MAN Diesel service letter provides guidelines for cylinder lubrication

Search
Close
MAN Diesel
MAN Diesel AIS Denmark
Service Letter SL07-479lHRR

June 2007
Cylinder Lubrication
New ACC Guidelines
All MCIMC-C and MEIME-C type engines
Mk 6 and higher, with Alpha ACC System
Action Code: WHEN CONVENIENT
Dear Sirs
Since our last Service Letter SL05-455 concerning Cylinder Lubrication, the default
feed rate sulphur proportional factor has been in the range of 0.34 to 0.26 gIkWh x
S%, with an absolute minimum at 0.70 - 0.60 g/kWh.
However, many engines have followed the lowest level in the range, and evaluations
of the results regarding wear, scuffing resistance and TBO show that this dosage is
superior to higher levels. Therefore, we now recommend a fixed schedule for
navigating from the upper level to the lower level in the range, within a 2,000-hour
period.
Consequently, the recommended basic feed rate after running-in is 0.26 g/kWh x S%,
with the absolute lower limit at 0.60 g/kWh.
Specific Cylinder Oil Dosages
Alpha ACC is the default lubrication mode for modern MAN B&W two-stroke engines,
i.e. lube oil is dosed at a feed rate proportional to the engine load and proportional to
the sulphur content in the fuel oil. This ensures that the alkali additives in the cylinder
oil are applied proportionally with the amount of sulphur entering into the combustion
chamber. The build UD of a safe oil film is ensured at any time by the lower limit of
HEAD OFFICE (8 postal address1 Primesaw PRODUCTION FORWARDING (L RECEIVING MAN Diesel N S
MAN D i e ~ e l N S Teglholmsgsde 41 T~glholmsgsde35 T~glholmrgsds35 Dmmsrk
Teglhdmsgade 41 2450CopenhsgenSV 2450CopsnhagenSV 2150CopenhsgenSV Reg. N0.:3%81314
2450C0penhsgsnSV Denmark Denmark Denmark
Dsnma* Phons: A 5 3 3 8 5 11 W Phone: +45 33 85 11 00 Phons: A 5 33 85 11 00
Phons: 445 33 85 11 00 Fax: A 5 33 85 1048 Fax: 445 33 85 10 17 Fox: A 5 3 3 8 5 1 0 1 6
Fax: A 5 3 3 85 1 0 3 0 dlessI.se~~iCBOdkmanbw.mm man~laoturine/cphodkcccbw.mm
manbwOdkmanbr.mm
MAN Diesel-a msmber d t h s MAN Grow
MAN Diesel
During the first running-in, we recommend a relatively high fixed dosage: 1.5 g1kWh
for the first 250 hours succeeded by 1.2 g/kWh for another 250 hours. After these 500
hours of initial running-in, where ample oil is used for flushing away wear particles
from the sliding surfaces, ACC running with the factor 0.34 g1kWh x S% should be
introduced.
The next 2,000 hours should be used for a gradual reduction towards the basic
, setting, i.e. the ACC factor 0.26 g/kWh x S%, see the feed rate chart below.
ACC Cylinder Lubrication, January 2007

1.70 5
1.60
1.50 -f
-
.c
1.40
1.30 [
:
-
1.20
5 1.10 +
m
1.00 :
;0.90 -!
g 0.80 .:
2 0.70 -'
-= 0.60 >-
{ 0.50 i Running-in range
0.40
Sulphur %
Fig. 1 : ACC Cylinder Lubrication. January 2007
Regulating from the upper ACC factor 0.34 glkWh x S% to the basic setting at 0.26
g1kWh x S% should take place stepwise over a 2,000-hour period. The size of the
steps may depend on the evaluation of the actual lubricating and deposit condition
appearing from scavenge port inspections.
Average Cylinder Oil Consumption
Due to the sulphur dependency, the average Cylinder Oil Consumption depends on
the sulphur content in fuel bunkers. According to DNV, worldwide deliveries in 2006
have been recorded as shown in Fig. 2 below.
MAN Diesel
SULPHUR 2006. source DNV Pelroleurn Services

211
SULPHUR CONTENT %
Fig. 2: Sulphur c o n t e n t 2006
About 40% of all fuel bunkers have a sulphur content below 2.3'10, and consequently
call for the minimum dosage of 0.60 g/kWh. About 60% of all fuel bunkers call for the
sulphur dependent lube control, i.e. 0.26 g/kWh x S%. On average, this results in a
yearly absolute Cylinder Oil Dosage of 0.70 g/kWh.
Operating o n low sulphur fuels
At sulphur levels below 2.2% the minimum dosages at 0.6 g/kWh should be
maintained. Consequently, when using a normal BN70 cylinder oil, there will be a
surplus of alkali additives. Unused alkali additives have a negative influence on the
cylinder condition due to accumulation on the piston top land and due to lack of
refreshment of the liner surface by corrosion. This negative influence is naturally time
based and becomes more and more severe the lower the sulphur content gets. As a
rule of thumb, we recommend to change to a lower BN cylinder oil when operating on
sulphur levels below 1.5% for more than 1 to 2 weeks.
Questions or comments regarding this SL should be directed to our Operation Dept.

LEO.
ours faithfully
AN Diesel AIS
Encl.
MAN Diesel
E n d 1 for
SLO7-479
Guiding Cylinder Oil Feed Rates

SILIK-MCIMC-CIMEIME-C, Mk 6 and higher,
with Alpha ACC lubrication system and coated piston rings
Standard EN 70 cylinder oil I BN 40 cylinder oil
Basic setting
Minimum feed rate
Maximum feed rate

during normal service
Part-load control Proportional to indicated engine load
First 5 hours: 1.7 glkWh

From 5 to 250 hours: 1.5 glkWh
Feed
Running-in From 250 to 500 hours: 1.2 g/kWh
rate:
new or From 500 to 2500 h: Stepwise reduction from
reconditioned 0.34 to 0.26 glkWh x S%
liners and
new piston
rings Engine
Stepwise increase to max. load over 5 hours
load:
Running-in new rings in

already run-in and well No load restrictions
running liners:
During starting, manoeuvring and load changes, the feed rate

Manoeuvring and load
should be increased by means of the "LCD" by 25% and kept at this
change situations.
level for % hour after the load has stabilised.
Frequent scavenge port inspections of piston rings and cylinder
liners are very important for maintaining a safe cylinder condition.
If irregularities are observed, adjustments of the lube oil rate should
Lubrication of cylinders
be considered.
that show abnormal
In case of scuffing, sticking piston rings or high liner temperature
conditions:
fluctuations, the feed rate should be raised to 1.2 glkWh and the P-
max and Mep reduced. As soon as the situation is stabilised, the
lubrication and the pressures should be normalised.
HRR 6: February 2007
MAN Diesel
E n d 2 for
SLO7-479
1 Adjusting Alpha Lub. using ACC, BN40 Cylinder Oil

I
MAN Diesel
End. 3 for
SLO7-479
Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil

MAN Diesel
.
MAN Diesel NS Denmark
End. 4 for
SLO7-479
ACC Running-in Schedule
m
V)
0
u
.-c
C
'E
-
1.4-
1.2 -
.... . -Fixed
-Feed
running-in dosage (glkWh)
rate factor reduction curve(glkWhlS%)

.....................................................
Scavenge port insp.
...
.............
m
.-
.-
d
1 '
I
....................................................................................... -
-c
.......... .:.......
..~ scavenge port inrp.
..............................
,
1
,
0.34
0.32 f
I
........:. ......
Scavenge pod inrp. 0.30
-;
i..
...............................
Scavenge port inrp.
...................................................................................... *
0.28
0.26 2
. .n
0.24
0 500 1000 1500 2000 2500 3000 3500 4000

Hours
ALPHA MAINTENANCE
1. Alpha Lubricator Overhaul Kit
2. Alpha Maintenance Materials
3. Alpha Maintenance service
4. Alpha Maintenance Package
Supply Items (98-70 bore engine)
1
Supply Items (60-50 bore engine) 4
Doosan Engine
Items based recommendation
* A :Adjustment to be carried out / C: Check the condition / R: Parts to be redaced

1. Lubricator overhaul (Replacement required parts) 1. 1 Engineer + 1 Technician (60-50 bore engine)
2. Lubricator injection timing checking & adjusting. 2. 1 Engineer + 2 Technicians (98-70 bore engine)
3. UPS system checking and battery replacement. 2. Working time(2days) + Traveling time(2days)
4. ALCU electric wiring condition checking. 3. Warranty period : 12 month after commissioning date.
5. Angle encoder condition checking & adjusting. 4. The incidental expense of maintenance should be
paid by ship's owner (Flight, Hotel, Agent fee, etc ...)
6. Load Transmitter setting value re-adjusting.
7. Basic program, parameters upgrade if necessary.
9. Alpha simulation test & safety function test.
10. Crew education for alpha Lubricating system.
11. Boost pump maintenance I.1 Engineer + ITechnician :
2. 1 Engineer + 2 Technicians :
1. Replacement of injection quill on cylinder liner.

Maintenance Package cost (Materials + Service) 4
1 LUBRICATOR O-RINGS I d I d I d I
.. . ;.'j., ..> <, :. .. . ~.
$ ~ k ; .. q... .
.
SEN^^
I '
IND~,~V E IN ~
..: ..,, 5 , . ~ . . ,. ',. , ~. ~, ~
., .... ~.~
, .>, ... ~ ' ,/. .. &
,.: , ~
, .
, ?
J .J
PICK UP SENSOR - FLY WHEEL SIDE d ./ d
SEAL OF PUMP FOR BOOST PUMP

., <. , . .,
J
:.,.
d J
$2 ;?:. .
~
&NGL,E:E~CODER;-.FORE-END,~CDE
. :. ::r,,*- :.,
~.':,... .~ b .,, ,>:
~
i..<,:~
. ....,..?~
.
, .,,. ..~ .
. .,>..:v 4 J
LOAD TRANSMITTER d
1 REPLACEMENT OF INJECTION QUILL 1 1 I J I

Doosan Engine
Maintenance Package cost (Materials Only)
1 ACCUMULATOR ON LUBRICATOR (SMALL) I d I d I d I

,:. ,. , ,
.:SOLENOI&VALVEON ~ I J B # @.. ~ T O R .. ....: : ~ , . . .d -. d d

LUBRICATOR O-RINGS d d d
I PICK UP SENSOR - FLY WHEEL SIDE I d I d I d I

SEAL OF PUMP FOR BOOST PUMP d d d
>. .?<,.$<): :g.:,;.
... . ".,<.-, ; .,. ...
. ...,.~. . ~
.~
.. .., ., .
.
AN@&:
.;-I-. EN@DER~~
>~.~::,..>., -.~,
FORE-EN.J:@&
.. . ..
. ...., ~...
., .
..
!.: . ,
. ..,
, ,
: $ d ,..
LOAD TRANSMITTER d d
REPLACEMENT OF INJECTION QUILL d

Dwsan Engine
MAN Diesel 3045-0110-0003
1
Alpha Lubricator System

Operation Manual
MC Engines
MCU Software Version 2.5
MAN Diesel & Turbo

branch of MAN Diesel &Turbo SE, Germany
Teglholmsgade 41
DK-2450 Copenhagen SV, Denmark
Phone +45 33 85 11 00
Fax +45 33 85 10 30
E-mail mandiesel-cph@mandieseI.com
MAN Diesel 3045-0110-0003
-1
Table of Contents
Page
List of Abbreviations: 7
1. General Information
1.1 Main components
1.2 Working principle
1.3 Guidance values automation
2. Operation of the System

2.1 HMI-Panel/Operating Panel
2.2 Control buttons and indicator lamps on pump station starter F
2.3 Start-up of Alpha Lubricator System (Engine not running)
2.4 Checks during start-up of the engine
2.5 Periodic checks during normal operation of the engine
3. HMI-Panel and Configuration of MCU
Description of HMI Panel

HMI-Panel operation and configuration of MCU
Navigation principle
Reading of total strokelmin [rXXX]
Reading of total strokes [Str.hi] and [Str.lo]
Reading of active alarms [ALRXX]
Reading of logged alarms [LALXX]
Adjustment of cylinder oil feed rate [F.rAtE]
Adjustment of Basic Feed rate [S.FACt]
Adjustment of Running in feed rate [F.runi]
Monthly change of operating pumps (master pump)
Test sequence for inspection during standstill
Menu structure
HMI panel parameter reference list
Check and adjustment of Index transmitter
MCU setup
Dip switches for MCU
Hardware Interface
VT 100 program requirements and setup
Upload of MCU basic program
Upload MCU set-up file
MCU LED information
Read-out of raw parameters in HMI Panel
MCU index scaling
Initialization
Calibration of load points
Adjustment of endpoints
Fuel Offset factor
Involved parameters
73045-0110-0003 MAN Diesel
Table of Contents Page
Configuration of BCU 56
Injection rate with BCU in control 56

Detection rate (BCU take over from MCU) 56
Number of cylinders for the engine 56
BCU board revision 57
Load down output 57
Number of lubricators 57
Upload of BCU basic program 58
Programming of BCU microprocessor 60
Preperation 60
Determining microprocessor type 61
Programming P89V51RD2 61
Programming P89C51RD2 63
Programming P89C51RD+ 64
Varifying BCU software version 65
Alpha Lubricator - Alarm Handling and Trouble Shooting Guide 66
Fuses 66
MCU-Unit 66
BCU-Unit 69
External alarm signals 71
Common alarm 71
MCU power failure 71
BCU power failure 72
MCU failure 72
BCU failure 72
Slow-down 72
BCU in control 72
MCU - alarm handling and trouble shooting 73
Alarms 1-24-Feedback failure 73
-
Alarm 29 Marker signal failure from encoder 74
Alarm 30 - BCU ~ i c k u o1 failure 75
~ l & m31 - ~ r i ~signal
~ e failure
r from encoder
- Alarm 33-Engine stop signal failure
5.3.6 Alarm 34 - -LCD
~ ~ - ~ . . abnormal
sianal~~
5.3.7 Alarm 35 - BCU alive signal missing

5.3.8 Alarm 36 - Astern signal abnormal
5.3.9 Alarm 37 - Prelubrication signal abnormal
5.3.10 Alarm 38 - Oil temperature high
5.3.11 Alarm 39 - Oil pressure low
5.3.12 Alarm 40 - Speed deviation alarm
5.3.13 Alarm 41 - Index transmitter abnormal
5.3.14 Alarm 42 - Cable failure index transmitter
5.3.15 Alarm 43 - BCU pickup 2 failure
5.3.16 Alarm 44 - BCU in control
5.3.17 Alarm 45 and 46 - Thermal overload electric motor
5.3.18 Alarm 47 - MCU parameter list not loaded
5.3.19 Alarm 48 - Angle deviation fail
MAN Diesel 3045-0110-0003
-?
Table of Contents Page
Alarm 49 - Stand-by pump is running

BCU alarms
Led # 1 BCU internal failure
Led # 2 Engine stop signal failure
Led # 3 MCU alive signal missing
Led # 4 Feedback signal missing on two lubricators
Led # 5 Feedback signal missing one lubricator
Led # 6 BCU marker signal 1 and 2 missing
Led # 7 and 8 BCU marker signal 1 or 2 missing
Emergency running without external trigger signals
Sequence diagram for alarm handling
Appendix 1 Function of the LEDs in the Intermediate Box

3
Appendix 2 Control Unit Cylinder Lubrication - Logic Diagram
Appendix 3 Replacement of MCU, BCU, SBU Boards
Appendix 4 Service Letter -SL09-507lHRR - Cylinder Oil Feed Rate
Appendix 5 ALCU signal description
Appendix 6 Back-up Control Unit - BCU
Commissioning
Maintenance
Components
Electrical Wiring
MAN Diesel 3045-0110-0003
3
List of Abbreviations:
This is a list of abbreviations used in this manual.
AC Alternating Current
ACC Adaptive Cylinder oil Control
ALCU Alpha Lubricator Control Unit
AMS Engine alarm System
BCU Backup Control Unit
DC D i ~ e cCurrent
t
ECR Engine Control Room
FBU Fuse Board Unit
FPGA Fast Programmable Graphic Array
HMI Human Machine Interface
IC Integrated Circuit
Lcd Load change dependent
LED Light Emitting Diode
MCU Master Control Unit
MEP Mean Effective Pressure
PCB Printed Circuit Board
RPM Revolutions Per Minute
SBU Switch Board Unit
TDC Top Dead Centre
UPS Uninterruptable Power Supply

MAN Diesel 3045-0110-0003
3
1. General Information
1.1 Main The Alpha Lubricator System Layout is shown in the diagram below:
components Alpha Lubricator System Layout
PUMP
STATION ----- Pipe System
Electrical Connection
j3045-0110-0003 MAN Diesel
lump station and si panels
The pump station consists of two individ-

ually operating pumps, heating coil, filters
and a suction tank. The power supply to
the pump station starter panels is taken
from two separate circuit breakers, one
supplying each pump.
For further information, see Maker's pump

I
station manual.
Lubricator units
The lubricator units, one for each cylin-
der, each comprise two lubricators for
98-70 bore engines and one lubricator for
medium and small bore engines. Each
lubricator unit is equipped with one accu-
mulator with nitrogen pre-pressure of 25-
30 baron the inlet side, and one accumu-
lator on the outlet side of each lubricator,
with nitrogen pre-pressure of 1.5 bar.
Each lubricator features 3, 4, 5 or 6 lubri-

cating pistons, depending on engine type,
a feedback pickup and a solenoid valve.
One-lubricator unit TWO-lubricatorunits
Alpha lubricator The three main electronic components for controlling the lubricating oil are
control unit comprised in one steel cabinet -the so-called ALCU unit.
ALCU
The three units are: MCU (Master Control Unit)
BCU (Backup Control Unit)
SBU (Switch Board Unit)
MAN Diesel 3045-0110-0003
A terminal block interfaces all electrical connections to the engine,
The 24 V DC power is supplied from two individual power sources, from differ-
ent breakers in the UPS unit. Please note that some installations might be con-
nected differently by the shipyard.
Load transmitter The load transmitter is connected to the fuel

rack, thereby continuously transmitting the
fuel index % t o the MCU, which calculates the
engine load from this information and the de-
tected engine rpm.
I"Tb
73045-0110-0003 MAN Diesel
Trigger system The shaft encoder is connected to the fore

(Shaft encoder) end of the crankshaft, and the signals are
transmitted to the computer panels via a
terminal box.
For engines on which the crankshaft fore

end is not available for angle encoder in-
stallation, a trigger ring and tacho pickups ?
are installed at the turning wheel.
8-
$
Backup trigger The backup trigger system comprises
system two tacho pickups in a box at the turning 2
wheel, thereby transmitting the engine rpm
to the BCU.
The backup pickups are also connected to

the MCU for surveillance purposes.
Human Machine On the HMI panel, individual cylinder lu-

Interface panel brication adjustment is possible, various
(HMU values and alarms are displayed, control
buttons for the pump station are available,
and manual execution of prelubrication is
possible.
As standard the HMI-panel is mounted in

the engine control room.
Bcu in ctd. I
0
MAN Diesel 3045-0110-0003
'I
1.2 Working The pump station supplies the Alpha Lubricators with 40-50 bar oil pres-
principle sure.
The MCU controls the oil injection by activating a solenoid valve situated on
the relevant lubricator.
A feedback signal from each lubricator indicates that oil injection has taken
place. This is shown by Light Emitting Diodes (LEDs) on intermediate boxes
for each cylinder.
Timing is based on two signals from the angle encoder, a TDC cyl. 1 marker
and a crankshaft position trigger. The Alpha Lubricator system is normally
timed to inject cyl. oil into the piston ring pack during the compression
stroke.
The cylinder lubrication is based on a constant amount of oil being supplied

per injection. The specific feed rate is controlled by variation of the injection
frequency.
The injection frequency is calculated from index and speed, and is normally
proportional to the engine MEP. However, a power Mode or RPM Mode is
possible.
The basic cylinder oil feed rate at MCR (100%) is calculated as a correlation
between a number of injections / rpm and the stroke of the lubricators.
On the HMI panel, adjustment of lubrication feed rate for individual cylinders
is poss~blebetween 60% and 200%. Default value 1s 100%.
During normal operation the system is controlled by the MCU. If any fail-
ures are detected in the system, a common alarm is activated in the control
room. The detailed alarm reference is displayed on the HMI panel.
If a critical failure in the MCU is detected, the BCU automatically takes over
(Note - control switch must be in "auto" position). An indication lamp "BCU
in control" is lit on the panel that contains the HMI panel.
Note that on older installations, the indication lamps can be situated else-
where.
The BCU is based on random timing and RPM Mode. The injection frequen-
cy is adjustable on the BCU and is normally, as minimum, set to the basic
cylinder oil feed rate for the engine, plus 50%.
1.3 Guidance Cylinder Lub. Oil Pressure Cylinder Lub. Oil Temperature
values automation Normal Service Value 40 - 50 bar Normal Service Value 40 - 60" C
Alarm min. 35 bar Alarm max. 70" C
c
e Alarm max. 60 bar
s+
D
.
::
7045-0110-0003 MAN Diesel
2. Operation of the System
2.1 HMI-Panel I As standard, the HMI panel (for description, see Section 3), a three-position
Operating Panel mode switch, and an indicator lamp are mounted in the engine control room.
However, an additional HMI panel, etc. can, as an option, be installed in one of

the pump station starter panels. In this case a local/remote switch has to be in-
stalled.
.
The three-position mode switch enables selection between:
Auto-mode - BCU takes over automatically, if lubrication cannot be main-

tained by the MCU. If the BCU has taken over the control, this mode can
only be cleared by manually switching to MCU-mode, and back to Auto-
position.
MCU-mode - Forced MCU control.
BCU-mode - Forced BCU is in control.
An orange Indicator lamp - Indicates that BCU is in control.
2.2 Control buttons Each starter panel contains the following switches, buttons and lamps:
and indicator lamps
on pump station A three-position switch controls the pump activity as follows:
starter panels
REM.(Remote) - Automatic control of pumps (normal working position)
LOC.(Local) - Manual start of the pump
OFF - Manual stop of pump.
A two-position main switch - Switches off 3 x 440 V AC power supply
A green indicator lamp - lights if pump is running
A white indicator lamp - lights if 3 x 440 V AC from fuse panels is switched

