Hcu and Hps Events For Me C and Me B Engines

Examining HCU Events
HCU events from a-z …
 Allan Juul Larsen, MDT LEO9

 Prime Serv Piraeus 2017-09
MAN Diesel & Turbo Allan Juul Larsen Examining HCU Events  27-09-2017 < 1 >
Content to cover…
• Basics
• What is a “HCU event” (data stored and saved in case of fault, thus including data before
failure)
• When is a HCU event stored (manual vs. automatic).
• Amount of data and marker line
• FIVA Basic understanding
• FIVA Internal parts.
• FIVA Flow diagram.
• Examining using LDE plot
• Signals
• Which signals are stored
• Alarms
• Explanation of most common alarms
• Don’t waste time on bad data… (jitter profile, engine not running)
HCU Events - Basics
What is a HCU event
• Hydraulic Control Unit Event
• Tells us what is going on in the FIVA control loop

• VERY important for troubleshooting Fuel and Exhaust valve problems!
• Many names: “HCU Event” “HCU Dump” “Log Dump” “Burst Log”
• Electrical signals related to exhaust valve and fuel booster

• Continuously sampled by each CCU
• In case of an critical alarm the data is send to the MOP and stored
• Both data before and after alarm is stored
• Stores a few seconds of data sampled at 2 kHz (2000 times pr. sec.).
• FIVA Setpoint, position, Fuel plunger and exhaust valve position
• Data size: 124 kb each. (~50 kb zipped)
HCU Events - Basics
What is a HCU event
• HCU Event retrieved

from the MOP GUI one by one
• Select one and export to
USB
• If more dumps are needed they

may be copied using explorer:
D:\MANDiesel\MAD
HCU Events - Basics
When is a HCU event stored
• HCU events are store either manually or triggered by a specific alarm.

• Information about the reason is stored in the HCU event.
• Header is composed of:

• MPC type.
• Date and time for event
• Trigger reason, actual alarm or manual dump.
• Make manual dumps from all cylinders for reference.

• The specific list of alarms triggering alarms is shown later.
HCU Events - FIVA
Internal part MDB FIVA
HCU Events - FIVA
Internal part MDB FIVA
Control signal CH70
Feedback signal
CH30
Solenoid Actuator
A T P
Pilot spool
Main spool
P = Hydraulic high pressure supply

CFI = Fuel booster
TFI = Fuel booster to tank
CVA = Exhaust actuator
TVA = Exhaust actuator to tank TFI CFI P CVA TVA
HCU Events - FIVA
FIVA main spool
Feedback signal
CH30
Main spool
TFI CFI P CVA TVA
P = Hydraulic high pressure supply
CFI = Fuel booster

TFI = Fuel booster to tank
CVA = Exhaust actuator

TVA = Exhaust actuator to tank
HCU Events - FIVA
Flow diagram
x-axis position [mm]

y-axis flow area [mm2]
-6mm ≈ 30 mm2
Pressure port to
exhaust valve actuator
-6mm ≈ 600mm2
Fuel plunger to tank
HCU Events - Basics
FIVA Set Point – For ME-C engine one engine revolution
Fuel injection
Levels found in Flow

diagram for valve
type.
“Preparation” return plunger and
close exhaust valve
Red area “dangerous”
only allowed here
near TDC!
Y-axis Exhaust valve opening

Position
mm.
HCU Events - Basics
How are axis scaled
• X-axis shows time in ms.

• Resolution is in 500µs (½ms)
• Resolution locked to MPC CPU clock of 2 kHz.
• Y-axis is scaled according to the signals being displayed:

• The resolution is 1 and the span is ±32767 (16 bit values).
• FIVA Set Point / Feedback are shown in mm * 1000
• Electrical current is shown in A/D Counts
• Electrical voltage is shown in A/D Counts
• Exhaust valve position in mm but must be scaled according to parameter
• Tacho angle is shown in deg.
HCU Events - Basics
Amount of data stored
• Time stored dependents on the number of signals.

