly with mV-meter for
monitoring, though this system is extended with an isolation amplifier. This makes it possible
to connect the system directly to the alarm computer in the ship with a signal on 4-20 mA or it
can be used with a signal on 0-20 mA.
BAC NO: 539700
SHAFT GROUNDING ASSEMBLY WITH mV- METER AND AMP.
METER MOUNTED IN A MONITORING BOX.
This system is identically with BAC Shaft Grounding assembly with mV-meter for
monitoring but it consists of a monitoring box where voltage and current can be read.

14

Please note following:


When you order a BAC Shaft Grounding system the price of the silver band is depending on
the size of the shaft, and therefore the cost of the silverband will be quoted separately. Please
contact BAC, we can help you with commercial terms and calculations.
It is very important that the Shaft Grounding system is equipped with a kind of measuring
instrument, which can show the fimction of the system.
BAC is able to update the different BAC Shaft Grounding systems. For instance with a mVmeter for monitoring or amplifier for alarm output giving you a better and precisely measure
of the system.
BAC can further more offer you an alarm system to ensure that the connection between the
shaft and hull is according to BAC standard specifications.

15