ON.
2.3 Start-up of 1. To fill the pump station with cylinder oil, open the valves for the cylinder oil
Alpha Lubricator supply line and the venting cock (if installed). Close the venting cock when
System (Engine cylinder oil flows out into the venting line.
not running)
2. Switch on the main switches on the pump station starter panels.
3. Switch to "Local" and manually start pump 1 and subsequently pump 2

Check that both pumps can run simultaneously.
4. Check that the pressure differential indicator on the pump station filter is
green, when one pump is operating.
MAN Diesel 3045-011 0-0003
5. Check that the oil pressure builds up

to 40-50 bar, or carry out adjustment
on the pressure control valve on top
of the pump station.
6. Check that the pressure remains at an

.
acceptable level, also with two pumps
rn
running. 'D
7. Press [esc] and [prelub] at the same

time on the HMI panel to activate the
test sequence, and check that all lu-
bricators are operating correctly by
watching the LEDs (feedback signals)
on the intermediate boxes for each
lubricator.
8. Stop the test sequence by pressing

[prelub] again.
9. At commissioning or after overhaul of

the system, checkvisually from the
scavenge air receiver that all non-
return valves inject cylinder oil into the
cylinder liners.
10. Stop the pumps manually, and switch to "Remote" on the starter panels.
The Alpha Lubricator System is now ready for normal operation.
For engineers commissioning the Alpha Lubrication System, procedures are

made for Testbed Commissioning and Dock Trial Commissioning. The proce-
dures are shown in the Commissioning chapter. For flushing the system, please
read special instruction.
2.4 Checks 1. Upon start of the engine's auxiliary blowers, the Alpha Lubricator System
during start-up of is programmedto carry out automatic prelubrication. The pump station will
engine automatically stop if the engine is not started shortly after.
2. Check that the pump station automatically starts up when the engine is
started, and that the cyl. oil pressure builds up to 40-50 bar.
3. Check that all the green LEDs flash on the intermediate boxes for each lubri-
cator.
4. Check that no alarm is detected in the control room and on the HMI panel.
Start of engines under cold conditions occasionally results in feed-back failures.
In order to prevent this, the circulation of the cylinder oil in the main pipes under
these cold conditions is improved by introducing a manually-operated by-pass
valve provided in the opposite end of the lube oil inlet.
This by-pass valve is only introduced on engines with two lubricators per cylin-
der.
-33045-0110-0003 MAN Diesel
On engines with one lubricator per cylinder, the valve on the cylinder block in-
tended for emptying the accumulator at overhaul can also be used as a by-pass
valve.
The main purpose of the new by-pass valve is to heat up the pipes by circulat-
ing the cylinder oil in the main pipes with open by-pass valve before engine
start. The valve is to be closed just before engine start.
2.5 Periodic checks Check that all lubricating points supply oil by:
during normal
operation of the a) inspecting that all LEDs for feedback indication on the intermediate
engine boxes are flashing
b) feeling the pressure shocks from injection of the lubricators on each

lubricator pipe. If in doubt, dismantle the pipe at the cylinder liner to
observe the oil flow.
2. Inspect the local oil pressure gauge on the pump station. Normal ser
vice value = 40-50 bar.
3. Check for oil leakages in the system
3. HMI-Panel and Configuration of MCU
3.1 Description
Bar graphs The two upper bar graphs display relative values in percent of engine speed and
fuel index (= mep%), respectively. The range is from 0 to 120 percent, where 100
percent corresponds to the physical values at MCR. The third upper bar graph
displays oil pressure in the range of 0 to 100 bar.
Five LEDs for indication of fault category are placed below the numerical display,
Fault category
as follows:
indicators
. Oil pressure low
. Fuel index failure
. MarkerITrigger failure
. Feedback failure
. Common alarm -
For explanation of the alarm code, see the alarm list in Section 5.
MAN Diesel 3045-011 0-0003
Buttons [A 1 Move up in the HMi panel menu structure. See item 3.2.9.
[v 1 Move down in the HMI panel menu structure. See item 3.2.9.
[ESC] Move to the left in the HMI panel menu structure.

See item 3.2.9.
[ENTER] Move to the right in the HMI panel menu structure.

See item 3.2.9.
[LAMPTEST] All lamps are lit in the HMi panel.
[WMPI] Starts or stops booster pump 1.
PUMP^] Starts or stops booster pump 2.
[PRELU~] Can only be activated when engine is stopped. Activates prelu

brication sequence.
The lubricators will be activated continuously from Lubricator 1A.
lB, 2A,... 148. The cycles will be repeated a pre-programmed
number of times (normally 12).
+ [PRELUB]Starts test sequence of 1000 pre lubrications. The test sequence

[ESC]
is stopped by pressing [prelub] again.
[ESC]+ PUMP^] Selects default booster pump to be pump 1.
[ESC]+ PUMP^] Selects default boosterpump to be pump 2.
This section describes the menu system in the HMI-panel numerical display. Six
of the most common manoeuvres are described below and the complete struc-
ture and parameters are shown in items 3.2.11 and 3.2.12.
3.2.1 Navigation HMI panel menu system is a hierarchic menu system. The following four buttons
principle are used to navigate through the menu system.
[A ] Move up in the HMI panel menu structure.
[V ] Move down in the HMI panel menu structure.
[ESC] Move to the left in the HMI panel menu structure.
[ENTER]Move to the right in the HMI panel menu structure.

73045-0110-0003 MAN Diesel
3.2.2 Reading of Press [ A ] or [ V ] until rXXX is shown in the display (Note that this value is an
total strokelmin average value over 1 min.).
[rXXX]
3.2.3 Reading of
total strokes 1. Press[ A ] or [ V ] until diSP is shown in the display.
[Str.hi] and [Str.lo]
and [ A ] or [ V ] until Str.hi or Str.10 is shown in the display
2. Press [ENTER]
3. Press [ENTER]
to read the stroke counter.
4. Press [ESC]
to return to main menu (one press [ESC]
= one step backwards).
5. The total number of strokes is a ten digit number and is obtained by com-
bining the values of Str.hi and Str.10 as follows:
Menu Navigation
The value of Str.10 represents the five rightmost figures and the value of Str.hi
the five leftmost figures.
8 Total number
The total stroke amount is used to calculate the amount of cylinder lube oil used
within a specified amount of time. The following formula can be used:
See example on page 31 (stchi).
3.2.4 Reading of Press [ A ] or [ V ] until ALRXX is shown in the display. -----

active alarms
[ALRXX] For explanation of the alarm code see the alarm list in Section 6
5.
MAN Diesel 3045-011 0-0003
7
3.2.5 Reading 1. Press [ A ] or [ V 1 until LALxx is shown in the display.
of logged alarms For explanation of the alarm code see the alarm list in Section 5.
[LALXX]
2. To clear a logged alarm, press [enter] when the alarm is shown in the
display. To clear all logged alarms, press [enter] for 5 seconds while an
LALxx is shown in the display.
3.2.6 Adjustment For systems with Alpha ACC (Adaptive Cylinder Oil Control) the feed rate is set
of cylinder oil feed proportionally to the sulphur content in the fuel oil and can be adjusted by en-
rate [F.rAtE] tering the percentage of Sulphur directly into the HMI panel as shown below.
Menu Navigation - feed rate adjustment
s-Pct
,- -:$ :~.> Ar to chanee
:: , T,L'.C-,< ENTER to Sam
. .. L 2>.-:
I.:
. . .
' V ] until [ F.rAtE ] is shown on the display.

i[ A ] or [ V ] until [F.SEt] is shown on the display.
' ~ntil[ S-PCt] is shown in the display.
[ A ] or [ V ] to adjust the desired value.
is stored in the computer memory, and the main

Save".
'urn to main menu.

-73045-0110-0003 MAN Diesel
3.2.7 Adjustment Adjustment of basic feed rate is carried out when changing between cylinder oil
of Basic Feed rate with varying base number ie..BN70 t o BN40
[S.FACt]
1. Press [ A ] or [ V ] until F.rAtE is shown on the display.
2. Press [ A ] or [ V ] until F. SEt is shown on the display.
3. Press [ A ] or [ V ] until S.FACt is shown on the display.
4. Using [ A ] or [ V ] adjust the EN factor setting as described in the latest service let
ter. (BN70=0.20, BN60=0.23, BN50=0.28 and BN40=0.35)
Press [enter] -The value is stored in the computer memory, and the main display will
prompt with "Save".
Press [ESC] repeatedly times to return to main menu.
Menu Navigation - Basic feed rate adjustment
3.2.8 Adjustment Press [ A ] or [ V ] until F.rAtE is shown on the display.

of Running in feed
rate [F.runi] Press [ A ] or [ V ] until F. SEt is shown on the display.
Press [ A ] or [ V ] until F.mni is shown on the display.
Press [Enter] and [Cyll] is shown in the display
Press [ A ] or [ V ] until the cylinder to be adjusted is shown in the display or select

SEt.AL to set all the cylinders to the same value.
Press [Enter] and the current feed rate is shown. Please note that if SEt.AL was sel
ected the value shown is the last value saved in SEt.AL, and thisvalue is nottrue if any
cylinder has been individually adjusted since.
c
Press [ A ] or [ V ] - The oil feed rate [glkWh] can be changed to the desired value. o
?
a
Press [enter] -The value is stored in the computer memory, and the main display will
prompt with "Save".
-
Gw
Press [ESC] repeatedly to return to main menu,

MAN Diesel 3045-011 0-0003
3
Menu Navigation - feed rate adjustment - Running In
r r to chanoe
.......... ENTER to saw
(permsnsnuy on1
SEt.AL
3.2.9 Monthly 1. Check which pump is running (1 or 2)

change of operat-
ing pumps (master 2. Press [ESC]+ [PUMP
I] or [PUMP
21 (pump not running).
pump)
3. New master pump is now chosen and running.
3.2.10 Test se- Press [ESC]+ [PRELUB]

simultaneously (the lubricators will lubricate 1000
auence for inspec- times).
tion during stind-
still 2. Press [PRELUB]
the test sequence will stop.
m
c
MAN Diesel
-33045-0110-0003
MenuI Structure
Alpha lubricator HMI panel menu structure part I.-

feed rate adiustment
enu navlaatlon :
up = [A] down = [V] right = [ENTER] left = [ESCI
F l w Chart 1
MAN Diesel 3045-011 0-0003
-
Alpha lubricator HMI panel menu structure part 2, display
enu navmation :
up = [ A ] down = [V] right = [ENTER] left = [ESC] I
(LCD status)
(active alarms!
H
-1
Par.Ch
(MCU psremeler checksum)
(FPGA ~
(~
~
ws
fo
a
fe
rs
h
ec
~~
um
~) rsvlaim numbeO
~3045-0110-0003 MAN Diesel
-
Alpha lubricator HMI panel menu structure part 3, setup menu
Menu naviqation :
up = [A] down = [V] right = [ENTER] lefi = [ESC]
password =
F
h [bar] In.Lo [mAmpl
(lndsxln rloppmitlm - M I N
i n r m 4 O 3 C barj
electrical signal I
,aanr 35 hzr;
[TI in.hi [mAmpl

O"dBxrn slop screw-MPX
("W" "-80 'C,
declrial slgnd)
(il:r:rr? 75 Xi
(P- a1 100% load1
(pressat 75% load1
s 50% load1
( ~ r e at
(Pressa, 25% load1
Flow Chart 3
MAN Diesel 3045-011 0-0003
3
Alpha lubricator HMI panel menu structure part 4, setup menu -
password =
" [ V ] [ A ] [esc] [enter]'
--
p r e u 'ENTER' La SAVE
inl.oF ['I
(injection timing adjurlmsnl (mjedion ofkel, mmmon
menu) engls m s t for all minds-)
! ! -
hY.dEL [ms]
(hydraulic dew, mmrnon
time o w l fw all W n d e s )
! !
I !
I I
-
LCd
(load dlange dependent
-
P.6
(telegraph signal -le) press 'v A ' 0 change
l u b ~ t i o adj.
n menu) (0.200 %) orerr 'ENTER' l o SAVE
(LCD r a m )
(norm 125 %I
Menu navigation
(holding lime) "m5S.V *.,OSBeG!
(norm 30 m1n.l
(-rage time)
("0"" 10 set.)
(devlalim 50
(norm. 10 %)
(LCD mode) i signal. LCD s M
7 (number of ~rp-lubricnlionrl
irpm run .djus~nent) 1 (norm. EFL)
n
Menu mvlgation
pms.. A- ,.,Id-
omrc'EMER'loSAVE
1- (permment on)
j3045-0110-0003 MAN Diesel
-
Alpha lubricator HMI panel menu structure part 5, setup menu
password = (reM,",ionr par inledion a,

100 %,norm. 2 1061
press ..
A. lo change
(upper limit lor LCD edra

lubrblbn, narm 1501
(LCD sblus)
(level tor shangs ,omanue1

edre lubr', norm. 199)
p r e s .ENTER. I SAVE
MAN Diesel 3045-0110-0003
3
3.2.12 HMI panel
parameter refer- A.inJ ["I (abbr. of angle injection)
ence list
The specific crank angles for oil injection for each lubricator. Normally it is the
crank angle at the point where No. 1 piston ring passes the oil quills on the up-
ward stroke of the piston.
The number consists of an online measurement of the angle for the first flank of
the feedback signal plus the angle corresponding to the hydraulic delay time.
Only active when engine is running ahead. Normal value for cylinder one is
around 270 to 310".
AbS.Lo [%I (abbr. of absolute low)
Absolute minimum reduction percentage. The injection frequency can be re-

duced to the value of AbS.Lo in % of the basic frequency. The basic frequency
is the frequency at 100 % load, 100 % rpm, 100 %feed rate setting and is de-
fined as l/rE.inj
Example:
Maximum number of revolutions between injections = 10 revolutions =>

1 --
-
1 =
minimum injection frequency =
max.nos.of rev betweeninjections 10
= o.l[injl rev]
1 1
rE.inj = 4 revolutions basic frequency = = - = 0.25[injlrev]
r E ~ d4
minimum injection frequency =--

0.1 -0.40 =40%
AbS.Lo =
basic frequency 0.25
The normal maximum number of revolutions between injections is 15.
The actual calculated feed rate is displayed here. The feed rate is calculated
based on the measured lubricator strokes.
ALR XX (abbr. of alarm XX)
Code number for active alarms, where the number 'XX' represents the alarm
code. For explanation of the alarm code see the alarm list in Section 5.
Ang.dE (abbr. of angle deviation)
The Maximum allowable angle difference between the marker signal (TDC sig-
nal) from the encoder (or trigger ring) and the marker signal from the BCU pick-
ups. Only valid when engine is running ahead. Normal value is 2 degrees.
13045-0110-0003 MAN Diesel
bAS.FE [S% x sulphur factor] (abbr. basic feed rate)
The basic feed rate is displayed here. ( basic feed rate adjustment is common
for all cylinders)
Co.ALr (abbr. of common alarm)
Manual activation of the MCU common alarm output.

ALCU/xl:l, ALCU x1:2 (MCU/J32:1, MCJ/J32:2), dry contact, normally closed.
Connt (abbr. of connection test)
Connection test menu. Blocked when the engine is running.
diSP (abbr. of display)
Access to display menu ( see F.diSP) Values and parameters are displayed, but
cannot be changed from diSP menu.
F.diSP (abbr. feed rate display menu)
Access to feed rate display menu. Values and parameters related to feed rate
are displayed but cannot be changed.
FE.Adj (abbr. of feed rate adjustment)
Feed rate regulation parameter adjustment menu
F.hi [g/KWh] (abbr. of feed rate high)
Feed rate setting high limit. The maximum possible feed rate setting on the HMI
panel. The value is a percentage of the basic recommended feed rate setting.
Normal value is 1.7 g/KWh
F.Lo [g/KWh] (abbr. of feed rate low)
Feed rate setting low limit. The minimum possible feed rate setting on the HMI
panel. The value is a percentage of the basic recommended feed rate setting.
Normal value is 0.6 g/KWh
F.rAtE (abbr. of feed rate)
Feed rate setting adjustment. The feed rate is set with respect to the fuel oil sul-
phur content and the chosen sulphur factor based on cylinder lubricating oil BN.
The actual feed rate can be set individually for each cylinder or for all cylinders
at one time with the Set.Al function
Reference is made to the normal guidelines for cylinder lubrication. (Latest Ser-
vice letter see appendix 4).
rn Setting between 0.6-1.7 overrides basic feed rate unless set to OFF
F.runi (abbr. running in feed rate)
Running in feed rate. Normal setting is OFF). Normal working range is 0.6-1.7
Setting below 0.6 = OFF.
Feed rate setting menu
F.SCuF 1%) (option) (abbr. of feed rate scuffing)
Feed rate increase in case of scuffing. Input for each cylinder on the MCU
board can receive signal from a cylinder liner temperature monitoring system.
If beginning scuffing is detected, a signal can be given and extra lubrication
activated. Please contact MAN B&W if this function is needed. Normal value is
200 %
Fu.OFF [%I Fuel Offset
Adjustment for fuel quality (caloric value 1 density) and wear of fuel pumps, etc
by fuel index off-set compensation. The actual fuel index should be compared
with engine builder shop test record for fuel index at same mean effective
pressure, and corrected by this fuel off-set adjustment. The fuel offset fac-
tor acts as a gain raising or lowering the index at any given fuel rack position.
Maximal offset is +/-15%. -default value from engine builder 0%.
FPgA (abbr. of fast programmable graphic array)
FPGA software revision number. The IC (Integrated Circuit) (u33) contains the
program for the FPGA. If the FPGA code is updated, a new IC will have to be
installed. The current FPGA software revision is 8.
gEn (abbr. of generator)
Load transmitter calibration menu for engine operating on generator curve ie.
normally only power plant engines. With engine running on generator curve
follow the menu structure at different engine loads and press [ENTER] - The
idle adjustment is done at minimum engine load i.e approx. 3%
hY.dEL [ms] (abbr. of hydraulic delay)
Hydraulic delay (time offset value). The value is inserted to compensate for the
time-delay from the first flank of the feedback signal, until the oil enters the
cylinder through the cylinder liner non-return valves. The longer the hydraulic
delay - the earlier the solenoid valve is activated. The Hydraulic delay is calcu-
lated in the design process and is confirmed by measurements on prototype
engines. A good estimate of the value is 1 ms for each meter pipe length from
the lubricator to the cylinder liner. The value cannot be adjusted individually for
each cylinder, but is common for all cylinders. Normally values are from 1 to 6
ms.
in.A [mA] (abbr. of index ampere)
Read out of the index transmitter current. The mA signal from the index trans-
mitter without scaling. Used for mechanical adjustment of the index trans-
3045-0110-0003 MAN Diesel
mitter during commissioning. The index transmitter is adjusted to 4.5 mA at

mechanical minimum index and to 19.5 mA at mechanical maximum index. The
adjustment is made on testbed before initial start up.
in.AdJ (abbr. of index adjustment)
lndex transmitter adjustmentlcalibration menu. Accesses the parameters for ei-

ther propeller curve (ProP) or generator curve (gEn).
in.hi [YO] (abbr. of index high)
lndex transmitter raw calibration value. The index transmitter calibration values
are given as an index low (in.Lo) value and an index high (in.hi) value. These val-
ues are the theoretical index percentages when the pickup gives respectively 4
and 20mA. Estimated values are pre-programmed from MAN B&W, and the sys-
tem is calibrated by means of the (ProP) or (gEn) menus on testbed. The raw
values should only be changed if the automatic calibration in the ProP a n d
gEn menus, proves insufficient.
The values are normally around -30 to -10 for [in.Lo] and around 125 to 140 for
[in.hi].
in.Lo [%] (abbr. of index low) See in.hi.
-
init Basic adjustment of lndex transmitter. The adjustment should be approx.
4,5 mA in stop position i.e Omm and approx 19.5 mA at max fuel index ie. me-
chanical stop screw limiter active.
inJ.AL (abbr. of injection algorithm)
lnjection amount algorithm menu. lnjection rate calculation can be chosen

in proportionto mean efficient pressure (nneP),rpm (rPnn) or power (Po.). Normal
mode is Po (power proportional).
inJ.oF ['I (abbr. of injection offset)
lnjection offset. Angle offset inserted to compensate for small deviations be-
tween the injection angle determined in the design process and the actual crank
angle for injection. The actual crank angle for injection is normally when the first
piston ring passes the oil quill during the upward stroke of the piston. inJ.oF can
be adjusted within +/- 5 4
The value cannot be adjusted individually for each cylinder, but is common for all
cylinders.
Normal value is 0.
LALXX (abbr. of logged alarm XX)
Logged alarms where the number 'XX' represents the alarm code. When an
6
alarm is activated, it will appear as both ALRXX and LALXX. The LALXX will
remain after the alarm is gone. For explanation of the alarm code see the alarm 9
list in Section 5.
?
D
To clear a logged alarm press [ENTER] while the alarm code is displayed. To clear ::
all logged alarms press [ENTER] for 5 seconds while one of the alarm codes is
displayed.
-1 MAN Diesel 3045-0110-0003
Led X (abbr. of load change dependent X)
Load change dependent extra lubrication status. X indicates the status. When
LCD is active, i.e. when a load change situation occurs, the status changes from
0 (=off) to 1 (=on). The normal hold time is 30 min.
Lcd (abbr. of load change dependent)
Load change dependent extra lubrication parameter adjustment menu. Six pa-
rameters. P i to P6, can be adjusted. For further explanation see Pi to P6.
L . c ~Geometric
~- lubricator volume inclusive hydrualic efficiency
Ltr.hi - Lubricator flow meter in liters
Ltr.10 - Lubricator flow meter in liters