• Number of signals depend on engine type:
• ME-C 6 signals = 5.250 sec.
• ME-B DOT3 5 signals = 6.300 sec.
• ME-B 4 signals = 7.875 sec.
• ME-B (2 cyl. pr. MPC) 7 signals = 4.500 sec.
• In total 31500 samples are stored.
• Marker line indicated the time where the HCU event was triggered.
• ECS Parameters determine the time before and after Marker line.
HCU Events - Signals
Overview
• Now with this FIVA basics settled lets look at the signals:
• FIVA Set Point Ordered main spool position

• FIVA Feedback Main spool position
• FIVA Control Control signal to pilot spool
• Exhaust valve position (only ME-C) Exhaust valve pos.
• Plunger position (only ME-C) Fuel Plunger position
• Tacho Angle Cyl. 1 Other cylinders must compensate
• ME-V Feedback (only ME-B DOT3) ON/OFF timing unit feedback
• Naming differs a little on ME-C vs. ME-B and ME-B DOT3 I will not distinguish between ELFI,
ELFIA, or FIVA in the following but call it FIVA.
FIVA Set Point
• Set point signal very important.

• Shows us what is ordered by ECS.
• Not a physical signal!
• Not possible to measure anywhere.
• Calculated set point from the control loop.
• Where do we want the main spool to be!
• Set point is specified in parameters.

• Designed by performance measurements.
• Fuel profile.
• Exhaust valve open slope
• Exhaust valve close slope
Fuel injection
ME-C and ME-B
FIVA Feedback CH30 – Setpoint
Feedback follows set

point nicely.
Small time delay seen

at fast changes.
FIVA Feedback CH30 – Fuel profile
Nice step at prep.
No overshoot
Fuel profile
Prepare for Offset is a
fuel injection few ms.
Flow diagram – Fuel injection
Flow towards fuel injection

start between -0.5 and 0.75 mm
Lets just say 0 mm
Plunger position CH31 – Fuel profile start
Flow to
plunger
Mechanical system Start of fuel profile
with some reaction time
Feedback passes
0.0 mm
Plunger position CH31 – Fuel profile shape
Start of fuel profile
Profile shape determines

plunger acceleration
Plunger position CH31 – Fuel profile end
After small time delay

Flow to plunger plunger is stationary
stops
Top dead point of fuel
plunger movement.
Feedback passes
0.0 mm
Plunger position CH31 – Fuel plunger return
Final
position
Fuel plunger return
Flow from plunger to Increases movement.
tank means plunger tank flow and
will return. plunger
return speed
Main spool in More negative

negative position position.
Plunger position CH31 – Different loads
Engine running
10% load
Engine running
25% load
Engine running
40% load
Engine running
50% load
Engine running
75% load
Engine running
90% load
Engine running
100% load
Exhaust valve
ME-C
Flow diagram – Exhaust valve opening
Flow towards exhaust valve

opening start
between -4 and -6 mm
Lets just say -5 mm
Exhaust valve Position CH34 – Exhaust valve opening
Flow to Exhaust
valve actuator
Feedback passes
-5.0 mm
Exhaust valve Position CH34 – Exhaust valve
Opening speed determined

by constant flow rate.
Constant main spool position
Exhaust valve Position CH34 – Exhaust valve close
Exh.v. closing will start.
Speed determined by
flow rate to tank
Feedback passes
-5.0 mm
Exhaust valve Position CH34 – Exhaust valve damp
Final close speed is

controlled by exh.v. damper
step one and step two.
Exhaust valve Position CH34 – High force Exhaust valve
Good ability to
Dampened
stay open
opening
Highforce exhaust
Step 1 damper
valve
Step 2 damper Different opening
profile with overshoot
Exhaust valve Position CH34 – High force Exhaust valve
Slow open and close slopes

Highforce exhaust
valve
Different opening
Exhaust valve Position CH34 – Low force Exhaust valve
Fast open and close slopes

Lowforce
exhaust valve
Different opening
Exhaust valve Position CH34 – Low force Exhaust valve
Overshoot at Slowly closes

open stroke due to leakage
Lowforce
exhaust valve
Different opening
Exhaust valve ME-B

ME-V timing unit
ME-V feedback. 1 – Digital “position” signal
The up wards flank is Return flank is

“preparing” the ME-V critical.
Timing is not critical. Time is adusted
to get accurate
timing of exh.v. Activation is not time
close critical, and will
change with load.
Return stroke timing is

important. Will control
Pcomp/Pscav ratio
Tacho Angle
Tacho Angle Cyl. 1 – How to use
Tacho angle values

Zoom the area that is interesting. are small compared to
Zoom wide and low to get best view other signals and thus
not readable
Want to know angle

for exh.v. start open?
Angle is difficult to read. Due to other signals scaling.
Tacho Angle Cyl. 1 – Zoom on event and note time
Use cursor to read exact time

925.0 ms.
Tacho Angle Cyl. 1 – Zoom on tacho at exact time
In the same way

Angle is in steps of 1 deg. zoom on tacho signal
121 deg. around that time.
920 to 930ms.
Or use cursor to
read values Again zoom “low” to
get good resolution in
y-axis
time 925.0 ms.
HCU Events - Basics
Examining using LDE plot
• Windows application to examine HCU Events at office.