Lubr - Access to setting of lubricator volume and cylinder oil density
MEP [YO](abbr. of mean efficient pressure)

Mean effective pressure percentage (equal to torque percentage and index per-
centage). Scaled read out of the index transmitter input. The value is used for
the amount regulation. When generator curve running the value is equal to the
load percentage. When ideal propeller curve running normal values are: 25 %
load = 40 % MEP, 50 % load = 63 % MEP, 75 % load = 82 % MEP, 100 % load
= 100 % MEP. The value changes according to the propeller margin.
n [rpm] (abbr. of speed)
Engine speed.
nne.Li [%] (abbr. of MEP limit)
Example 1 (propeller curve running):
Desired:Change to RPM dependent lubrication under 25 % load,
-
Conditions at change point Load % = 25 % propeller curve MEP % =
=40%-RPM%=63%.
(Example 2 (generator curve running):
I I
Desired: Change to RPM dependent lubrication under 25 % load.
-
I
Conditions at change point: Load % = 25 %generator curve MEP % =
=25%-RPM%=100%.
I
-9045-0110-0003 MAN Diesel
,
MEP relative limit. Only used when inJ.AL is set to nnep. Minimum relative re-
duction percentage for the MEP dependent amount regulation. The parameter
is used for defining the level where the algorithm changes from MEP dependent
regulation to RPM dependent regulation. The parameter is relative i.e. the load
point of change is independent of the feed rate setting.
nor.hi [%I (abbr, of normal high)
Upper limit for automatic extra lubrication (LCD) i.e. (basic feed rate / 1.1 g/kwh)
* 100 * LCD factor will be limited by normal high setting 200% (2.2 g/kwh). Nor-
mally disabled by setting parameter to 199
n.PrL (abbr. of number prelubrications)
Number of prelubrications. Number of prelubrication sequences carried out when

signal is given to ALCU/Xl:25, ALCU/Xl:26 (MCU/J30:7, M CUN30:8) or [PRE-
LUB.] button in HMI panel is pressed. Only active when the engine stopped.
Normal value is 12.
0iL.d [ g/cm3] -Typical value at 45 'C = 0.92 g/cm3
P.1 (abbr. of parameter 1)
LCD mode. The following modes can be chosen:
OFF Off Permanent off - e.g. used for testing

on On Permanent on - e.g. used for testing
int. Internal All functions controlled internally by ALCU, based on index de-
viation.
E.FL External Start and duration is controlled externallv bv b i n a i~n ~ ufrom
t
flag governor. Only amomt s conlrolco by ALCU ~ i c o n t a c from r
governor to ALCU/X2:1 A_CL/X2:2 (MCU/ ,30:3. MCb/J30:4)
ESig External Start is controlled externally by binary input from governor.
signal Duration and amount are controlled by ALCU. Dry contact from
governor to ALCU/X2:I, ALCU/X2:2 (MCU/ J30:3, MCU/J30:4)
lELE.P Telegraph All functions controlled internally by ALCU based on analogue
position input from governor proportional to telegraph handle position.
4-20 mA signal from governor to ALGU/ XI :33, ALCUIXI :34
(MCU/J40:1, MCU/J40:3) Used in case of mechanical gover-
nnr
Normal mode is E.FL,
P.2 [%I (abbr. of parameter 2)
LCD deviation percentage. Used only when P.l is set to int. or tELE.P. To acti-
vate LCD, the index (or telegraph position in case of tELE.P mode) must change
6
more than the LCD deviation percentage (P.2) within the reset time (P.3). D
N
*
Normal value is 10 % in case of internal mode (int.). Normal value in telegraph s::
position mode (tELE.P) is 2 % or a sufficient value to insure that the smallest
step on the telegraph handle (e.g. dead slow to slow) releases LCD.
MAN Diesel 3045-0110-0003
-')
P.3 [sec.] (abbr. of parameter 3)
Average time or more correct: reset time. Used only when P.l is set to int. or
tELE.P. To activate LCD, the index (or telegraph position in case of tELE.P
mode) must change more than LCD deviation percentage (P.2) within the reset
time (P.3). Normal value is 10 sec.
P.4 [min.] (abbr. of parameter 4)
Holding time. Used only when P.l is set to int., E.Sig, or tELE.P. When the LCD
function is activated, it will remain active for a period of the holding time (P.4).
Normal value is 30 min.
P.5 [%I (abbr, of parameter 5)
LCD factor. When LCD is active the feed rate setting for each cylinder multiplied
by the LCD factor (P.5). When the LCD function is active, the injection algorithm
(inJ.AL) is set to RPM (rPnn). Default value is 125 %.
P.6 [%I (abbr. of parameter 6)
Telegraph signal scale (used in tELE.P mode only). Scale factor for the mA input
to terminals ALCU/X1:33, ALCU/X1:34 (MCU/J40:1, MCU/J40:3).
Examples:
1) If 4-20 mA corresponds to 0-100 % RPM, the value of P.6 should be 100 %.
2) If 4-20 mA corresponds to -100 to 100 % RPM, the value of P.6 should be
200%: Normal value is 100 %.
Par (abbr. of parameter) (in diSP menu) (far MAN B&W sewice engineers)
'Raw' read out of all setup parameter values. The parameters are numbered 1
through 196. Please contact MAN B&W for further information.
Par (abbr. of parameter) (in SEtuP menu) (for MAN B&W seruice engineers)Raw'
adjustment of setup parameters. The parameters are numbered 1 through 196,
Please contact MAN B& W for further information.
-
: U.." ~ ....
~ .. . ~ ~ .-.-.
. < . .. --.. .~~
....-.
A .
Adjusting the values in the "Par" menu may cause damage to the engine and
orised personn
... . . .. .
~
~ ~ ..
The menu is entered in the following way:
1. Navigate through the SEtuP menu until Par is displayed on the HMI
panel.
2. Press [enter] - the system will respond PASS.
3. Enter the password sequence: [ESC][A] [V] [ENTER]
4. Press ""A V"" to select parameter number.
Par.Ch (abbr. of parameter check)
MCU parameter check sum,

,73045-0110-0003 MAN Diesel
PASS (abbr. of password)
Password required. The menu you wish to enter is password protected to pre-
vent access. The password for the SEtuP menu is = [A] [V][~sc][ENTER]
The password for the Par sub menu in the SEtuP menu is = [ESC][A] [V] [ENTER]
Pmcr (KW) Total engine power in KW
Po.Li [%] (abbr. of power limit)
Power relative limit. Only used when inJ.AL is set to Po. Minimum relative re-
duction percentage for the power dependent amount regulation. The parameter
is used for defining the level where the algorithm changes from power depen-
dent regulation to RPM dependent regulation. The parameter is relative, i.e. the
load point of change is independent of the feed rate setting.Normal value is 40
%.
Example 1 (propeller curve running):
Desired: Change to MEP dependent lubrication under 25 % load.
Conditions at change point

Load % = 25 % propeller curve - MEP % = 40 % - RPM % = 63 %.
Po.Li =
Load%x100 - 25%x100 = 40%
R P M% 63%
Example 2 (generator curve running):
Desired: Change to MEP dependent lubrication under 25 % load.
Conditjons at change point

-
Load % = 25 %generator curve - MEP % = 25 % RPM % = 100 %.
Lond%xlOO -
-
25%x100 = 25%
Po.Li =
R P M% 100%
pOil [bar] (abbr. of oil pressure)
Booster pump pressure.

Normal value is 40-50 bar.
Alarm level is 35 bar
Prop (abbr. of propeller)
Load transmitter calibration menu for engine operating on propeller curve i.e.
normally all vessels. With engine running on testbed on propeller curve follow
the menu structure at different engine loads and press "Enter" -The Idle adjust-
ment is done at minimum engine speed i.e. approx. 30% rpm
MAN Diesel 3045-0110-0003
Pu (abbr. of pump)
Booster pump adjustment menu. The following parameters can be adjusted:

Pu.SEt, Pu.dEF, Pu.int. For details see the respective parameter
Pu.dEF (abbr. of pump default)
Default pump selection. Used only when Pu.SEt is set to backup mode. If e.g.
PI is chosen, pump no. 2 will only start in case of low pressure alarm. The de-
fault pump can also be chosen by "short cut" from the HMI panel by pressing
[esc] and PUMP^] or PUMP^] simultaneously.
Pu.int [hour] (abbr. of pump interval)
Pump interval time. Used only when Pu.SEt is set to Auto mode. After an inter-
val of Pu.int the master pump is automatically changed from pump 1 to 2 and
vice versa.
Normal value is 12.
Pu.SEt (abbr. of pump setup)
Pump mode setup. backup or Auto mode can be chosen. In backup mode the
master pump is selected manually by the operator by pressing [EX] and [PUMP XI
on the HMI panel. In Auto mode the master pump changes automatically after
an interval of Pu.int.
Normal value is backup.
r XXX (abbr. of rate xxx)
Strokes per minute. Read out of total number of lubricator strokes per minute for
the whole engine. The number is the average over one minute. The instant feed
rate can be calculated based on total strokes per minute.
Example:
Lubricator volume (compensated for volumetric efficiency 0.97) = 1.8 cm3

(The value can be found on page 2 of the setup document enclosed with the
ALCU unit)
oil density = 0.94 kgll
power = 70000 kw
r XXX = strokes per minute = 462
~ e e rate[gkwh]
d =
r ~ ~ ~ [ s t r o k e / m i nlubricator
]x volume [cm3] ~ o i l d e n s i ~ ~ b/ c6 d0
power [kw]
--
462[stroke/min]x 1.8 [cm3] x 0.94 [g/cm3]x 60 = 0,65[g,,whl
70000 [kw]
Please note that a much more accurate calculation can be made using
the Str.hi and Str.Lo in the diSP menu.
MAN Diesel
rE.inj [revolutions] (abbr. of revolutions/injection)
Revolutions per injection. The number of revolutions between oil injections on a

cylinder at 100 % load, 100 % rpm and 100 %feed rate setting. The parameter
has to be changed if the recommended basic setting of cylinder oil feed rate is
changed. Reference is made to our general guidelines for cylinder lubrication
and service letters.
Normal values are 2 to 6.
r.run [rprn] (abbr. of rpm run)
Rpm run. Engine run detection limit. When the engines rpm is above r.run, lu-
brication will start and when rpm is below r.run lubrication will stop.
Please note that the parameter influences the alarm delays for the tacho sys-
tem and should therefore not be changed without consideration. Default value
is 8 rpm.
Ser.hi [%I (abbr. of service high)
Feed rate setting max. normal service. Only used when inJ.AL is set to nneP
or Po. If the feed rate is set above Ser.hi - the feed rate is set over the limit for
normal service lubrication. A feed rate setting over the limit for normal service
lubrication is per definition "manual extra lubrication", i.e. used for breaking-in
new liners and rings. The feed rate calculation algorithm is therefore changed
to RPM dependent, disregarding the setting of inJ.AL. (Reference is made to
the guidelines for cylinder lubrication and service letters).
Normal value is 200 %. Normally disabled by setting parameter to 199
SEtuP (abbr. of setup)
Setup menu. Values and parameters can be changed in the SEtuP menu. The
menu is password protected to prevent access.
The menu is entered in the following way:
1. Navigate through the menu level until SEtuP is shown in the display.
2. Press [enter] the system will respond PASS.
3. Enter the password sequence: [A] [V] [EX] [ENTER]
4. Press ""A r"" to select the parameter you want to adjust
S.FACt [ g/kWh x S%] - Basic sulpur facto,: The standard and Running -in
(Phase 1 and Phase 2) ACC factor is set here.
Reference is made to the normal guidelines for cylinder lubrication (Latest ser-
vice letter and Appendix 4 of this manual)
Sof.Ch - MCU software checksum

'I MAN Diesel 3045-011 0-0003
SoFt (abbr. of software)
MCU software revision number.

The current MCU software revision is 2.5
So1.t (abbr. of solenoid valve test)
Solenoid valve test - Manual activation of solenoid valves. Blocked when the en-
gine is running.
Each solenoid valve can be activated in the following way:
1. Enter the So1.t menu
2. Choose the lubricator number by pressing the [A] and [V] key.
3. Select the lubricator by pressing [enter]
4. Press [A] to set lubricator on, press [V] to set lubricator off.
S.Pct - Fuel oil sulphur content. The actual fuel oil sulphur content is set here.
Str.hi [strokes* lo5](abbr. of stroke high) (in diSP menu)
Total lubricator stroke counter. The total number of solenoid valve activations
durlng the hfetime of the engine. The Str.hi menu shows the values from lo5 to
lo9.The Str.Lo shows the values from 1 t o lo5.
The feed rate can be calculated based on the change of Str.Lo and Str.hi over
period of time,
Example:
Lubricator volume (compensated for volumetric efficiency.) = 1.8 cm3

- 2 of the setw document enclosed with the
(The value can be found on .vase
ALCU unit)
oil density = 0.94 kg/l
power = 70000 kw
Measurements at time = 00:OO

Str.Lo=Illll
Str.hi = 12345
Measurements at time = 01 :00

Str.Lo = 44444
Str.hi = 12345
Feed rate [gkwh] =
(total stroke 2 - total stroke I) x lubricator volume [cm3] x oil density[g/cm3]

power F w ] x .(time 2 - time 1[how])
Feedrate [glkwh] =
(1234544444- 1234511111) x1.8 [cm3]x 0.94[g/cm3 ]

= 0.8l[ghh]
70000 F w ] x .(Ol:OO- 0O:OO [hour])
73045-0110-0003 MAN Diesel
Str.hi [strokes* lo5](abbr. of stroke high) (in SEtuP menu)

Total lubricator stroke counter. Adjustment of total stroke counter in case of i.e.
change of MCU board, etc.
Str.Lo [strokes] (abbr. of stroke low) (in diSP menu)
See Str.hi (in diSP menu)Str.Lo [strokes] (abbr. of stroke low) (in SEtuP menu)
t.dLy [ins](abbr. of time delay)
Activation delay time. On line measurement of the time from activation of sole-
noid valve to the first flank of the feedback signal, used for automatic compen-
sation of timing of the solenoid valve activation.
The delay can also be used for trouble shooting by observing if the delay time
deviates on a lubricator.
tEcH (abbr. of technical)
Technical parameters. Sub menu in diSP menu containing the menu items,
which are not used for normal operation.
For explanation of their functionality see SoFt, SoFt.ch, FPgA, Par.Ch and Par.
ti.Adj (abbr. of timing adjustment)
Injection timing adjustment menu. Used during commissioning

For further explanation see hY.dEL and inJ.oF.
toil [ O C ] (abbr. of temperature oil)
Booster pump suction tank oil temperature.

Normal value is 40 to 60 "C.
Alarm level is 70 "C.
vALue (abbr. of value)
Manual correction of electrical values - It is possible to read and modify these

end points of the index scaling. If the mechanical end stops are moved or
change this might the needed. The lowest allowed signal is 4 mAmp and highest
allowed signal is 20 mAmp. The default values are 7 mAmp and 16.5 rnAmp.
XXX
Display of a number,
-\ MAN Diesel 3045-01 10-0003
3.2.13 Check and adjustment of index transmitter

The following guidelines are relevant for the adjustment or replacement of the
index transmitter on engines in service.
Adjustment 0f Adjust the index transmitter electrically until:

index transmitter The minimum index from the engine side control console corresponds to 4.5mA.
The maximum index from the engine side control console corresponds to
19.5mA.
See Testbed Commissioning Procedure on page 129.
Adjust the fuel rack on the engine side control console to an index correspond-
ing to 50% load at testbed conditions ,POX
Calibration of index (relevant values can be found in the Enma =P- bOOOOOOOOOOOOOOOOOO4
signal shoptest report).
1"d.Z ~000000000000000000
Navigate, via the HMI panel, to the In-
dex Adjustment menu. P,-*~-~OOOOOOUOUOOOOOOOOO
Choose either the generator curve or ,c 0
the propeller curve, depending on the "-"ID
measurements obtained on the test- IIIz,IU. U. U. U. lzijll
Select 50% in the Menu, and press

[ENTER].
When the groaeller curve and 50%

are selected, and enter is pressed, the
index readina will be: 63%
Adjust the fuel rack on the engine side control console to an index correspond-
ing to 100% load at testbed condition (relevant values can be found in the shop-
test report).
Navigate, via the HMI panel, to the Index Adjustment menu. Choose either the
generator curve or the propeller curve, depending on the measurements ob-
tained on the testbed.
Select 100% in the Menu, and press [ENTER]. The index transmitter has now
been adjusted.
Password
These settings are only 100% valid when running on diesel oil. When running on heavy
fuel there can be a minor offset, which can be compensated for by adjusting the me-
chanical connection from the fuel rack to the index transmitter.
,73045-0110-0003 MAN Diesel
3.3 MCU setup

3.3.1 Dip switches Two blocks with each 8 dip switches are available on the MCU board, SW 0
for MGU and SW 1. The MCU DIP switches must be set correctly prior to starting the u p -
load of application. The DIP Switches set the bootloader baud rate for the MCU.
DIP SWO
Hard1ware Reset
9 pole SUB-D J51
DIP SW1
The first DIP switch SWO is located at the left side of the MCU.
This switch must be set as the pictureltable below indicates: Next to the DIP
switch the hardware reset button can be seen.
MAN Diesel 3045-01
The second DIP switch SWl is located on the top of the MCU, where all the
other connections are made.
This switch must be set as the picturehable below indicates:
OFF
3.3.2 Hardware Interface
RS232 link The download of program code is done through a standard RS232 null-modem
cable.
On the MCU use the 9 pole SUB-D male connector J51.
The baud rate on the serial link is 38400 baud, which the VTlOO terminal RS232
interface must be able to handle.
Cab'e & connectors A single standard null-modem cable is required in order to connect the VTlOO
terminal to the unit. The cable must hold a 9 pole SUB-D female connector in
one end and an appropriate connector to the VT100 terminal - normally either 9
or 25 pole SUB-D female.
If a standard cable is not available a cable can be made by you. Only three wires
are required to make up a usable null-modem cable. However if the cable is very
long (> 5 meters) shielded cable of reasonable quality should be used.
Null-modem cable 9 pole to 9 pole connector:
Pin 2 t + Pin 3
Pin 3 t + Pin 2
Pin 5 C+ Pin 5
-)3045-0110-0003 MAN Diesel
3.3.3 VT100 program requirements and setup
Terminal A standard VT100 terminal is required. This may be any standard terminal soft-
requirements ware which is able to fulfil the following requirements:
Asynchronous communication at 38400 baud.

VT100 terminal emulation
XMODEM protocol.
The XMODEM protocol should be able to handle retransmissions. However
this is not a requirement.
One example of such a program is the standard "HyperTerminal" supplied with

all versions of MS-Windows. The usage and setup of this program is described
in the following chapter.
Many other adequate programs are available in both commercial and shareware
versions.
HyperTerminal Before using HyperTerminal please check the program date which must be dat-
setup ed 1998 or later. Previous versions of HyperTerminal have a bug in the Xmodem
protocol.
To setup the HyperTerminal follow these simple steps:
1. Start the program "HyperTerminalV

2. Select Page -> Properties:
. .. . -. . .......--...... ....-. .... - .- -.. .-
,ha Lbbiicntor Seriel Connection Propeltier
-. .- - -
izk
[ T I p&r
b
3. Select the appropriate communication port on the scroll-box "Connect w
using".
4. Press the "Configure" button.
3 MAN Diesel 3045-0110-0003
5. Select the following port settings:
Bits per second (baud rate): 38400

Data bits: 8
parity: None
Stop bits: 1
Flow control: none
6. Optionally the setup may now be saved as a file in order to reload the
setup at a later time.
Now you will be ready to use Bootloader.
Connecting two PCs to each other through the null-modem cable may test the
VTIOO terminal setup. If the setup is correct it will be possible to write messages
between the two terminalsIPCs.
3.3.4 Upload of The PC is connected to the MCU by means of the RS 232 serial cable, and the
MCU basic pro- VTIOO terminal is started. As explained in the previous sections.
gram
Power up the MCU or reset it by using the hardware reset button. Dependent on
the state of the MCU continue with section ( MCU without application) or ( MCU
with application).
>3045-0110-0003 MAN Diesel
MCU without If the MCU has not previously been programmed the VTIOO terminal looks like
application this when the MCU starts up: Type password "manbw" and press return this will
enter the Bootloader MainMenu
iting ~/ur...oK
s t i n g BPROM.. .OK
s t i n g PROM . . . FAILED!
i t i a l i s i n g BES k e r n e l . . .OK
*" B o a t l o a d e r Program, AlphaLube +++"
l j e c t r e v i s i o n number: b o o t l o a d - 0 8 0 6 - 1 . 2
MCU with If the MCU already contains software but this software has to be updated with a
application new version the password must be entered at the correct time during the start
up sequence.
When the service terminal prints "CODELOAD Password:" it waits a few seconds
before continuing. At this moment type "manbw" and press return. This will en-
ter the Bootloader MainMenu.
Press the hardware reset button to try again if not successful at first
T e s t i n g R W ... OK Type password now to enter Bootloader MainMenu

T e s t i n g BPROH ... OK
T e s t i n g PROM ...OK
/ Function t o program u n i t .
....o r
t o s t a r t normal p r o g r a m e x e c u t i o n .
Press hardware reset button to try again or type password to

enter Alpha Lubricator MainMenu
MAN Diesel 3045-011 0-0003
7
Uploading application from Bootloader MainMenu
Now the MCU should be in the "Bootloader, MainMenu" and the VTlOO terminal
should look like the picture below.
If it doesn't look like the picture but the first line is: "MainMenu for Alphalubrcator"
the password was typed to late in the start up sequence. Please press the hard-
ware reset button and try entering the ~ootloaderMainMenu again
To start downloading a new program to the MCU select "Download new applica-
tion program (binary)" with the arrow and press return.
>>> B o o t l o a d e r , HainMenu <<< (255) NODFF

I>-Download new a .p.p l i c a t i o n proararn ( b i n a r y )
I:
-
Force r e s t a r t
Clear FLASH memory
Kernel Assert ~ o g
E x i t Service Terminal
~ ~ ~~
Before proceeding make sure that you have

the new application ".bin file ready!
If you have the new application ready press return to confirm that the current
program in the MCU will be erased and a new application uploaded
73045-0110-0003 MAN Diesel
]I >>> Download new a p p l i c a t i o n program ( b i n a r y ] <<< (255) NOOFF

'1.
sack t o M a i n Menu (2 x Esc) . .

~ -- ~
,.
~
..,. .. . . ,. ... . ..,

",,m -MI., . . .i. . - . I
Wait for the current application to be erased from flash. When the text
"Send application program using XMODEM.." is displayed the MCU is ready to re-
ceive the new application
...
;*I!
Erasing a p p l i c a t i o n f l a s h devices OK
Send a p p l i c a t i o n program u s i n g XNODEM ...C- 14
I:
I I
1
1:
On HyperTerminal the transfer is started by selecting: "Transfer -> Send File" to

send a file: Be sure to select the correct protocol: "Xmodem".
Type in the name of the file to be uploaded, and press "Send".
MAN Diesel 3045-0110-0003
3
/I Folder: M:\lubricator\trn 1
Protocol: -- ~
; Xrnodem /"j
. .
-
A window showina transfer statistics will now amear, the file transfer takes sev-
era1 minutes:
.. ... ... . . . . . . . . . . . . . . . .. ... .. . . .. ... . . . ...-

. ..
. ...
(modkm file send f o r ~ l p h a . l u b ~ i c a t o
~ re t ' i eCbnnection
l
Sending: M:\lub~icator\trn~MCU-ver2.4.bin -
---- -.
Packet: ;332
.................... 1 Error checking: , CRC
................ j
.............. ...........
Retries:.. . .0 . . ......... ..! ....Lotalretries:..&O ................. 1.. ............
................. .
File: i ~ t ~
..... . . . . . . ........
E apse& 00'00 23
. . . . .
Rernamg 00 03.45 -.
.................
Througnput 1769 cps . .
When the transfer has ended, the MCU will calculate a checksum of the file
received and compare it against a checksum within the received file together
with file length. If correct the MCU will program the FLASH and reboot without
further notice.
-33045-0110-0003 MAN Diesel
~ ~ . . .. . ~ .. ~ ~ .. ~ . ... .. . . ~.
Ir&alulieald! SP~~ICYIIIWCI~DI;. nyptl~~hd
--
~ ~
ie tdl *w Cd ,,& HIP

z 11B e8
E r a s i n g a p p l i c a t i o n f l a s h d e v i c e s ... OK
. .,
send a p p l i c a t i o n p r o r a m u s i n g XMODEM...CCCCCC OK '
C h e c k i n g CRC o f d o m q o a d e d program.. .- */
i
: I!
!
,
1
8
j
I
: bI
! I
: i
Verifying MCU
software version Verify that the programming of the MCU was successful by reading the soft-
ware version number shown in the menu. This is viewed by typing the password
"manbw" when the start up sequence has ended. This will enter the Alpha Lubri-
cator MainMenu. From this menu select "Revision Menu".
The current software version number is printed at the top: "Software Rev" ::
MAN Diesel 3045-01
II R e v i s i o n Menu
3.3.5 Upload MCU The PC is connected to the MCU by means of the RS 232 serial cable, and the
set-up file VtlOO terminal is started.
From the Alpha Lubricator menu, press [I] (Transfer of setup data), followed by
[I] (Upload setup file). A capital C will start moving from left to right, indicating
the time remaining for uploading of set-up file. If the file is not uploaded suc-
cessfully the first time, just try again. This is not critical.
In the VTIOO terminal, select menu item rransfer] followed by [Send File], then
browse until you have found the correct setup file on your PC. Select the file and
press [Send].
When the file is transferred, ignore the command "Type password", which is dis-
played for a few seconds. Press M. Now the new configuration parameters are
uploaded.
Interrupt the 24DC volt power supply. The green light will turn on and the MCU
is ready for operation.
If the MCU set-up file generated by the set-up program does not match the
basic MCU program, the VTIOO terminal will display an error message and the
MCU will load the default set-up file.
The remedy for this is to download the default set-up file from the MCU to your
PC and manually change the displayed parameters for this specific file to match
the originally generated parameters. Save the new set-up file on your PC and
upload it to the MCU.
If the MCU is not able to receive the set-up file, turn to the VT100 menu 9 (MBD
Development menu) in order to reset RAM.
-?045-0110-0003 MAN Diesel
3.3.6 MCU LED On the MCU a main LED is positioned in the upper left corner. The status of the
Information unit is given as follows:
Red/green flashing: The MCU basic program file is not loaded. Green flashing:
MCU set-up file is not loaded. Green light: Normal condition. Red light: Alarm
condition
3.3.7 Read-out of The HMI panel facilitates a menu that enables the use of read-out of all set-up
raw parameters in parameters. This feature might be helpful when troubleshooting the system.
HMI panel To read-out the raw parameter, follow the instruction below:
Navigate through the menu as follows:
Menu Navigation - Display Menu
Press [ A ] or [ T ] to display the parameter number. When the requested param-

eter number is displayed, press [ENTER]. The parameter value is displayed.
To view a new parameter number, press [esc] until the parameter number is dis-
played again. Press [ A ] or [ T ] to select a different parameter. To return to the
RPM read-out, press [esc] four times.
3 MAN Diesel 3045-0110-0003
3.4 MCU lndex scaling improvement
Improved index (% MEP) calibration of the Alpha Lubricator mkll
3.4.1 lnitialization
3.4.2 Calibration of load points
3.4.3 Adjustment of endpoints
3.4.4 Fuel Offset fact01
3.4.5 Involved Parameters
Calibration of the mA reading from the fuel rack at fixed engine loads should be
done at test bed.
Depending on whether the engine is driving a propeller or a generator the load

relates to the different lndex values. The following illustrations are shown for an
engine driving a propeller.
In the following sections index % below zero is discussed, it is important to note

that the index will never go below zero when operating the Alpha Lubricator.
In order to obtain the correct slope towards zero it is acceptable to have index
% below zero in the calibration values.
3n4dinitialization lnitialization is carried out to ensure that all the calibration points are evenly
spaced between the mechanical end stops, and that the end stops are defined
correctly. This ensures that calibration will run problem free.
.. Initialization must always be made with stopped engine.
. Initialization must always be made before calibration.

Initialization overwrites the current calibration points.
Steps 1. The lndex transmitter must be adjusted to give approx. 4.5 and 19.5 mA. at
0 mm. and maximum possible index. Access the index transmitter adjust-
ment menu on the HMI panel as described in the Testbed Commissioning
Procedure page 129. (See also page 24 and 30 for more information.)
2. Adjust lndex to 0 mm: SEtuP+ In.Adj +Prop or gEn+init +in.Lo+done
3. Adjust lndex to max: SEtuP+ In.Adj+ Prop or gEn +init +in.hi+done

-7045-0110-0003 MAN Diesel
When the mechanical stops are adjusted correctly and the initialization is made
for either propeller running or generator, the values in between are calculated.
The values are shown below.
Propeller Generator
Load % Index% I mA Index % I mA
* Default values
Initial calibration data

1440 1
.",-
Fuel rack position [mA]
MAN Diesel 3045-0110-0003
3'4'2 Of
The calibration is made at 5 fixed load points. This is preferably done at testbed
load points but if this is not possible then the testbed fuel rack measurements are to be
used.
The following is shown for an engine running propeller mode.
Steps 1. Adjust engine load to 0% (Engine running at idle)
2. SEtuP + In.AdJ + Prop + idle + done

3. Adjust engine load to 25%
4. SEtuP +ln.AdJ + Prop + 25% +done

6. SEtuP +ln.AdJ + ProP + 50%+done

8. SEtuP + In.AdJ + ProP + 75% + done

9. Adjust engine load to 100% (Engine running at MCR)
10. SEtuP + In.AdJ + ProP + 100% +done

Calibrated index scaling may look like the illustration below
- -
Calibrated values
II Fusl rack poslllcm ImA]

-j3045-0110-0003 MAN Diesel
3'4'3
Of It is possible to read and modify the end points of the index scaling. If the me-
endpoints
chanical end stops are moved, this may be necessary.
Only the mA value is changeable.

Reading / changing the values are done viathe Index adjustment menu onthe
HMI as follows:
SEtuP + In.AdJ + VALUE+ in.Lo 1 in.hi upfdown modifies * 0,OlmA

The first point is changeable
From 4 mA (the lowest allowed signal level)

Up to the idle calibration value (default this is 7 mA.)
The last point is changeable
From the 100% calibration value (default this is165 mA.)

Up to 20 mA. (the highest allowed signal level)
The illustration below shows these limits. As it is seen it might be a good idea to
make a complete initialization and calibration if the end values get close to the
calibrated values.
End point adjudment
.-,-
Fuel rack posltlon ImAI
MAN Diesel 3045-0110-0003
3
3.4.4 Fuel Offset
factor It is now possible to adjust the fuel quality in the range of +15%. The adjust-
ments are made to the lndex calculated on basis of the calibration values.
The illustration below shows how the Fuel Offset Factor acts as a gain raising
or lowering the index at a given fuel rack position.
The Fuel Offset Factor is modified via HMI:
Menu Navigation - Fuel Offset factor

Upldown modifies -t 0.1%
- ,> - -
~>.:
.~.
-.>
:L-L
., ~
., . ,. ,
. .~. ......
r r tochange
ENTER losavs
3.4.5 Involved The calibration values are saved in the parameter file. In total 14 parameters are
Parameters used.
Values contain the mA values at the fixed load points (0, 5, 25, 50, 75,
100.130)%
mA. values xl00 thus 4.54 mA is represented by 454.
All values must be greater than 4,00 mA
All values must be smaller than 20,OO mA
Values must be ascending, IndexCurrent[i]<lndexCurrent[i+l].
Values contain the lndex % at the fixed load points (0, 5, 25, 50, 75,
100,130)%
lndex % values x10, thus 82,5% is represented by 825.
All values must be greater than -20%
All values must be smaller than 130 %
Values must be ascending, IndexPercent[i]<lndexPercent[i+l].
The parameter has to be consistent; they must be ascending and within limits
This is verified during calibration of each load point. If the value is not be-
tween the previous and the following it is neglected and error is indicated at
HMI.
When a parameter file is read the values are also verified and if not consis-
tent the complete parameter set is discarded. The invalid parameter is iden-
tified by the line number.
7045-0110-0003 MAN Diesel
4. Configuration of BCU
Two dip switches, S W l and SW2, are placed in the upper left corner of the BCU
board. These dip switches are used to configure the BCU, see below in Items
4.1 to 4.6. (See also Appendix 6).
4.1 Injection rate