• Intuitive user interface and proper screen resolution.
• Sort multiple events based on:
• Dump cause.
• CCU number.
• Data / Time.
• Change colors and line width.
• Export and print to improve documentation.
• Show short DEMO
HCU Events
Break time?
HCU events from service
Things NOT to look at….
• Use your time well - on the real problems

• Many HCU events are triggered by unimportant events.
• Remove / apply connections
• Electrical noise
• Follow alarms to other alarms (Find first alarm and start here)
• Start / stop
• Some examples.
Know what is NOT important look at
This HCU event

should not give raise
to much concern?
Zooming in on Tacho
signal.
Engine is not running.
May be interesting but
not related to engine
running.
Connector on/off
Burst and Prep

Sync missed!!
Tacho?
After TDC it will jump to 0 deg.

normal
Tacho is jumping
Indicates that the
engine direction have
just changed!
Tacho angle is always
counting positive.
New angle
= 360-old
Migth setup exh.v. open and then this is “missed”
due to the tacho suddenly jumping to a new position.
What is wrong?
Electrical noise is on
channel not in HCU
event.
No information in this
event besides engine
running fine.
HPS pressure drops.

Connector removed.
Engine not running.
Dither function – Zoomed to show feedback
One sine
One square
Avoid that FIVA is

sticking
May give a idea about

the FIVA condition.
Dither function – Situation 1
All OK
Feedback is “dead”
Control signal is
running
Missing hydraulic
pressure.
Set point is “running”

No control signal?
No feedback?
FIVA in safe position,

Control signal forced
to exh.v. open
Things to look at….
• Selected HCU events found for this occasion.
Exhaust valve stroke low.
Exhaust valve stroke

is reduced for each
revolution.
At the marker the fuel
is stopped.
Exhaust valve
activation continoues.
Exhaust valve stroke low.
Reason:
SW related?
Exh.v. Mech?
Hydraulic?
Sensor?
Manual dump - Feed back not following well.
Manual dump
troubleshoot.
Fuel plunger OK
Exh.v. OK
Feed back not following well.
Closer look at
feedback.
Unable to follow set
point.
Large Control signal
amplitude.
Reason:
Worn out FIVA.
Illegal FIVA Position
Exhaust valve open to avoid

Cover lifting. Feedback cross zero
when prep. Is made!
Control signal is set to
safe.
Note that set point
keeps “going” only
intern signal.
Illegal FIVA Position – zommed
A bit closer
FIVA is reacting and

following control
signal safe position
Illegal FIVA Position – zoomed more..
Even closer!
At first sample
crossing zero control
signal is set to safe.
Illegal FIVA Position – Using DOT’s to see each sample
First feedback
>0.0mm In some cases using
Next sample is DOT’s help to see
set to safe exact timing of events.
position.
Exhaust valve closed position changed
Large control signal

tells that FIVA is not
reacting!
Exhaust valve closed position changed – compare revolutions
Note the “short” fuel

injection
FIVA Pilot spool is
stuck at exh.v. open
position.
Unable to control
FIVA.
Exhaust valve closed position changed- The good
After fuel injection

control signal settels
as FIVA stoppes at
desired position.
Exhaust valve closed position changed – and the bad
Control signal keeps

going positive to stop
FIVA movement.
FIVA is NOT following
control signal.
May be caused by
particle in oil.
Exhaust valve stroke low– OR what is going on?
Something is very
wrong here. But
what?
electrical signal
error
CH30?
CH70?
Exhaust valve stroke low– OR what is going on?
Electrical fault!
Fault on
MPC output: CH70 or Which signal?
FIVA input
Is Feedback correct
CH30?
Exhaust close position change – OR what is going on?
Look like previous