with BCU in control Injection rate for the BCU is set on the dip switches SWl positions 1 - 4, as a
binary value.
Examples:
If SW1.l-2 is ON and SW1.3-4 is OFF, the injection rate will be 3 rev/injection
3 rev/ inj
~ ~ W. 1
P
4.2 Detection
rate (BCU take The lowest injection rate the MCU can perform before the BCU takes over, is set
over from MCU) on the dip switches SW1 positions 5-8, as a binary value.
Examples:
If SW1.6 and SW1.8 are ON and SW1.5 and SW1.7 are OFF, the lowest injection
rate is 20 rev/injection for the MCU before BCU will take over control.
4.3 Number of The number of cylinders for the specific engine is set on SW2 positions 1-4, as a
cylinders for the binary value.
engine
eg. 7 cyl. YW
~~~~~[~
2
MAN Diesel 3045-01
4.4 BCU board The revision number of the printed circuit board is set on SW2.6,
revision
po~~l[~fl-& OFF
2
1 2 4 8 2
4 2 . 6
For installations with revision B, SW2.6 must be OFF.

For other installations SW2.6 must be ON.
The revision is printed on top of the board below the MAN B&W logo,
as "BCU-250-X"where X is the revision.
4.5 Slow down The slow down output switch (BCU terminal J8.3, 4) is NC(norrnally closed) if
output SW2.7 is ON and NO (normally open) if SW2.7 is OFF.
The output is connected in parrallel with slow-down output from MCU. The MCU
slow-down output is non-configurable, always NO. Consequently the BCU slow-
down output must also be NO, i.e. SW2.7 OFF.
4.6 Number of
lubricators he number of lubricators for each cylinder is set on SW2.8.
For installations with one lubricator on each cylinder SW2.8 must be ON.
For installations with two lubricators on each cylinder SW2.8 must be OFF
OFF
1 2 4 8 2 4 8 1 6
* 2.8
-3045-0110-0003 MAN Diesel
4.7 Upload of BCU To identify the component, see Document: ASD244-4090.

basic program
1. Connect a NULL-MODEM cable between the PC and BCU (J27)]
2. Connect the BCU to a suitable power supply (24V and minimum 2A)
3. Set Switch (SW3) on the BCU in position "Program Mode"
4. Press [RESET] button (SW4) on the BCU (the LED D50 located in the u p
per left corner of the PCB will turn off)
5. The device is now in programming mode (ISP mode)
6. Start the FlashMagic program
7. In the FlashMagic program window part 1 - key in the following data:

COM Port COM1 (or which ever com port is used)
Baud Rate 115200
Device : P89C51RD2XX
(processor versions can vary - the version can be read
on the processor itself - U24 on the BCU board)
Oscillator Freq : 22Mhz
In the FlashMagic program window part 2 - key in the following data:

Select "Erase all Flash+Security+Clks"

Enter the pathlfilename of the relevant INTEL hex file to be programmed
into the device, or press the [BROWSE] button to choose the file.

Select "Verify after programming"
Check that "6 clks/cycle" (if present) is NOT selected
Press the [START! button
In the FlashMagic status line, the following information should appear:

Erasing Device
Programming Device
Verifying
Finished
The BCU has now been programmed
When the uploading is completed, set switch SW3 on the BCU back in
position [NORMAL] and interrupt the power supply.
- MAN Diesel 3045-0110-0003
14. Verification
When the power supply is reconnected, the diode D50 in upper left cor
ner will initially lit constantly green. This verifies that the unit is now pro
grammed with application software. The diode may change to constant
ly red if e.g. external signals are not present.
The actual software revision programmed can be verified by connecting

to the BCU via the Hyper Terminal program.
The hyper terminal communication settings should be:
Baud rate 57600

Data bits 8
Parity None
Stop bits 1
Flow control : Xon - Xoff
When connected press [ ~ s cand

] a menu is shown
Press [RN] and the software revision number is shows as below:
Type (SC, SS , SL, UC, US, UL, HH. RN, ES) : Revision Number: 13.11
~ ~ . . . .. ~ . . . ....
The [reset] button (SW 4) must not be pressed during normal opera-
tion. This will cause "Internal Failure" (Alarm LED #8).
If, by mistake, the [reset] button has been activated and the LED #8 is lit, the er-
ror message can be removed by interrupting the 24V power as follows:
- Remove plug FJ1 on the filter board of the BCU.
7j3045-0110-0003 MAN Diesel
4.8 Programming of BCU microprocessor
The purpose of this instruction is to enable MAN Diesel service and technical
personal, Subcontractors and Licensees to program the microprocessor used
in the MAN Diesel Alpha Lubricator BCU using one of the following processor
types:
Furthermore the purpose is to enable the reader to verify the version of the soft-
ware programmed into a BCU.
4.8.1 Preparation
A single standard null-modem cable is required. The cable must hold a 9 pole
SUB-D female connector in one end and an appropriate connector to the VT100
terminal - normally either 9 or 25 pole SUB-D female. (See chapter 3.3.1 Hard-
ware interface for more information about cable connection)
Disconnect the 24 VDC power supply cables at J1. Connect the null-modem
cable from the PC serial port to the BCU connector J27, leave the power at J1
unplugged.( see drawing of BCU onpage 71 of this manual )
Flash Magic ISP In this document Flash Magic version 5.39.1797 is used (Ref 1). The latest ver-
too1 sion of Flash Magic may be download at: http://www.flashmagictool.com/down-
load.html&d=FlashMagic.exe
Flash Magic advanced options may have to be corrected, see Figure 1:
I
, Assert DTR and RTS wh~leCOM Port open
I
I
MAN Diesel 3045-01 1
4.8.2 Determining The ALCU BCU is fabricated with different microprocessor types. The program-
mi~r0prO~eSSOr ming differs slightly from one type to another. The microprocessor is mounted
type as U24 on the BCU PCB.
An example of one microprocessor type is illustrated in Figure 2. The picture

shows the same microprocessor type produced by Phillips and NXP.
The programming procedure is the same independent of brand
Figure 2
Left: device from Philips P89VC51RD2FA, Right: Device from NXP P89V51RD2FA
When determining which processor type at hand, pay close attention to the fol-
lowing letters:
4.8.3 Programming It's assumed that the device has been prepared for flashing and that the Flash
P89V51RD2 Magic advanced settings is as described earlier.
Use the settings displayed in Figure 4 and select the appropriate COM Port and
file to be programmed.
-~
. ....
~
!
..~.
':
Flashmagic ;- ;",as.
.
~
; -
.,
[S.I.,
&
*-
?
,-.
--
& J
-u ,
_._
~
~.
D ~ v ~ o~~ '.~
.~~ . GS
.-
COW P a l :COW I
q
. IRDZ
~;.!a
~ @a
--
-
g @
/Y!
..... ..
~
,
,i
~
: BaudRafe :I15200 .bzi

-3045-0110-0003 MAN Diesel
Reset device
Reset the device into ISP rnode now
Click on the Start button.

When You are prompted to "Reset the device into ISP mode now" (Figure 4): re-
connect power to the BCU at J1.
At this moment Flash Magic transmits a series of ASCII "U" characters. When
these characters are received by the device during its power-up (the first 400
ms.) the device enters ISP mode
The prompt disappears when the programming starts.

If a error message appears asking to lower the baud rate, press ok and start to
try once more. This should start the programming. If the problem persists lower
the baud rate and retry.
In the Flash Magic status line at the bottom, the following information's will ap-
pear when the programming is started:
Erasing Device
Programming Device
Verifying
Finished
When Finished is displayed in the bottom line the programming process has
ended.
Disconnect the 24 VDC power supply cables at J1.
The device has now been programmed and verified. Follow instructions in 4.8.6
to verify that the software has the expected revision number.
MAN Diesel 3045-01
4.8.4 Programming ~tjsassumed that the device has been prepared for flashing and that the Flash
P89C51RD2 Magic advanced settings is as described earlier.
Flashmagic .-
,,...~ . .~ :~.. ,:.~..
*: i,;.,i;; ,,,. : ! ; ; : ;,;.; ; . .,.,, - . .. , . .; : .,.., .,
.. ... ... . : ..
. .
Set SW3 in "program" mode and then click on the Start button.
Reconnect power to the BCU at J1.
If a error message appears asking to lower the baud rate, press ok and start
to try once more. This should start the programming. If the problem persists
lower the baud rate and retry.
Erasing Device
Programming Device
Verifying
Finished
When finished is displayed in the bottom line the programming process has
ended.
Set SW3 back to normal.
73045-0110-0003 MAN Diesel
4.8.5 Programming It's assumed that the device has been prepared for flashing and that the Flash
P89C51RD+ Magic advanced settings is as described earlier.
Set SW3 in "program" mode and then click on the Start button.
Reconnect power to the BCU at J1.
If a error message appears asking to lower the baud rate, press ok and start
to try once more. This should start the programming. If the problem persists
lower the baud rate and retry.
Erasing Device
Programming Device
Verifying
Finished
When finished is displayed in the bottom line the programming process has
ended.
Set SW3 back to normal.
MAN Diesel
4.8.6 Verifying BCU To verify that the programming of the BCU has been successful, the version
software version number can be read from the BCU service terminal.
Reconnect the null-modem cable at J27.
Reconnect the 24 VDC power supply cables at J1.
The diode D50 in upper left corner should initially be lid constantly green. This
verifies that the unit has been programmed with correct software type.
The diode will change to constantly red afterwards if external signals indicate an
alarm state. This is normal and correct ifthe BCU is not installed together with a
MCU that is running as well.
A standard VT100 terminal is required. This may be any standard terminal soft-
ware which is able to fulfil the following requirements:
Asynchronous communication at 57600 baud

VTlOO terminal emulation
One example of such a program is the standard "HyperTerminalnsupplied with

all versions of MS-Windows.
Many other adequate programs are available in both commercial and shareware
versions.
The VTIOO terminal should be set up to:
Baud rate: 57600

Data bits: 8
Parity: None
Stop bits: 1
Flow control: XonIXoff
When connected press [ESC] and a list of options is shown: see Figure 7.
Type " R N and enter, the software revision number is printed, in this case
13.18.
Verify that the number is as expected.

Finish by powering off the BCU, remove null-modem cable and switch the power
back on to proceeded with normal operation.
-j3045-0110-0003 MAN Diesel
Alpha Lubricator - Alarm Handling and Trouble Shooting Guide
If you encounter difficulties while operating the engine with the Alpha Lubricator
system, this guide will help find and solve some of the problems.
The information in this section will help you with:
5.1 Fuses
5.2 External alarm signals
5.3 MCU - alarm handling and trouble shooting
5.4 BCU alarms
5.5 Emergency running without external trigger signals
5.6 Sequence diagram for alarm handling
Fuses Schematic drawing of the ALCU power connections are shown in Appendix 2,
page 3.
MCU-Unit Normally, a fuse does not blow without reason. It is therefore important to lo-
cate and correct the problem before normal operation can be restored.
There are two different fuse ratings: 12 Amp and 3 Amp. It is very important to
replace a fuse with one of the correct rating and type.
MAN Diesel 3045-0110-0003
3
MCU fuses
The MCU unit has three fuses located on the filter board, as indicated in the
drawing below.
The designations are F1, F2 and F3.
F1 Main fuse
Fuse F1 is rated 12 Amp and is the main fuse for the MCU unit.
If this fuse is blown, a consumer connected to plugs FJ8. FJ9, FJII, FJ12. FJ13,
FJ14 may be suspected of overloading the fuse.
Check for shorts by removing the fuse. Connect a multimeter to the right fuse
holder and measure the resistance to the negative terminal of FJ1
,3045-0110-0003 MAN Diesel
L I \
\ \
r 7
I I FEU board
A measurement below 10 ohm is defined as a short. If the measurement indi-

cates a short, disconnect plugs FJ8 to FJ14 one by one and observe the reading
on the meter.
If the short can be located by this method, continue investigating the problem in
the circuit connected to the suspected plug.
If the reason for the short cannot be found by the procedure described above,
an internal MCU failure may be suspected.
Fuse F2 is rated at 3 Amp and is the main fuse for the SBU unit when running
MCU mode.
This fuse supplies control power (pump running signal) to the pump station via
the SBU unit when running in MCU mode as well as power to the feedback sen-
sors.
If this fuse is blown, a fault in the pump station wiring or in the connections to
the cylinder intermediate boxes may be suspected.
z
In order to check whether the problem is in the pump station or the intermediate
boxes, follow the check procedure below: e8
+::
Remove fuse F2. Connect a multimeter to the right fuse holder clip, and mea-
sure the resistance to the negative terminal of FJl (right terminal). A measure-
ment below 10 ohm is defined as a short.
MAN Diesel 3045-0110-0003
3
If the measurement indicates a short, disconnect plug FJ5 on the MCU filter
board (disconnecting the supply to the pump station) and observe the meter
reading. If the short is still present, disconnect the plugs L1 to L14 in the SBU
one by one until the short is located. Investigate the problem further by discon-
necting the plug J1 in the intermediate box and reconnect the suspected plug in
the SBU. If the problem disappears, the short is located in the intermediate box
or the lubricator units.
Fuse F3 is rated at 3 Amp, and is the main fuse for the shaft encoder. If this fuse
is blown, a fault in the encoder connections may be suspected.
5.1.2 BCU-Unit There are two different fuse ratings 12 Amp and 3 Amp. It is very important to re-
place a fuse with one of the correct rating and type.
BCU fuses The BCU unit has three fuses located on the filter board as indicated in the
drawing below.
13045-0110-0003 MAN Diesel
F1 Main fuse
Fuse F1 is rated at 12 Amp and is the main fuse for the BCU unit.
If this fuse is blown, a consumer connected to the plugs FJ8, FJ9, FJ11, FJ12,
FJ13, FJ14 may be suspected of overloading the fuse.
Check for shorts by removing the fuse. Connect a multimeter to the right fuse
holder, and measure the resistance to the negative terminal of FJ1.
A measurement below 10 ohm is defined as a short. If the measurement in-

dicates a short, disconnect plugs FJ8 to FJ14 one by one and observe the
reading on the meter.
If the short can be located by this method, continue investigating the problem
in the circuit connected to the suspected plug.
F2 and F3 The fuse F2 is rated at 3 Amp and is the main fuse for the SBU unit when run-
ning BCU mode. This fuse supplies power to the feedback sensors in BCU
mode as well as power to the pump station.
c
m
If this fuse is blown, a fault in the pump station wiring or in the connections to 0
the cylinder intermediate boxes might be suspected. !
;
n
Remove fuse F2. Connect a multimeter to the right fuse holder clip, and mea- Cu
sure the resistance to the negative terminal of FJ1 (right terminal). A measure-
ment below 10 ohm is defined as a short.
MAN Diesel 3045-0110-0003
3
If the measurement indicates a short, disconnect plug FJ5 on the BCU filter
board (disconnecting the supply to the pump station) and observe the meter
reading. If the short is still present, disconnect the plugs Ll to L14 in the SBU
one by one until the short is located. Investigate the problem further by discon-
necting the plug J1 in the intermediate box and reconnect the suspected plug in
the SBU. If the problem disappears, the short is located in the intermediate box
or the lubricator units.
Fuse F3 is rated at 3 Amp, and is the main fuse for the BCU pickups. If this fuse
is blown, a fault in the wiring to the BCU pickups or a fault in the BCU box con-
nections might be suspected.
5.2 External alarm signals
Alarm system signals:
Common alarm
MCU power failure
BCU power failure
MCU failure
BCU failure
Safety system signals.
State indicator:
BCU in control
Please note that some installations might have some alarm signals connected in
serial to save alarm channels in the alarm system.
5.2.1 Common The common alarm is a normally closed contact. In case the MCU system de-
alarm tects a fault, the alarm will be released. Information about the cause of the alarm
can be read of the number in the HMI panel.
To solve the problem, read the information related to the alarm number found in
the HMI panel.
! 5.2.2 MCU power The MCU power failure alarm is a normally closed contact.
%D failure In case the power to the MCU system is interrupted the alarm will be released.
:
N
0
Start by checking the breaker and fuse in the UPS cabinet. If no problem can be
found in the UPS, check that 24 V is present at terminal XI PWR A in the ALCU
box. Continue by checking the fuse F2 on the MCU filter board (see page 83).
7j3045-0110-0003 MAN Diesel
5.2.3 BCU power The BCU power failure alarm is a normally closed contact.
failure In case the power to the BCU system is interrupted, the alarm will be released.
Start by checking the breaker and fuse in the UPS cabinet. If no problem can be
found in the UPS, check that 24 V is present at terminal XI PWR B in the ALCU
box. Continue by checking the fuse F2 on the BCU filter board (see page 44).
5.2.4 MCU failure The MCU failure alarm is a normally closed contact.
The BCU system has detected that the MCU system program execution has
halted.
Start by checking if the power to the MCU system is OK.

See Item 5.2.2 MCU power failure.
If the Power supply is OK interrupt the power to the MCU for 5 secs. in order to
reset the MCU. If the MCU failure alarm is still active, the MCU itself might be
damaged and has to be replaced.
Note that if the power to the BCU is interrupted, the MCU failure will be activated
eventhough the MCU system is working well.
5.2.5 BCU failure The BCU failure alarm is a normally closed contact.
The BCU system has detected a fault in the BCU system.
Check the LED on the BCU board and read the instruction in item 5.4.
The BCU is not connected to the HMI panel and, consequently, no alarms from
the BCU will be displayed.
The slow-down output is a normally open contact.

The slow-down command is released if the MCU and BCU systems fail to lubri-
cate one or more cylinders.
Check for other alarms in the HMI panel and follow the recommendations
stated.
5.2.7 BCU in
control The BCU in control is a normally closed contact.
This output indicates that the backup control unit is controlling the lubrication.
If the BCU system is able to re-establishthe lubrication, the lubricators are c

working properly. The problem is to be found in the MCU system. Check for o
other alarms and read the alarm codes on the HMI panel and follow the recom- r
mendations stated. z
m
D
MAN Diesel 3045-0110-0003
7,
5.3 MCU - alarm handling and trouble shooting
5.3.1 Alarms 1-24 If for any reason a feedback signal from a lubricator is measured as abnormal
d b ~by the
~ ~ ~ failure ~ MCU
k a feedback alarm will be given. A common alarm will trig the AMS
system (engine alarm and monitoring system) and an alarm code will be stored
in the HMI panel.
If the alarm stated in the HMI panel is a logged alarm (the alarm has disap-
peared again) the alarm will be displayed as LAL XX
The alarm code in the HMI panel provides information about which lubricator is
suspected to fail. (Alr 2 in the HMI panel indicates that lubricator 2 on cylinder 1
is failing.)
Note that in case of one lubricator per cylinder (engines with a bore below
0 6 0 m), the alarm will only read uneven numbers e.g. 1, 3, 5, 7 for cylinder 1, 2,
3, 4.
Generally it is recommended that a defect lubricator is replaced completely with

a spare when convenient (in case of one lubricator per cylinder, the defect unit
must be replaced immediately)
In the event of feedback failure, check as follows:

First check the feedback indicator light on the intermediate box
If the feedback indicator light is:
. t Continually on the lubricator might be sticking in a position where the feed-

:+
.+;
. back sensor gives signal all the time.
..
To verify that the problem is in the lubricator, disconnect the plug for the
lubricator and observe the indicator light on the intermediate box. If the light
t u k s off after the plug is removed, the problem is located in the lubricator.
The-lubricatormust be replaced and overhauled. (see instruction 903.2)
..
Alternatively, if the light in the intermediate box remains lit after the plug to
the lubricator has been removed, the fault is not in the lubricator. Check the
cable and plugs from the intermediate box to the lubricator for shorts.
. .
The intermediate PCB might also be suspected.
7045-0110-0003 MAN Diesel
Continually off start by checking if the red light in the lubricator solenoid plug
flashes.
Note that in the event of a feedback failure, the remaining working lubricator i s
running double feed rate, and the defective
lubricator is checked by the MCU by activat-
ma once everv ten lubricator strokes to deter-
mine if the lubricator is still failing. (for engines
with two lubricators per cylinder)
If no light flashes in the solenoid plug, remove

the plug from the solenoid and check again if
the light starts flashing. If yes, the solenoids
coil may have an internal short, which can be ;
confirmed by measuring the coil resistance.
The normal resistance is 15 to 22 ohm for a 5
new solenoid. 2
4
If the red light flashes in the solenoid plug,
but no feedback is observed, check the connections in the lubricator plugs,
mounted on the cable from the intermediate box, for loose connections or
shorts.
If connections in the plug are OK, the lubricator

must be replaced and overhauled (Instruction
903-2 ).
Flashes according to the light in the lubrica-

tor plug (once every ten lubricator strokes) the
lubricator is working well but the feedback sig-
nals are not detected bv the MCU. Re~lace
~~~ ~ the
intermediate box PCB (Printed Circuit '~oard).
If the fault is still present, check the cable to the $

ALCU box.
1
D
8
5.3.2 Alarm 29 The Marker signal (one pulse per revolution) is abnormal. The system will change
Marker signal to random lubrication based on the remaining good signals. First check the
failure from electrical connections in the encoder terminal box as well as the connections to
encoder the ALCU control box.
If no problems are found in the wiring or fuse, replace the encoder.

Adjustment procedure can be found in Procedure 905-8.
MAN Diesel 3045-0110-0003
7
533 A'arm 30 - The two marker pickups mounted on the flywheel side of the engine gives one
BCU pickup pulse every one engine revolution. These signals are used by the BCU system
ure to determine the engine speed. The signals are also used by the MCU system to
monitor the signals and release an alarm in case of signal failure.
Alarm number 30 indicates that BCU pickup # 1 is abnormal and alarm number
43 indicates that BCU pickup # 2 is abnormal.
If the A l ~ h alubricator svstem is runnina in BCU mode due to a MCU unit failure
the alarms for pickup failure can be found by observing the LED on the BCU
pcb (see picture below).
The BCU system can be operated with only one pickup signal present.
Failure of one sensor is not critical and can be replaced when convenient.
The BCU pickups have a built-in indicator lamp which will flash once every one
engine revolution.
In case one of the pickup alarms is observed, first check that the light flashes in
the pickup. If not, check that there is 24 volt at terminals 1, 2 and 4-5 in the BCU
terminal box. If power is present at terminal 1 and 2 disconnect the sensor wire
connected to terminal # 3 (sensor # 1) or terminal # 6 (sensor # 2) and observe
if the light starts flashing. If yes the wiring from the sensor to the ALCU box is
shorted. If the indicator light still does not flash, replace the pickup
3045-0110-0003 MAN Diesel
Sensor gap is to be adjusted to 3+0/-1 mm.

Regarding distance: Always refer to manufacturer's recommendations.
/5.3.4 Alarm 31 The trigger signals (1024 pulses per revolution) are abnormal. The system will
Trigger signal change to random lubrication based on the remaining good signals. First check
failure from for loose connection and shorts in the encoder terminal box, as well as the wir-
encoder ing to the ALCU control box.
If no problemcare found in the wiring or fuse, replace the encoder.

Adjustment procedure can be found in Procedure 905-8.
In the event of failure of all Tacho signals, see item 5.5.
5.3.5 Alarm 33 - Engine stop signal failure will be released if the engine stop signal is detected as
Engine stop signal abnormal by the MCU.
failure
There are two cases that will trigger the stop signal alarm.
1. The engine is running above 8 rlmin and engine stop signal is present at
the MCU input for more than 20 minutes.
Check the engine stop signal circuit in the bridge control system.
2. The engine is stopped (detection is only active for 30 seconds after

stop) but there is no engine stop signal present at the MCU input.
Check the engine stop signal circuit in the bridge control system.
5.3.6 Alarm 34 - The MCU has detected that the external LCD signal has been continuously ON
LCD signal for more than 48 hours.
abnormal Check the LCD signal and parameters in the governor system.
MAN Diesel 3045-011 0-0003
7
5.3.7 Alarm 35
The MCU has detected that the BCU is abnormal.
BCU alive signal
missing Start checking if there are other alarms from the system. Power fail from the
BCU will give this alarm.
Check the wiring in MCU plug J52 terminal 4 and 5 as well as BCU plug J7 ter-
minal 3 and 4. (BCU alive signal connections) The alive signal is a pulse signal
with a frequency of approximately 1 Hz. An oscilloscope or a multimeter, ca-
pable of measuring frequency, must be used to measure this signal.
If none of the above problems are found, try to interrupt the power to the BCU
unit for 5 sec. If the problem is still present, the BCU is probably damaged and
must be replaced. However, the engine can be operated in MCU mode until a
new BCU unit can be obtained
5.3.8 Alarm 36 The MCU unit has detected that the astern signal has been ON for more than
Astern signal 24 hours.
abnormal.
The engine can be operated with this alarm present, however the lubrication
amount is increased.
Check the astern signal circuit in the bridge control system
5.3.9 Alarm 37 The MCU has detected that the prelubrication signal is ON and the index is
Prelubrication higher than 80%.
signal abnormal This fault is not critical.
Check the prelubrication signal circuit.
5.3.10 Alarm 38 The oil temperature has exceeded the alarm level normally adjusted to 70%.
Oil temperature Check the oil temperature sensor (Pt-100 type) by disconnecting the plug from
high the sensor and measure the sensor resistance.
At: O•‹C, the reading must be 100.0 ohm

20•‹C. the reading must be 107.8 ohm
30•‹C, the reading must be 111.7 ohm
40•‹C,the reading must be 115.6 ohm
50"C, the reading must be 119.4 ohm
60•‹C. the reading must be 123.2 ohm
70•‹C,the reading must be 127.1 ohm.
If the readings do not correspond the values stated above, the sensor is dam-
aged and must be replaced. This fault is not critical and the sensor can be re-
laced when convenient.
4 0 4 5 - 0 110-0003 MAN Diesel
5'3d1 Alarm 39
The oil pressure is below the normal alarm level of 35 bar.
Oil pressure low
Automatic start of stand-by pump and common alarm is activated plus alarm 49
in the HMI panel.
If oil pressure is re established after start of stand-by pump, common alarm is
not de-activated until the stand-by pump is manually stopped.
Both pumps will run continuously due to the detected fauit. This fault is cleared
by manually pressing one of the PUMP-buttons on the HMI panel.
Check if the pumps are running. Check for leaks in the high-pressure supply
lines.
Check the oil pressure sensor (4-20 mA type) by measuring the sensor current
and comparing it with the pressure.
if the current and pressure differ, the sensor must be replaced/calibrated.
5.3.12 Alarm 40 The MCU has detected that one or more of the four speed measurements are
Speed deviation abnormal.
alarm
Check the alarm list in the HMi panel to see which sensor is abnormal (BCU
pickups or the angle encoder) alarm 29, 30, 31 and 43 and read the chapte~
concerning the alarm.
5.3.13 Alarm 41\ The index level does not correspond to the engine rpm.
Index
abnormal Fuel index is internally set to a fixed value of 100 percent due to the detected
\
fauit. The fault is cleared by activation of engine stop signal.
Check the adjustment of the index transmitter, according to instruction

-.
5903-21.
The index transmitter itself might be damaged.
5.3.14 Alarm 42 The index transmitter cable is interrupted or the index transmitter is damaged,
cable failureindex Correct the cable failure or replace the index transmitter.
transmitter
If the index transmitter is replaced, readjustment is needed. Follow the index ad-
justment instruction 5903-25
5.3.15 Alarm 43 Please see item 5.3.3.

BCU pickup 2
failure
MAN Diesel 3045-0110-0003
7
5.3.16 Alarm 44 The lubricators are running BCU mode.
BCU in control
Check that the mode switch is in auto posi-
tion.
Find the cause for the BCU takeover. If the

BCU mode has been started automatically
and is running without slow down com-
mand, the MCU system may be abnormal
5.3.17 Alarm 45 46 Electric motor # 1 or 2 is tripped by thermal overload

Thermal overload
electric motor Check the thermal trip breaker in the pump station control box
Press the reset button on the thermal overload breaker to reactivate the pump
motor and check the current at the ammeter local side.
Check that the voltage on all three phases is OK. If not, check the fuses in the
feeder panel. Also verify that the motor windings are OK by measuring the resis-
tance of the individual windings.
If no electrical fault can be found check the oil pump for mechanical damage.
5.3.18 Alarm 47 This alarm indicates that the MCU computer has lost its configuration file or
MCU parameter list that it is missing.
not loaded
Change to forced BCU operation by using the mode switch and replace the
MCU with a spare when possible.
5.3.19 Alarm 48 The angle difference between the TDC marker from the angle encoder and the
Angle deviation fail TDC markers from the BCU pickups exceeds the alarm level.
Check the Initial adjustment of the angle encoder and adjust as necessary. The
adjustment procedure can be found in Procedure 905-8.
Also check the flexible coupling between the engine and angle encoder for
good condition.
5.3.20 Alarm 49 The stand-by pump has been activated either by the user or automatically due
Stand-by pump is to a low-pressure alarm. See alarm 39.
running
-7045-01 10-0003 MAN Diesel
5.4 BCU alarms
Alarm Led
BCU board
.--
J28
*= 4
SYJ
r
LJ
Z ~ : S W ~
I sCU ~DU,, ..... 0.. i"di..t.d b" 1

Vrn Lm I BCU i"..rn.L I.,,"".
--
r---T---T---T---T
Jlb
---
217
-12
-
' --
-
-
JIB
,-' --
A9
- -
- -- --- -
- z z90-
= T9-
--- -2 = = = >y= >*
T d ? 6 Td,, Ta-
- " - ' 7 - " - " - " "
*
A
Td,
d*--~L-d,
1
'
9 1
0
r---T---l
I 1
p -------
---
JI2
?=----- 3 4 4
---- -------
r---l
K,,T--T-~
p=--- 3 p=----
rar-irs-ir~-i
,2d3 p = ='Jf=Jf=J 7 - - - 7 - 7 7 - -
h r q r i
I I I I FBU board
z -_ I I I I
Y
4 l J 1
;
I ----
+Id
F
,3
~ - 7 6 1W--?W
,---
wf--2- -E--
w---pcPC , , r-1
rMi , lld >Id +>Id .Id
, , Izzzl
~ W T U ~~ ~ ~ T W T J ~ ~ T ~ ~ T ~ ~ T ~ S A ~
e 7 F 7 F - 7 - 7 7 r -
-111 -1
Below is a list of BCU alarms and their description:
5.41 Led # 1 BCU internal failure
An internal failure in the BCU is detected. Check that the small switch SW3 on
the BCU board is in the normal position.
Reboot the BCU computer by interrupting the power supply for 5 sec. (Plug
FJ 1).
DO NOT PRESS THE RESET BUTTON on the BCU unit.
5.4.2 Led # 2 Engine stop signal failure

s
The engine stop signal has been on for more than 20 minutes with the engine 6
running. The engine stop signal is off and the engine is not running (only for 30 ::
seconds). Check the stop signal wiring and the engine control system for cor-
rect operation.
7 MAN Diesel
5.4.3 Led # 3
MCU alive signal missing
The BCU unit has detected that the MCU unit is abnormal. The BCU is still full
operational in this condition.
Start checking if there are other alarms from the system. Power failure from the
MCU will give this alarm as well as a common alarm.
Normally this situation will give a BCU take over.
Check the wiring in MCU plug J52 terminal 2 and 3 as well as BCU plug J7 ter.
minal 1 and 2. (MCU alive signal connections).
The alive signal is a pulse signal with a frequency of approx. 0,5 Hz. An oscillo
scope must be used to measure this signal.
If no problems, as described above, are found try to interrupt the power to the
MCU unit for 5 sec. If the problem is still present the MCU unit is probably dam-
aged and must be replaced. However, the engine can be operated in BCU mode
until a new MCU unit can be obtained.
5.4.4 Led # 4 Feedback signal missing on two lubricators
If, for any reason, a feedback signal from a lubricator is measured as abnormal
by the BCU, an alarm will be given (BCU fail alarm).
Note that if the system is running in BCU mode due to a MCU failure, the MCU
might not be able to show any alarm codes in the HMI panel. The defect lubri-
cators are to be found by observing the feedback signal indicator lights at the
intermediate boxes at the engine.
This alarm indicates that the lubrication is stopped on a cylinder. A slow-down

command will be released.
First check if the fault is concerning more than one cylinder. If more than one
cylinder is affected, check the oil supply system. The oil pressure might be low
or the oil supply from the gravity tank has stopped. Check for leaks on the oil
supply lines.
If the problem can be isolated to only one cylinder, check the feedback wiring
from the defect cylinders intermediate box to the control box (ALCU). The inter
mediate PCB (Printed Circuit Board) itself might be damaged.
To check if the BCU board is damaged, the plug for the defect cylinder can be
removed from the BCU and a plug from a working cylinder can temporally be
mounted instead. If this cylinder that previously worked well is now faulty, the
BCU board is probably damaged.
Remember to remount the plugs in the correct sockets.

The BCU computer can be rebooted by interrupting the main power supply for
5 sec. (Remove plug FJl on the BCU filter board).)
DO NOT PRESS THE RESET BUTTON!

,3045-0110-0003 MAN Diesel
Led # 5 Feedback signal missing one lubricator
If, for any reason, a feedback signal from a lubricator is measured as abnormal
by the BCU, an alarm will be given (BCU fail alarm).
might not be able to show any alarm codes on the HMI panel. The defective lu-
bricators are to be found by observing the feedback signal indicator lights at the
intermediate boxes on the engine.
Generally it is recommended that a defect lubricator is replaced completely with

a spare when convenient (in the case of one lubricator per cylinder, the defective
unit must be replaced immediately)
For further information, see chapter covering MCU feedback fail alarms.
Led # 6 BCU marker signal 1 and 2 missing
The two marker pickups mounted on the turning wheel end of the engine give
one pulse every engine revolution. These signals are used by the BCU system
to determine the engine speed. The signals are also used by the MCU system to
monitor the signals and release an alarm in case of signal failure.
may not be able to show any alarm codes on the HMI panel.
This case needs prompt attention. The lubrication will stop, and a slowdown
command will be activated.
This type of fault is normally caused by mechanical damage to the pickups 01

interruption of the power supply to the BCU pickups.
Check the sensors and the trigger-bracket on the flywheel for mechanical dam-
age. Sensor gap is 3.0 mm. (Regarding distance: always refer to manufacturer's
recommendation).
Check that there is 24 volt on terminals 1 and 2 in the BCU terminal box. If there
is no power present on terminals 1 and 2, investigate further for short-circuited
wiring to the BCU pickup system.
Led#7&8 BCU marker signal 1 or 2 missing
The BCU system can be operated with only one pickup signal present.
Failure of one pickup is not critical and it can be replaced when convenient.
c
m
The BCU pickups have a built-in indicator which flashes once for each engine
revolution. Ga
G
0
MAN Diesel 3045-011
If one of the pickup alarms are ob-

served, first check that the lamp in the
pickup is flashing. If not, check that
there is 24 volt on terminals 1 and 2
in the BCU terminal box. If power is
present at terminals 1 and 2, discon-
nect the pickup wire connected to
terminal # 3 (pickup # 1) or terminal
# 6 (pickup # 2) and observe if the a
light starts flashing. If yes, the wiring
from the pickup to the ALCU box is
1z
shorted. If the indicator light still does
not flash, replace the pickup.
Pickup gap is to be adjusted to 3+0/-1 mm.

(Regarding distance: Always refer to manufacturer's recommendation).
5.5 Emergency running without external trigger signals

We strongly recommend that all efforts are made to repair the trigger system
before switching to the emergency mode.
In the event that all trigger signals to the lubricator system fails (angle encoder
and pickups for the BCU system), it is possible to maintain a certain level of lu-
brication by means of an internal stroke generator on the MCU or BCU card.
This stroke generator emits one pulse per second, i.e. approx. 60 rpm.
To be able to run in this "emergency mode", the following electrical connections

must be changed:
Remove the wire from MCU-J22 terminal 1
Connect an extra wire from MCU-J52 terminal 4 to MCU-J22 terminal 1
MCU board
-\3045-0110-0003 MAN Diesel
The system now starts lubricating regardless of whether the engine is running
or stopped.
The system will also give various alarms,
However, feedback alarms will still function and indicate whether all cylinders
are being lubricated. When running in this mode, the BCU system is not active.
The MCU slow-down function remains active.
Lubrication is effected as "random" and "rpm-dependent", however with a sup-

plement of 25% of the amount set for the individual cylinders, but with a fixed
number of revolutions of 60.
MAN Diesel 3045-0110-0003
5.6 Sequence diagram for alarm handling
HMI Panel Alarm llst
Alr 1-24 :Feedbackslgnal tellum

-
Alr 29 :Mruksr lallum enmderlWgger dng
-
Alr 30 :Marker lallum B W pldcup no. 1
Alr31 : T ~ Y l u m - e n m d e r l f i g g e r d n g
Alr 33 :Endne stoD slanal tellurn
. .
Alr44:BWhmntml
--
Alr 45 :Themvll overload el. Momr 1
Alr 48 :Thermal overload el. Motor 2
MAN Diesel 3045-0110-0003
-'I
Appendix 1
Function of the LEDs in the Intermediate Box
The two green LEDs D, and D, (FB-signal input A and FB-signal input 8) light when there is an
input from one of the feedback sensors.
FB-signaloutput is also a green LED D,, which flashes every time a feedback signal is sent to the
Switch Board Unit. There has to be a flash at FB-signal output every time, shortly after there is an
input on one of the two FB-signal input.
The Error LED D, indicates with a red light, if there is an error on the cable from the FB-signal
output, or if the input at the Switch Board Unit has an error.
If there is an error, remove the plug from J1 and see if the LED still indicates error. If it does then
change the circuit board, if this does not remove the indicated error, then look for any damage on
the cable. If the cable is damaged, then change it or, if possible, repair the damage. If there is not
any damage on the cable, then the source of the error could be the input channel at the Switch
Board Unit.
MAN Diesel 3045-011 0-0003
3
Appendix 2
Control Unit Cylinder Lubrication - Logic Diagram
I I
TDC MARKER 1 lME0 FEED BACK
I FEED BACK I
EVALUATION 1 SIGNAL I
CONTROL
I ov I LOGIC I
3CU PICK-UP I 1
I
P 9 7 BCU I 1
- 1
o v t
-
- J22
2
UNT M E 0
MODE
ItJ
3CU PICK-UP t 2
3
o v t
-
4
CONTROL
LOGIC
L
I BACK
FROMSENSORS
FEED
I I
I I
BCU MODE I I
CONlROL I I
LOGIC
I I
1 :fLpUA"p;"o"NL
I
I FEE0 BACK SIGNALS
I
MAN Diesel 3045-0110-0003
-73045-0110-0003 MAN Diesel
m
0
- 21
0
oa
XZD m:3-!
z
u U L -<
<
>
0
m-0
<-
5%
rn oza
w-3 5%
z W"rn
Lrn2 zz
-. MAN Diesel 3045-011 0-0003
)
-.3045-0110-0003 MAN Diesel
MAN Diesel 3045-011 0-0003
ALCU
BOX
-Xi
rMCU
_ _ _ ---_------
- - - 7
I I
I 7
I I I
POWER A
POWER
P W P STATION POWER SUPPLY

:i SLOW DOWN
OUlPUT
m-1
L - - J
ECU
CONTROL
SIGNAL
SIGNAL
CYLINDER 1
FROM ENGINE
MAN Diesel 3045-011 0-0003
Appendix 3
Replacement of MCU, BCU and SBU Boards
If one of the PCB's in the ALCU box is to be replaced, note as follows:
Before removing any plugsfrom the PCB ensure that the plugs are numbered in order to remount
them in the correct place.
The SBU unit does not need any programming or setup. This board can be replaced directly with
a spare.
MCU and BCU units:

Normally the spare units are delivered programmed and ready to use.
Remove all plugs from the PCB.

Remove the eight screws that fasten the unit to the ALCU.
Mount the new unit and remount the plugs in the correct position.
MCU replacement If the MCU unit has been replaced, check the following:
Note that a new MCU unit is adjusted to a feed rate of 200% (factory setting)
1. Read out the feed rate setting for the individual cylinders on the old MCU in order to adjust
the new MCU to the same setting
2. Start the prelubrication sequence and checkthat all cylinders are lubricated by observ-
ing that all LEDs on the intermediate boxes flash. Also check that no feedback alarms are
present in the HMI panel.
3. W i the engine running, check the injection angles in the HMI panel and compare these
with the angles stated in the test sheet supplied with the ALCU box.
4. Adjust the lubricationfeed rate according to the settings the engine had before this re-
placement.
5. Check and adjust the Index Transmitter as explained in S-procedure 3.2.13
If the BCU unit has been replaced, check the following:
BCU replacement 1. Checkthat the DIP switch settings on the new board are corresponding to the settings of
the old board.
2. With the engine running, switch to forced BCU operation and checkthat all cylinders are
lubricated by observing that all LEOSon the intermediate boxes flash. Switch back to auto
mode.
3. Check that no alarms from the BCU are present.
4. If the SBU unit has been replaced, check the function by carrying out the checks stated
under both MCU and BCU replacements.
MAN Diesel 3045-0110-0003
Appendix 4 : Service Letter SL09-507lHRR
Contents Cylinder lubrication page 101

Cylinder chemistry page 101
Standard operation page 101
Low-sulphur fuel operation page 102
Running-in operation page 103
Cylinder oil feed rate page 105
Running-in Schedule page 106
ACC settings for BN page 107
Cvlinder Four factors determine the lubricating oil fc!ed rate:

librication
sulphur content in the fuel oil
alkali content in the cylinder lube oil
engine history
engine load.
An Alpha Lubricator or ME Lube operating in ACC-mode (Adaptive Cylinder oil

Control) adapts the lubricating oil feed rate to the fuel oil sulphur content and the
engine load. The ACC-mode has been the standard on MAN B&W two-stroke
engines since 2004.
The ACC factor is the determining factor in the feed rate equation: Feed rate =
ACC factor x sulphur%. The recommended ACC factor is based on practical
experiments
performed on different types of engines under varying running conditions. When
determining the recommended ACC factor, we consider engine performance,
engine service life, environment and economy.
This service letter describes the cylinder feed rates in the following operation
situations:
standard
low-sulphur fuel
running-in.
Cylinder chemistry The combustion process turns sulphur in the fuel oil into sulphuric acid. The
higher the sulphur content in the fuel oil, the more sulphuric acid is created.
The alkaline content in the lubricating oil adds base to the chemical environment
in the cylinder. The base in the lubricating oil will neutralise the sulphuric acid
developed from the fuel sulphur.
The more base available, the more sulphuric acid can be neutralised. This is why
lubricating oil with a high level of alkaline additives, i.e. high-BN (base number)
oil, is particularly advantageous when operating on high-sulphur fuels
MAN Diesel
The target EN-value in the cylinder drain oil is around 15-20.
A more acidic environment than recommended will increase the cold corrosion
and, consequently, the wear on the cylinder liner.
In a more alkaline cylinder environment, surplus alkaline additives may accumu-

late as calcium deposits on the piston top land, possibly leading to mechanical
bore polish. Lack of corrosive refreshment of the liner surface is another risk
factor leading to chemical bore polish. Bore polish is one of the reasons for the
most feared cylinder condition problem, i.e. scuffing.
Standard operation
We continuously perform lubrication feed rate tests on the different MAN B&W
engines types, under varying running conditions and with varying fuel oil sulphur
contents.
Our most recent research shows that the optimum lubricationfeed rate is lower
than our previous recommendations.
New recommendations for standard operation with standard BN70 lubricating

oil:
IFuel oil with sulohur content 3% and below 10.60 41kWh I

Fuel oil with sulphur content above 3% 0.20 g/kWh x S%
Low-sulphur fuel oils call for less alkaline lubricating oil (see page 3). Below is
given the recommendations for selected types of less alkaline lubricating oils:
- -
Fuel oil with sulphur content 2.6% and below 0.60 g/kWh
Fuel oil with sulphur content above 2.6% 0.23 g/kWh x S%
Fuel oil with sulphur content 2.1% and below (0.60g/kWh

Fuel oil with suiohur content above 2.1% 1 0.28 o/kWh x S%
FJel oil w ~ t hsulphJrconrent 1.7% and oelow 0.60 gkWh
FLel oil wiIn s~lphurcontent above 1.7% 0 35 gkWh x S %

MAN Diesel 3045-011 0-0003
-1
ACC Cylinder Lubrication
F7g. I: Recommended cylinder lubrication few' rate as a function of the fuel oil sulphur content for se
iectediubricating oils (BN40-BN70)
Based on calculations of the average worldwide sulphur content used on MAN

B&W two-stroke engines, the average cylinder oil consumption will be less than
0.65 g/kWh when these new recommendations become effective.
LOW-~UIphllrfuel Low-sulphur fuel oil is necessary when operating in sulphur emission control
operation areas (SECA).
Operation on fuel oil with around 1.5% sulphur should preferably be done in cornbi-
nation with a low-EN cylinder oil. However, continuing on BN70 cylinder oil is pos-
sible for a limited period of 7-14 days without any serious risks of over-alkalinity.
We recommend using a lower-BN cylinder oil, when operating on low-sulphur

fuels for extended periods (more than
14 days).
BN and low-sulphur MAN Diesel recommends a minimum oil feed rate of 0.60 g/kWh for any lubri-
fuel cating oil for hydrodynamic purposes.
However, to avoid surplus alkaline additives in the cylinder, we generally recom

mend that the alkaline content in the lubricating oil match the sulphur content
in the fuel oil. This is particularly crucial when operating on low-sulphur fuel for
extended periods (more than 14 days).
Low-BN oils should be chosen for low-sulphur fuels, and high-EN oils for high
sulphur fuels.
-?045-0110-0003 MAN Diesel
Running-in
A MAN B&W two-stroke engine requires extra attention and extra lubricating oil
operation during its first 2,500 running hours, the first 500 hours being the most dernand-
ing period.
We classify the running-in period in three categories:

1. breaking-in (0-500 hours)
2. running-in, phase 1 (500-1,500 hours)
3. running-in, phase 2 (1,500-2,500 hours).
The purpose of extra lubricating oil during the running-in

period is to:
help flush away wear particles
build up oil film in a not yet run in cylinder.
The running-in process has been eased and shortened considerably by our
alu-bronze running-in coating on all 4 piston rings (standard on all MAN B&W
two-stroke engines). Cylinder liner run-in is facilitated by our semi-honed liner
surface.
We recommend frequent scavenge air port inspections during the first 2,500
running hours (see Fig. 2).
Breaking-in Piston ring and liner breaking-in takes 500 running hours, maximum. We recom-
(0-500 hours) mend a fixed, relatively high lubrication feed rate during the breaking-in period.
During breaking-in, the running-in coating on the piston rings will gradually wear
off, and the wave shape of the cylinder liner surface will smoothen. During this
process, extra lubricating oil is required to flush away wear particles and build a
satisfactory oil film between the still relatively rough sliding surfaces.
During breaking-in, we recommend checking the piston rings and the cylinder
liner through the scavenge air ports every 100 hours. Do not proceed to the next
lubrication step if the scavenge air port inspection reveals seizures or other ir-
regularities!
0 - 5 hours 1 1.70 glkWh

5 - 100 hours 1 1.50 d k W h
1 200 - 300 hours 1 1.10 g/kWh I

300 - 400 hours 0.90 g/kWh
400 - 500 hours 0.70 g/kWh
MAN Diesel 3045-0110-0003
7
To avoid a high torque during breaking-in,we recommend a 16-hours stepwise
load increase from 50% load to max. load.
When running in new piston rings in well running liners, we recommend a 5-hour
load-up from 50% load to rnax. load. This load limitation can be set for a single
cylinder unit by adjusting the individual fuel pump index.
Running-in, phase After the first 500 running hours, standard sulphur-dependent lubrication can be
1 (500-1,500 hours) applied. Hence. ACC can take over lubrication.
For a BN70 oil, MAN Diesel recommends a running-in,

phase 1 dosage of 0.26 g/kWh x sulphur %.
1 500 - 1.500 hours 1 0.26 dkWh x S% I

Running-in, phase After 1,500 hours, the running-in piston ring alu-coating is usually worn through,
2 (1,500-2,500 and the base material or the cermet coating on the top and bottom rings is vis-
hours) ible.
When reaching 1,500 running hours, carefully check the piston rings and the
cylinder liner through the scavenge air ports. If the alu-coating is worn through,
proceed to running-in, phase 2.
For a EN70 oil, MAN Diesel recommends a running-in, phase 2 dosage of 0.23
g/kWh x sulphur %.
1,500 - 2,500 hours 1 0.23 g/kWh x S%
Inspect the piston rings and the cylinder liner through the scavenge air ports
after 2,500 running hours. If no micro seizures or other irregularities are found,
we recommend switching to the standard operation feed rate of 0.20 g/kWh x
sulphur%.
I I
Basic settina" 1 0.20 dkWh x S% I 0.23 g/kWh x S% 1 0.28 g/kWh x S% I 0.35 g/kwh
I
soh
Minimum feed rate 0.60 g/kWh
Maximum feed rate during running-in 1.7 glkWh
Part-load control 100% to 25% load: proportional to indicated engine load
25% load and lower: proportional to rpm
Running-in new or reconditioned Feed rate First 5 hours 1.7 g/kWh
liners and new piston rings based 5 - 500 hours: stepwise reduction from 1.5 to 0.6 g/kWh
on standard EN70 cylinder oil 500 - 1,500 hours: 0.26 g/kWh x S% (absolute min. 0.60 g/kWh)
1,500 - 2,500 hours: 0.23 g/kWh x S% (absolute min. 0.60 g/kWh)
From 2,500 hours: 0.20 g/kWh x S% (absolute min. 0.60 g/kWh)
Engine load Testbed: stepwise increase to max. load over 5 hours
In service: from 50% to max. load over 16 hours
Runnina-in new rinas in alreadv run-in and well From 50% to max, load in 5 hours
running liners (standard EN70 cylinder oil) Feed rate: +25% for 24 hours
- - situations
Manoeuvrina and load chanae 1 During starting,.~
manoeuvring and load changes, increase feed rate by means of the. "I-"-
Cn" -,
hv
25% if p level for '/2 hour after the load has stabilised.
the actual figure. ~ e e this
Lubrication of cylinders that show abnormal Frequent scavenge air port inspections of piston rings and cylinder iinersare very important
conditions for maintaining a safe cylinder condition. If irregularitiesare observed, consider adjustments
of the lube oil rate.
In case of scuffing, sticking piston rings or high liner temperature fluctuations, raise the feed
rate to 1.2 g/kWh and lower p, and mep. Assoon as the situation has been stabilised, set
the lubrication feed rate and the pressures back to normal.
NswACC Running-inschedule (liner and rings)
-
g 1.6
t 'Scavenge port insp.
..
.... .....
.-......... .-
-
Fixed running-in dosage (glkWh,
ACC control (g/kWh/S%)