situation.
Dependent on other
alarms and conditions
the controller might be
active and try to
control the error.
Could also be CH70
error.
Rev. time ≈ 3 sec.
But Why is the control

signal active NOW?
= 20 RPM
= ? Load
= ? Pscav
Below 0.9 bar!!
ME-V feedback looking weird.
ME-B 60 bore
First ME-B DOT3
Incorrect design of
piston.
3 groves like alpha
lubricator!
From
Troubleshooting guide
Typical example of
noise due to loose
connection or
defective cable.
From
Troubleshooting guide
Piston difficult moving.
Partly stuck in bottom.
ME-B Timing unit not operating
Looks like “normal”

timing unit problem at
deactivation.
But occur at High

load. And sounded
BAD!
Incorrect ME-V
parameters.
Note different set
point between two
revolutions.
ME-V Missing
return
Timing unit piston is

returned at Fuel
injection prep step.
Exh.v. close DURING
fuel injection!!
MPC failure
MPC failure but which

channel?
MPC failure
CH30 matches
exhaust valve and
plunger.
Fault is on CH70
CH30 is not changing
abrupt (one sample to
the next)
MPC failure
Same ship different

MPC.
Which signal?
MPC failure
CH30 changes
~14mm in ONE
sample.
This is not possible.
Electrical fault on
CH30 signal
MPC failure
SAME SHIP!!
MPC replaced and
fault removed!
Which signal?
MPC failure
Fault seen on 3
signals AT ONCE
• exh.v. pos
• Fuel plng. Pos
• FIVA feedback
Almost same value.
Common electrical
fault on MPC affecting
all analogue inputs.
ELFI Fluctuation G95
ELFI Fluctuation G95
SOMETHING CLEVER
• I hope this lecture have given you a :

• Practical ways to look at HCU Events.
• Better understanding of the signals presented in HCU Events
• Understanding that not all HCU Event contain important information
• Gained some idea of the complexity of looking at HCU Events
• If you have funny looking HCU Events or get some. Let me know and I will comment on them.
• Question…..
Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially not guaranteed in
any way. Depending on the subsequent specific individual projects, the relevant
data may be subject to changes and will be assessed and determined
individually for each project. This will depend on the particular characteristics
of each individual project, especially specific site and operational conditions.
Do you have any more questions?
Allan Juul Larsen

Manager
EEO9 Control and Electronics
Operation
Allanj.Larsen@man.eu

Hcu and Hps Events For Me C and Me B Engines

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Examining HCU Events

HCU events from a-z …

 Allan Juul Larsen, MDT LEO9

• Hydraulic Control Unit Event

• Tells us what is going on in the FIVA control loop

• Electrical signals related to exhaust valve and fuel booster

• Data size: 124 kb each. (~50 kb zipped)

• HCU Event retrieved

• If more dumps are needed they

• HCU events are store either manually or triggered by a specific alarm.

• Header is composed of:

• Make manual dumps from all cylinders for reference.

Control signal CH70

P = Hydraulic high pressure supply

TFI CFI P CVA TVA

P = Hydraulic high pressure supply

CFI = Fuel booster

CVA = Exhaust actuator

x-axis position [mm]

Levels found in Flow

Y-axis Exhaust valve opening

• X-axis shows time in ms.

• Y-axis is scaled according to the signals being displayed:

• Time stored dependents on the number of signals.

• In total 31500 samples are stored.

• FIVA Set Point Ordered main spool position

• Set point signal very important.

• Set point is specified in parameters.

Feedback follows set

Small time delay seen

Nice step at prep.

Flow towards fuel injection

Lets just say 0 mm

Start of fuel profile

Profile shape determines

After small time delay

Main spool in More negative

Flow towards exhaust valve

Lets just say -5 mm

Opening speed determined

Constant main spool position

Exh.v. closing will start.

Final close speed is

Slow open and close slopes

Fast open and close slopes

Overshoot at Slowly closes

Exhaust valve ME-B

The up wards flank is Return flank is

Return stroke timing is

Tacho angle values

Want to know angle

Angle is difficult to read. Due to other signals scaling.

Use cursor to read exact time

In the same way

time 925.0 ms.

• Windows application to examine HCU Events at office.

• Show short DEMO

• Use your time well - on the real problems

This HCU event

Burst and Prep

After TDC it will jump to 0 deg.

HPS pressure drops.

Avoid that FIVA is