............................
.........................
............................
t
C
Scavenge port insp.
................ ..... ...............
4E
.- ,.
2 1.2
.-.-
C
-
scavenge port in
0.8 ...
Scavenge port imp.
. ....................... i
.. 0.35
0.34
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Hours
,3045-0110-0003 MAN Diesel
Table II: ACC settings for BN70, BN50 and EN40 lubricating oils for MCIMC-C engines
ACC factor
Dosage
factor x
.-. .- 0.28 0.32 0.36
I
Sulohur % 1 1 gkWh
* Absolute minimum dosage

MAN Diesel 3045-0110-0003
7
Appendix 5
ALCU signal description
CD signal ar polenllal free codacilram GovsmDr. For Input, w l . Free <-
IsdmnlcGlrremarr.
solenoid i~eedbacxcyl.I . .Cyl.
iolenoldl a~vefionor s o m a rehsrror [njaaon MIUQ oat LIL12
-
:edbach: /4eed*c*sBnals genelaled byinduaive renrar on 12.3.45.6 Outpul. 24 W C -)
cy1 12
:yt. I.... ubllcalor~ Inoul. 24 W C r.
plcluprrvpp~yBCUW roc for bscxur, runnlne. 1

I dm, 3 I
MCU
J20:l: i D C + , J20:J: TRIGG+ Encoder
J201.3. FJ7:I.Z Oulpul. 24 YDC supply .>
FJI: Supply
Input.21 W C r -
+r
MCU
3:IW 4:lk. 5:GND 1 J56:3.4.5 Oulpul. 24 VOC rupply .r
SBU Input, pol. Free <-
FJZ: SeleclarSwilch Infsn,nl<->
FJ2:1.2.3. FJ4:I
FA:Supply
SBU
sfanen
I P Z : l 3 FJ5:1,2 Oulpuf. 24 W C - >
"'WSP" Input, Analog, 4-2Omi: r -

W'
MCU
!I J25:1,3
1
Themalcul.ulXl.n2
In*,. pol. Free s.
MCU
OIPmrruW
J4M Inpul. lvlabg. 4.20-
MCU
oil Tempemlure
J43:1.2
j Inpu,,iinolog, PI-100<.
-
MCU
Index
J42:l Input, Analog, 4-20mA <-
MCU
J30:7,6 --Prelub Input. wI.FreB<-
MCU
m,sm
J30:5.6 Input, pal. Free<-
S,"""rDndm no
IUk
1:1
:
A4
TIP
ALCU signal descriplion 1 PO#' NO.
02 103) MAN1 ,dm", NO
Control Unit. Cyl. Lub. 0789390.:

i l M I " ~ r I d a 1NO
ko be closed when englne 10 Stop. I =
BCU
BCU Slop
~nput,pot. Freer-
FJ13:I. JS:3 Inpuf, pol. F n e c- '

MCU
Slow down OulpuI. POI.
Free.,
J91:5.6
BCU I
BCU
olenllal free wnlacl from ALCU. BCU fall
J10:I.I OulpuI. POI
Free-)
penwhen BCU hsr alarm. ~ ~
BCU
MCU fall
otenllal B e urnlad imm ALCU. !
pen when M c u lalb. I Jt1.2 Oulpul, pol. Free ->
'I
:U In CTRL: a d 1ndlca1100,
~ palenllal rms urnlan from ALCU.
SBU
FJ28:12
BCU In CTRL
Oulpul, pol. Free -,
I
ossd wnen BCU incontrol,
MCU
MCUPOwPiiail
CUPowsrfail: FJ3:IZ
I OYIPYI. POI. Free-,
SBU
I
MCU
Com Alarm
om. Alarm: J32:l.Z Oulpul, pol. Free-,
BCU
power B
owsr B: vppw p w e r BloALCU, svppllsr BCU and SBU n FJI:lZ 26 VDC supply <-
cu mode.
MCU
awerA: l o ALCU. Swpller MCU and SBU in
"pp~yp o w e r ~ 1:24YDC. 2: 0 VDC
FJI:1,2
cu made.
-73045-0110-0003 MAN Diesel
MAN Diesel 3045-011 0-0003
Appendix 6
Back-up Control Unit
I I
M i c r o s w i t c h s e t t i n g s f o r SW 1 .
Switch 1 .2.3 .4
No. o f r e v . / l n l . In BCU nod.
A L L malnam I b l n o r l 20 SYI \
Microswitch settings for SW 2.
Switch 1
n o . o f srllndsrm
. . .
2 3 4
Switch 5
not i n u..
4 crl. I blnerr 4
6 crl. I b l n m r ~6 If X - B I off
Switch 7
I! c r l . I blnarr I!
7 Index
Operation
Commissioning
Maintenance
Components
Electrical Wiring
Commissioning
-7
Table of Contents
See
1. NZ Charging Maintenance 903-2.1, page 2-3 and 103-2
2. Flushing 5903-24
.
8 Testbed Commissioning Procedure <--.
S903-21
-1
4. Angle Encoder Maintenance 905-8.1 and 105-8
5. Tacho Pickups Maintenance 905-7.1 and 105-7
6. Timing Check Procedure 5903-20
7. Testbed Trial Test Scheme
8. Dock Trial Commissioning Procedure
9. Dock Trial Test Scheme
'
i 1 When referring to this page, please quote Commissioning TOC
MAN B& W Diesel AIS, Copenhagen, Denmark
Flushing of Pipe System on
S903-24
B&W Alpha Lubricators
1. Preparation
1.1 Connect a 440 V power supply to the two pump starter cabinets, and start the two
pumps locally for a brief period to check that they run in the correct direction of
rotation.
1.2 Check, and if necessary adjust, the current limits on the two motor-start relays so
that they comply with the rating plate on the motor.
1.3 Connect and activate the heating element in the suction tank.
1.4 Dismount the inlet and outlet pipes to the lubricator blocks and mount U-pipes
with shut-off cocks instead (bypass the blocks).
Remember to seal off the free pipe connections on the lubricator block to prevent the in-
gress of dirt.
Mount an extra full-flow filter (15to 35 p) in the return pipe from the engine to the pump
station.
Disconnect the service tank as hydraulic oil is to be used for flushing.
1.5 Mount a U-pipe with shut-off cock on the end of the oil supply main pipe.
1.6 Close all shut-off cocks on the U-pipes at the lubricator blocks and open the cock
at the end of the main pipe.
1.7 Fill the suction tank on the pump station with hydraulic oil.
1.8 Open all relevant cocks on the pumps.
1.9 Start pump No. 1 locally via the starter cabinet.
1.10 Adjust the pressure regulator on the pump station to maximum pressure.
1.11 Check that there are no leaks in the pipe system.
1.12 Check the oil level in the suction tank and, if necessary, top up until the level is
stable.
1.13 Shut-down pump No. I.

1.14 Start pump No. 2 and check that it can maintain a pressure level similar to pump
No. 1.
1.15 Start both pumps.
1.16 Regularly check the oil level in the suction tank and top up as necessary.
1.17 Regularly check that the pressure drop across the suction filters and in the full-
flow filter in the pressure outlet do not exceed the maximum level. Replace the fil-
ters if clogged.
When referring to this page, please quote Procedure 5903-24 Page 1 (3)
MAN B&W Diesel AIS, Copenhagen, Denmark
S903-24
Alpha Lubricators BRW
3 2. Flushing
The following flushing procedure is to be carried out before starting up on the testbed:
After five hours' flushing, open one half of the shut-off cocks on the U-pipes on
the lubricator blocks, and close the cock at the end of the main pipe.
Continue flushing for at least five hours.
After five hours' flushing, open the other half of the shut-off cocks on the U-pipes
and close the half that were open.
Continue flushing for at least five hours.
Close the inlet and outlet cocks on the pump station, and drain the oil from the
suction tank.
Switch-off the 440 V power supply to the pumps and tank heater via the main
switch on the starter cabinets.
Remove the inspection cover on the suction tank and clean the inside of the tank
so that it is completely free of any oil or dirt.
Dismount all U-pipes and re-install all the original pipe connections.
Open all relevant cocks on the pumps and open for the supply of cylinder oil from
the service tank (gravity tank).
Start a pump from the pertaining start button on the starter cabinet and adjust the
pressure regulator to 45 bar.
Check that there are no leaks in the pipe system or lubricators.
Check and, if necessary, adjust the thermostat to 45' C, after dismounting the
cover on the heater.
The oil system is now ready for service.
3 Page 2 (3) When referring to this page, please quote Procedurer 5903-24
MAN BBW Diesel A/S, Copenhagen, Denmark
Alpha Lubricators -
-7 The filter must be a "bag-type" filter
U-pipe with valve

/I. #2 /
Return line
-
Extra
full float
flushing filter
Group #1
w Group #2
:.I When referring to this page, please quote Procedure 5903-24 Page 3 (3)
MAN B&W Diesel N S , Copenhagen, Denmark
Testbed Commissioning Procedure
.'-I
ALCU - Testbed Procedure
1. Disconnect the connections to the HMI pan-

el. (HMI panel side).
2. Check the power supply for correct polarity

before connecting the power to the ALCU
control box terminals. Check both Main A
and Main B.
3. Check the HMI panel power connection for

correct polarity, and connect the HMI panel.
MAN B&W Diesel AIS 2003-01-28
Testbed Cornrnissioninq Procedure ~ a w
4. Set the Index transmitter to approx. 4.5 mA

at 0 mm index and approx. 19.5
, mA a t max-
imum possible index on the Local Operating
Panel. The mA level can be read on the
HMI panel.
Navigating in the HMI panel menu i s done

as follows:
[ENTER] goes forward (right) in

the menu or changes a set point.
[ESC] goes backwards (left) in the menu.
[ A ] goes up in the menu.
[ T I goes down in the menu.

P
W
( diSP # in.A XXX [rnA]
5A. Aft Fore

5. Adjust the angle encoder to give TDC sig-
nal at TDC cylinder No. 1 (turn the engine
to bring the piston of cylinder 1 to TDC po-
sition, and turn the encoder until the LED
on the encoder junction box lights up).
S e e Procedure 905-8for angle encoder ad-
justment.
Adjust the BCU pick-ups, as described in

Procedure 905-7.
Start one pump.

Check that the oil pressure builds up to 40-
50 bar, or carry out adjustment on the pres-
sure control valve on top of the pump sta-
tion. The pressure can also be read on the
HMI panel display.
Check that the pressure remains at an ac-

ceptable level, also with two pumps run-
ning.
Page 2 (8) When referring to this page, please quote Procedure 5903-21
2003-01-28 MAN B&W Diesel A!S
6. Turn the mode switch to BCU position and

check that both booster pumps are running.
Turn the switch back to AUTO position.
7. Check the connections to the lubricators by

activating the lubricators one by one via the
HMI panel connection test menu (start one
booster pump from the HMI panel).
N
PRESS
8. Check the lubricator system by activating

the pre-lubrication function. Press the ESC
button and the PRELUB button on the HMI
panel simultaneously. Check that no feed-
back alarm is activated.
M A N BBW Diesel A 6 2003-01-28
Testbed Commissioning Procedure mew
9. Turn the engine to approx. 10" before TDC

of cylinder No. 1.
Continue turning the engine and check that

the small LEDs on the MCU unit - desig-
nated D88 (above J20) D90, D91 (above
J22) -flash when the engine is turned and
passes TDC of cylinder No. 1.
Also check that the LED on the MCU unit -

designated D89 (above J20) - flashes ap-
prox. twice each second.
Page 4 (8) When referring to this page, please quote Procedure 5903-21
2003-01-28 MAN B&W Diesel N S
Cylinder Lubrication S903-21
BBW Testbed Commissioning Procedure
'3 10. Check the engine stop signals by simulating

run and stop condition from the governor
side. Check that LED D80 (abovelright J30)
on the MCU and LED D38 (above J5) on
the BCU turn on and off accordingly.
When referrhg to this page, please quote Procedure 5903-21 Page 5 (8)
M A N BBW Diesel N S 2003-01-28
~903-21 Cylinder Lubrication
Testbed Commissioning Procedure BEW
11. Check the common alarm connection by

simulation. Follow the HMI panel menu in-
ne
( Alarm System struction to activate a common alarm from
p !
the lubricator system as shown below.
-
7
Connt. Co.ALr oFF1on

0
z
Common Alarm
12. Check the timing adjustment as described

in Procedure S903-20.
Alpha Lub. test doc.

Injection angle:
Programmed Corrected
Page 6 (8) When referring to this page, please quote Procedure 590391
2003-01-28 MAN B&W Diesel N S
13. Carry out the tests according to the testbed

test scheme and fill in the check boxes
0: logged alarm Alarm outprnterminal

Inumber from:
14. When the engine load is increased to 50%

load, calibrate the index transmitter at this
load by means of the index transmitter ad-
\
. 1 justment menu in the HMI panel.
Follow the example in drawing 14.a.
~c OV,
DB"O
Mi". 0
U. U . U. U. U
;j
When referring to this page, please quote Procedure S903-21 Page 7 (8)
M A N B&W Diesel A 6 2003-01-28
14a. Password
-----
-----
-.--.
-----
-.--.
SETUP Value
-
(Password)
15. When the engine load is increased further

to 100% load, calibrate the index transmit-
ter at this load by means of the index trans-
mitter adjustment menu on the HMI panel.
Follow the HMI panel menu instruction.
9 PRESS
Page 8 (8) When referring to this page, please quote Procedure S903-21
2003-01-28 MAN B&W Diesel A!S
BEW Check of Injection Timing
1 Injection timing
I . Adjust the shaft encoder in accordance with

Procedure 905-8.3.
2. Remove the lubricator timing hole plug from

the exhaust side of cylinder liner No. 1. If
there is no timing hole, remove one cylinder
oil lubricating point non-return valve from
cylinder liner No. 1.
3. Turn the engine to BDC Cyl. 1. Check that

the timing hole is clean. Turn the engine
ahead until the upper edge of the top piston
ring becomes visible.
Note!
Compressed air is coming out of the tim-

ing hole when the piston is turned
upwards. Use eye protection.
4. Note the crank angle on the turning wheel.
5. Compare the angle obtained with the angle

stated on the test sheet in the lubricator
control unit. If the reading is not within the
tolerance stated on the test sheet, correct
all angles in the test sheet with the ob-
served difference.
Alpha iub. lest doc.

lnlectlon angle:
Programmed Correcled
Cyl. 3:
M A N B&W Diesel AIS
Check of Injection Timing
-
Run the engine at steady load. Read all in-

jection angles on the HMI panel.
Navigating in the HMI panel menu is done

as follows:
[ENTER] goes forward (right) in

the menu or changes a set point.
[ESC] goes backwards (left) in the menu.
[ A ] goes up in the menu.
In) [ T I goes down in the menu.
EZ Read all injection angles in the HMI panel,

starting at the [diSP] menu and follow the
sketch.
I--) Check that the angles correspond with the
angles on test sheet.
Str.hi
Str.Lo Lub. i XXX(O)
t.dLr(ms) I I
) A. InJ('1 - Lub .XX
-----
8. In case the angles are not within the stated

3 tolerance, adjust the common offset value
in the HMI panel SEtup menu.
See the sketch.
Password
m
8.
n(rpm)
-----
A ESC ENTER
-----
SEtuP
m
o ----- (Password) XXX("1
g
",
9. When the Injection offset [InJ.OF] is
checked or adjusted (if adjusted) press
[ENTER] (the HMI panel will display
[SAVE]). Return to the main menu by press-
ing [ESC].
Page 2 (2) When referring to this page, please quote Procedure S903-20
MAN BBW Diesel AIS
- ~
Alarm o u t ~ u t sto be activated

-
Alpha lubricator testbed trail test scheme
"1 I
Function t o be U d : I
I
Test by
I
Alarm number
displayed In HMI
I
Actlon
Common
alarm
MCU
power fall
BCUfgwer
BCU i n ctrl. MCU fail BCU MI slow down
Checked
Simulate common alarm from HMI panel Common alarm lums ON in alarm
alarm autpul menu system
MCU LED D6O above plug J30 light Slmulate englne stop signal from engine control system
2 Engine slop signal Simulaling Stop signal BCU LED D49 above plug J5 light
3 Standby pump Switch master pump OFF local side (39) + 49 Slandby pump darts
BCU take-over, standby pump Disconnect Plugs on bolh lubricalores Change over to BCU contml and
Varius standby pump slart, slowdown
slart and slowdown oulput one cylinder
ralld for ALCU system and MCU software Rev 1.6X

( ) : lagged alarm Alarm oulpul terminal number ham:
~
.....................X..I.......... . ..........
.... ........ ....... .... 1
.., ..................xi
. , ~
~~
........
. ~ .....~ .... ........
Iand2l3and6/
........... ..~-.~
~ . ~
........ ...~
~~~
1 1 I 1
................. . . . .......
........................ ..~
9 and 12
.......
~~~~~
~ ~......
~ ~
........... .~~~~
~
........
..............
13and 14 S a n d 16 17and 18
.................... ....... ...... ~ ~ ............
~~~
~
~ ~ . . .
~ ~ . ~
XI 7 and 8
Note lhal the contml switch must be in AUTO position during lhe test
All tests can be made wilh Engine wnning low load or wilh higger simulalorwithout engine running
Aner evetytesl the lagged alarms must be deieled in the HMI panel
After test 4 the conbol switch must be changed to MCU and back to AUTO mode
linimum requiremsnts at tesl bsd is m m m m alarm to be connecled to AMS system
0a.ilsSlsndards (MBD S0) & Suppl. Drawing No.: I ENZlCS011,mughner.
Slmllar Diawlng no.: RoZscamsnllolIdlmlno:

sale: Slze: ?age NO.:
1:l A3
Type
Testbed trail test scheme 01 101) MAN BBW Diesel AIS
Inlo No. Da.cdpllm Ids",. No.
>IS drawlno is ma ~ ~ ~ DIWI NS and IS to be iraaw a. mnndenUel by the pay 3 02 023 INSTRUCTION 0788812-9
p m p s w f y o l B(~W
I\N 88W Dlsrsl N S and la no1 lo be dlsdceed loany Mid p a ~ w i l h o uhl e s ~ e c l c ~ r i willen
or
~ . * h o mI ha. b a n aubrn~nedby
pemk%n ol MIW B&W Dlsrsl N S
&& Flnd User lnla No. Final User Descdpllon Final urar ldenl. No.
MAN B&W Dock Trial Commissioning Procedure
.
*LC" -
Dock Trial Commissioning Procedure
1. Disconnect the connections to the HMI

panel. (HMI panel side).
2. Check the power supply for correct polarity

before connecting the power to the ALCU
control box terminals. Check both Main A
and Main B.
3. Check the HMI panel power connection

for correct polarity, and connect the HMI
panel.
12
Alcu Box
24V DC
I Main B
When referring to this page, please quote S-Instruction S903 Edition 0039 Page 1 (5)
S903-0039 Cylinder Lubrication
Dock Trial Commissioning Procedure MAN B&W
T
4. Check the adjustment of the angle encoder.
Turn the engine until the LED on the en-
coder junction box lights up, and check
that the crank angle reading is 0" on the
flywheel (TDC cylinder 1). See Procedure
905-8.
Adjust the BCU pick-ups, as described in

Procedure 905-7.
5. Check the connections to the lubricators by

activating the lubricators one by one via the
HMI panel connection test menu. Follow
the HMI panel menu instruction.
6. Check the lubricator system by activating

the pre-lubrication function. Press the ESC
button and the PRELUB button on the HMI
panel simultaneously. Check that no feed-
back alarm is activated.
0'
PRESS
Page 2 (5) When referring to this page, please quote S-Instruction S903 Edition 0039
MAN B&W Dock Trial Commissioning Procedure
'3 7. Turn the engine to approx. 10" before TDC

of cylinder No. 1.
Continue turning the engine and check that

the small LEDs on the MCU unit - desig-
nated D88 (above J20) D90, D91 (above
J22) - flash when the engine is turned and
passes TDC of cylinder No. 1.
Also check that the LED on the MCU unit

- designated D89 (above J20) -flashes ap-
prox. twice each second.
When referring to this page, please quote S-Instruction 5903 Edition 0039 Page 3 (5)
S903-0039 Cylinder Lubrication
Dock Trial Commissioning Procedure MAN B&W
LCD connections and setup for CPP plants
(Only for controllable pitch propeller plants)
8. If the vessel is equipped with a controllable

pitch propeller the Load Change Depend-
ent extra lubrication (LCD) must be con-
nected and commissioned as follows:
An active 4 to 20 mA signal (not power

supplied from ALCU) "Telegraph handle
position", i.e. a signal representing the or-
dered engine power must be connected
from the remote control system or tel-
egraph system to ALCU/XI:33 and ALCU/
X1:34. The LCD signal connections from
the governor to ALCU/X2:1 and ALCU/X2:2
must be omitted.
Scaling:
4 mA zero load
20 mA max. handle position (overload)
The signal may be generated by the remote

control system as:
Pitch set % * RPM set % if convenient.
The configuration of the ALCU is carried

out as follows:
SEtuP/LCd/P.l = tELE.P
SETuP/LCd/P.6 = 100
See Figs. 8A and 88 and also section

3.2.9, Menu Structure (-part 2).
Page 4 (5) When referring to this page, please quote S-Instruction 5903 Edition 0039
- MAN B&W
Carry out the external connection test ac-
Dock Trial Commissioning Procedure
cording to the dock trial test scheme and

fill in the check boxes.
Alpha lubricaar dock trial test scheme Activated alarm outputs 1

Test by Alarmnumber
displayed on Adion
1 I
MCU LED D60 above
I I I
plug J30 lights
BCU LED 049 above
. "
DIUO J5 liohts
"
Simulate engine stop signal from engine control system
I I
I
4 AheadAstern Simulating Astern MCU LED 078 above Simulale Astern signd from engine control srjtem
signal signal plug J30 light
Simulate pre-lubricationsignal from engine control system
Slandby pump / Swnching master pump1

OFF local side
(39) +49 ISIandby pumpnans
7 BCU take-over.
stand-by pump
start and slow-
Disconnecting plugson
both lubricatorsfor one
cylinder
I 1 44 Change over to BCU
control and slandby
pumpnart, dow-dow
number from:
When referring to this page, please quote S-Instruction S903 Edition 0039 Page 5 (5)
Valid for ALCU system and MCU s o h r e Rev t 6 X
N o t e lhal the control switch must be in AUTO position during the test
'All tests can be made wlh Engine running low load orwith trigger simulator wilhoul engine running
'ARer every test the logged alarms must be deleted in the HMI panel
'ARer lest7 Ule conlml switch must be changed to MCU and back to AUTO mode
1 Index
Operation
Commissioning
Components
Electrical Wiring
Cylinder Lubricators 103-2
BEW Data
'3 SAFETY PRECAUTIONS Standard Tools: See Section 913
Stopped engine
rx I B I O C ~the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
H Shut off lubrication oil
Lock turbocharger rotors
Data
Ref. Description Value Unit
'3 D-1 Nitrogen pressure

-inlet accumulator 25-30 bar
D-2 Nitrogen pressure

-outlet accumulator 1.5 bar
D-3 Plug screw

-tightening torque 30 Nm
'
L 1
When referring to this page, please quote Data Dl0302 Edition 0020 Page 1 (2)
MAN B&W Diesel A/S
Cylinder Lubricators
Data
aaaw
Spare Parts
Plate- Item No. Description
Page 2 (2) When referring to this page, please quote Data Dl0302 Edition 0020
MAN BBW Diesel N S
Cylinder Lubricators 903-2.1
MAN B&W Diesel Checking
'
7
Check of Oil Injection:
With stopped engine and normally when the

system has been disassembled:
1. Press the ESC + PRELUB.-button on the

HMI control panel, and check that all lubri-
cators are operating correctly by watching
the LEDs on the intermediate boxes for
each lubricator.
2. If the cylinder cover or the exhaust valve is

removed, check inside the liner that all lu-
bricating points are working properly.
Othetwise, remove the covers for scavenge

port inspection.
Turn the piston to BDC and check inside

the liner with a mirror and a powerful light
source that all lubrication points are work-
ing properly.
'-1
\-
When referring to this page, please quote Procedure M90302 Edition 0249 Page 1 (12)
903-2.1 Cylinder Lubricators
Checking MAN B&W Diesel
.'7
With running engine:
3. Check that all lubricators are operating cor-

rectly by watching the LEDs on the inter-
mediate boxes for each lubricator.
The LEDs give signal when oil is injected.
Check the pressure shocks from the injec-

tion of the lubricators on each lubricator
pipe by feeling with a hand.
If in doubt, disconnect the pipe at the cyl-

inder liner to observe the oil flow.
Check of Accumulators:
4. Measuring the nitrogen pre-pressure can

only be done with stopped engine and
pressure-free lubrication system.
Stop both oil pumps. Close the inlet valve

and open the equalizing valve on the re-
spective lubricator.
The nitrogen pressure in the inlet accumu-

lator (0.7 litre) can be checked without dis-
mounting the accumulator. For use of the
pressure setting tool, see Step 5.
5. To measure the nitrogen pressure in the

outlet accumulator (0.16 litre), the accumu-
lator or the lubricator with accumulator
must be dismounted.
See Procedure 903-2.2.
For nitrogen pressure in the accumulators.

see Data.
Page 2 (12) When referring to this page, please quote Procedure M90302 Edition 0249
MAN B&W Diesel Checking
'
1
6. Use of Pressure Setting Tool
Assemble the pressure setting tool as
shown in Figure 5, and mount the reducing
valve on the nitrogen cylinder. If necessary,
use a threaded adaptor.
Mount a 0-60 bar pressure gauge on the
filling valve when the inlet accumulator (0.7
litre) is to be checked, and a 0-10 bar
pressure gauge when the outlet accumula-
tor (0.16 litre) is to be checked.
7. Before mounting the filling valve on the ac-

cumulator, check that the accumulator top
is clean.
Mount the filling valve on the relevant accu-

mulator with the union nut. Check that
valves C and F are closed.
Loosen the plug screw in the accumulator

using a %" square drive handle in socket E.
It is now possible to read the actual nitro-

gen pressure in the accumulator on the dial
gauge on the filling valve.
8. If the accumulator needs to be refilled with

nitrogen, open valve A and increase the
outlet pressure from valve C on spindle B
to 1-2 bar above the pressure stated in
Data.
Open valve C until the accumulator is filled

to the correct pressure.
Close valve C and tighten the plug screw

with socket E to the torque stated in Data.
Release the pressure in the filling valve at

bleed screw F.
Unscrew the filling valve from the accumu-

lator. Retighten the plug screw to the
torque stated in Data. Remount the accu-
mulator.
Dismantling MAN B&W Diesel
Dismantling of lubricators:
The engine must be stopped and blocked be-

fore dismounting a lubricator. Stop the cylinder
oil pump station.
1. Close the supply valve for the lubricator

and open the equalizing valve (turn both
handles to a horizontal position). Remove
the upper shield, if installed.
Disconnect the electrical plug on the side

of the lubricator.
2. Unscrew the six screws in the bottom of

the lubricator and disconnect the cover
with pertaining pipes.
3. Unscrew the four screws on the side that

secure the lubricator to the hydraulic block,
and remove the lubricator.
Special running
It is possible to change a lubricator while the

engine is running if a spare lubricator with O-
rings and the necessary tools is available. The
change should be done in a maximum of 15
minutes.
Reduce the engine load to below 40%

of MCR
Let the lubricator pump station run
Dismount the lubricator as described in

steps 1-3
Mount a spare lubricator as described

in Procedure 903-2.4.
MAN B&W Diesel Dismantling
Dismantling of accumulators:
4. The engine must be stopped and blocked

before the accumulator is dismounted.
Stop the cylinder oil pump station.
Close the supply valve for the lubricator

and open the equalizing valve.
Note!
When the oil pressure is released, a ni-
trogen pre-pressure of 25-30 bar will re-
main in the accumulator.
Carefully unscrew the accumulator to re-

lease the remaining oil pressure in the sys-
tem. Remove the accumulator from the hy-
draulic block.
'-1
'-
Overhaul MAN B&W Diesel
Place the lubricator in a bench vice with

soft "jaws".
Remove the adjusting screw with bushings.

Unscrew the oil accumulator.
Discard the O-ring from the adjusting

screw.
Remove the screws from the cylinder

block.
Pull up the cylinder block.
Remove the spring and actuator piston

with plungers.
Remove and discard the O-ring from the

cylinder block.
Remove the cover for the non-return

valves. Take out springs and balls. Remove
and discard the O-rings.
- II
MAN B&W Diesel Overhaul
?
) 4. Screw out the non-return valves and re-
move and discard the O-rings.
Clean the valves and check them with

compressed air.
5. Inspect the plungers, actuator piston and

cylinder block for wear, using a magnifying
glass.
6. Fit the non-return valve with new O-rings.
Mount the non-return valves in the cylinder

block.
:
I
I
Overhaul MAN B&W
7. Pre-assemble the cylinder blockwith the

actuator piston and plungers to ensure the
correct guidance of the plungers, before fi-
nally assembling the cylinder block unit.
Mount the spring and press down the ac-

tuator piston with plungers. Mount an M6 x
60 screw with a washer to keep the spring
compressed.
Fit the cylinder block with a new O-ring.
8. Remove the cover from the terminal box

and disconnect the wires for the feedback
(pick-up) sensor.
Remove the terminal box and the plug for

the solenoid valve.
Carefully unscrew the feedback sensor and

remove and discard the O-ring.
Clean the housing with diesel oil or kero-

sene and dry with a non-fluffy cloth.
MAN B&W Overhaul
--,
) 9 Turn the lubricator upside down in the vice.
Unscrew the solenoid valve.
Discard the O-rings.
10. Solenoid valve:
Disassemble and clean the valve.
Check the slide for wear. If the slide is

scratched or scuffed, the valve must be re-
placed by a new one.
Lubricate the slide with oil and check that

the slide can move lightly with a good fit in
the housing.
Assemble the valve.
See also manufacturer's instructions.
11. Before mounting the feedback sensor,

check that the sensor is flush with the sen-
sor housing.
Mount the feedback sensor or a new one, if

necessary, with a new O-ring.
Check with an object with a straight edge

(e.g. the end of a calliper) that the end of
the feedback sensor does not protrude into
the actuator piston cylinder.
Mount the terminal box.
Ip
I1
=!&olenoid valve
Feedback sensor
:--1
Overhaul MAN B&W
12. Connect the wires and mount the cover on

the terminal box.
13. Mount the solenoid valve fitted with new

O-rings. Coat the O-rings with a little
grease to keep the rings in place during
mounting.
14. Mount the cylinder block assembly in the

cylinder housing.
Check that the spring pin engages correctly

with the cylinder block assembly.
Mount the screws and tighten the block to

the housing.
Remove the M6 x 60 screw with disc.
MAN B&W
'
Overhaul
,-
15. Mount the adjusting screw fitted with a new

O-ring and the distance bushing.
Mount the oil accumulator.
16. If the lubricator is not to be mounted on

the engine immediately after overhauling,
cover all openings with plastic to prevent
dirt from entering the lubricator during stor-
age.
Cover all surfaces with a thin layer of oil.
- Mounting
Mounting of Lubricators
MAN B&W
1. Mount new O-rings on the hydraulic block

and on the cover with pipes.
Mount the lubricator and tighten the screws

on the hydraulic block.
Tighten the screws between the lubricator

and the pipe connection.
2. Open the supply valve and mount the elec-

trical plug. Check the injection of the cyl-
inder oil on the led on the terminal box for
the specific lubricator.
For checking injection timing, see Proce-

dure 905-8.1.
MAN B&W Mounting

.
) Mounting of Accumulator
3. Mount the accumulator. Remove the drain

hose from the minirness coupling. Open the
valve that connects the accumulator to the
distributor block.
Check the oil injection.

See Procedure 903-2.1.
.-)
Tacho Pick-Ups 105-7
MAN B&W Data
I
X Stopped engine
X Shut off starting air supply - At starting air receiver
X Block the main starting valve
Shut off starting air distributor/distributing system supply
Shut off safety air supply- Not ME engines
Shut off control air supply
Shut off air supply to exhaust valve - Only with stopped lubricating oil pumps
X Engage turning gear
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
-
Ref. Value Unit
-
D05-40 Tacho pick-ups for governor system

-check distance rnm
D05-41 Tacho pick-ups for Alpha lubricator

-check distance mm
Regarding distance: Always refer to manufacturer's instruction:
D05-42 mm
D05-43 mm
When refemng to this page, please quote Data Dl0507 Edition 0006 Page 1 (2)
Tacho Pick-Ups
Data MAN B&W
The task-specific tools used in this procedure are shown on the plates at the end of this chapter o r in
the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate Item No. Description
Page 2 (2) When refemig to this page, please quote Data 010507 Edition 0006
Tacho Pick-Ups 905-7.1
MAN B&W Checking
'7
The engine is equipped with two sets of pick-
ups:
Governor system pick-ups
Alpha Lubricator system pick-ups.
Governor system pick-ups:
1. The tacho pick-ups are placed next to the

turning wheel.
2. Check the distance between the tacho

pick-ups and the turning wheel, see Data.
If necessary, adjust the distance.
If the tacho pick-ups are renewed, note

down the wiring to ensure the correct re-
mounting.
Tacho Pick-Ups
Checking MAN B&W
Alpha Lubricator system pick-ups
(backup system for angle encoder):
3. Turn the crankthrow for Cylinder 1 to TDC.
Check the TDC of Cylinder 1 against the

mark on the turning wheel.
4. The pick-ups are placed next to the turning

wheel, see the sketch.
5. Check that the upper marker piece edge is

in the centreline of the pick-ups.
Check the distance between the pick-ups

and the marker piece on the turning wheel.
Adjust the distance if necessary. S e e Data.
If the pick-ups are renewed, note down the

wiring to ensure the correct remounting.
Tacho Pick-Ups 905-7.1
MAN B&W Checking
.-
I 6. To ensure an applicable pulse to the tacho
pick-ups, it is very important that the mark-
er piece, as a minimum, complies with the
dimensions stated in drawing 5 and 6.
:1
.-
Angle Encoder 105-8
BRW Data
3 SAFETY PRECAUTIONS
Stopped engine
~ ~ .
3
X
X
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors
Data
-
Ref. Description Value Unit
-
When referring to this page, please quote Data Dl0508 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
105-8 Angle Encoder
Data asw
The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the
chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.
Plate tern No, lescription
Page 2 (2) When referring to this page, please quote Data Dl0508 Edition 0007
MAN BBW Diesel A 6
Angle Encoder 905-8.1
MAN B&W Checking
7
Turn the crankthrow for cylinder 1 to TDC.
Check the TDC of cylinder 1 against the

Check that power is supplied to the inter-

mediate box.
The green indicator should now light.
For adjustment of the angle encoder, see

Procedure 905-8.3.
Remove the inspection cover.
Check that the rubber damper is intact.
Assemble the cover.
When referring to this page, please quote Procedure M90508 Edition 0206 Page 1(4)
905-8.2 Angle Encoder
Dismantling MAN B&W
1. Remove the inspection cover.
Cut the cable tie which holds the rubber

damper around the coupling, in the end
nearest to the engine, and loosen the cou-
pling.
2. Loosen the three adjusting screws o n the

front flange, and remove the angle encoder
and the coupling.
3. Screw out the flange screws and remove

the encoder housing. Take care not to
damage the guide pins.
Angle Encoder 905-5.3
-
)
MAN B&W
1. Turn the crankthrow for cylinder 1 to TDC.

Adjustment
1.
Check the TDC of cylinder 1 against the
Check the TDC position with the pin gauge

on the crankthrow, cylinder 1.
measurement from tip to tip with the val-

ue stamped on the in gauge, and/or the
check-marks stamped on the fore end of
I \
the cylinder frame. o
w
0
a
0
2. Loosen the adjusting screws which fasten z
the encoder to the housing. Slowly turn the
'
encoder until the green indicator lights on
the intermediate box.
Tighten the screws to secure the encoder

in the correct position.
905-8.4 Angle Encoder
Mounting MAN B&W
.-
1. Assemble the encoder housing. The t w o

guide pins indicate the correct positioning
of the housing. Tighten the screws.
2. Fit the angle encoder and the coupling.
Tighten the coupling, and mount new cable

ties around the rubber dam~er.
Adjust the angle encoder according to Pro-

cedure 905-8.3.
The adjustment will be easier if mounting

is in the same crank position as disman-
tlina.
3. Assemble the cover.
Alpha Lubricator System S903-0040
MAN B&W Check and Adjustment of Index Transmitter
' Check and adjustment of index transmitter
The following guidelines are relevant for the adjustment or replacement of the index transmitter
on engines in service.
Adiustment of index transmitter
Adjust the index transmitter electrically until:

The minimum index from the engine side control console corresponds to 4.5 MA.
The maximum index from the enaine side control console C O ~ ~ ~ S DtoO19.5
~ ~ mA.
S
See instruction S903-21, ~ e s t b e d ~ o m m i s s i o nProcedure.
in~
Calibration of index signal

120%
Adjust the fuel rack on the engine side IM~ ~000000000000000000~
control console to an index corresponding mom
to 50% load at testbed conditions (relevant
011P-8-~ooooooooooooooonoo~
values can be found in the shoptest report).
Navigate, via the HMI panel, to the lndex

~ d j u s menu.
t
Choose either the generator curve or the FasdbarklsilursO
propeller curve, depending on the measure- omm.n ah o
ments obtained on the testbed.
Select 50% in the Menu, and

Password press [enter].
-..-.
u A ESC ENTER NOTE: When the prooeller
sue and 50% are selected,
and enter is pressed, the in-
dex readina will be: 63%
-....
-....
N
"4
0
Adjust the fuel rack on the
_....
4 Prop engine side control console
;j
E:
-....
-
Gen 4 to an index corresponding to
SETUP Volue 100% load at testbed condi-
(Password) tion (relevant values can be
found in the shoptest report).
Navigate, via the HMI panel, to the lndex Adjust menu.

Choose either the generator curve or the propeller curve, depending on the measurements ob-
tained on the testbed.
Select 100% in the Menu, and press [ENTER].

The index transmitter has now been adjusted.
These settings are only 100% valid when running on diesel oil. When running on heavy fuel
there can be a minor offset, which can be compensated for by aflusting the mechanical con-
nection from the fuel rack to the index transmitter.
1
L'
When referring to this page, please quote S-Instruction S903 Edition 0040 Page 1(1)
'7 Index Operation
Commissioning
Maintenance
Components
Electrical Wiring
Cylinder Lubricator Unit Plate
90307-0035
Plate
Cylinder Lubricator Unit 90307-0035
- -
Bm em ltem Description
ltem Description
lo. lo.
- -
18 3all valve
31 ;tud
143 iydraulic block
155 dut
167 'lug screw
180 )-ring
I92 ntermediate pipe
14 kljustable elbow coupling
38 3all valve
51 Stud
75 ~bricator,complete
99 iydraulic block
109 3asket
!I0 Membrane accumulator
134 Screw
258 Adjusting screw
271 O-ring
!83 Spacer, tubular
295 Cover
305 O-ring
317 Non-return valve
329 O-ring
330 Cylinder block
342 O-ring
354 Spring
366 Plunger
378 Actuator piston
391 Straight stud coupling
401 Screw
413 Screw
437 Cylinder housing
449 Solenoid valve complete
450 Screw
474 Membrane accumulator
486 Gasket
498 O-ring
508 O-ring
521 Inductive sensor
533 Cable
545 Cable gland, complete
569 Housing
570 Plug
582 Plug
594 Screw
Intermediate Box Plate
90308-0012
Plate
lntermediate Box 90308-0012
[em Item Description Item Description

'lo.
lntermediate box, complete
Electric enclosure with cables
Circuitboard assy
Screw
Diode
Cylinder Lubricator Unit Plate
90307-0023
Cljnder Lubricator Unit Plate
90307-0023
-
tern tern Itern Description
Itern Description
No. No.
Membrane accumulator
Shim
Nut
Distributor block
Stud
Ball valve
Distributor block
Coupling
Coupling
Distributor block
Stud
O-ring
Lubricator, complete
Screw
Adjusting screw
O-ring
Distance pipe
Cover
O-ring
Non-return valve
O-ring
Cylinder block
O-ring
Spring
Plunger
Actuator piston
Coupling
Screw
Screw
Membrane accumulator
Gasket
Cylinder housing
O-ring
O-ring
Inductive sensor
Screw
Solenoid valve
Housing
Plug
Plug
Screw
Cable gland
Cable
Intermediate Box Plate
90308-001 0
lntermediate Box Plate
90308-0010
-
tern tem kern Description
Item Description 10.
no.
lntermediate box, complete

Electric enclosure with cables
Circuitboard assy
Diode
1- Cylinder Lubrication - Electronic Components Plate
9031 2-0004
A-A /206
-
Cylinder Lubrication Electronic Components Plate
9031 2-0004
p~
ltem Description ltem ltem Description

No.
Name plate
Pilot lamp
Name plate
Selector switch
Terminal
Terminal
Din rail
Terminal
Terminal
HMI panel
Mounting plate
Nut
Screw
Terminal
Load Transmitter Plate
90619-0018
P90619 Edition 0018
~ ~~
Load Transmitter Plate
9061 9-0018
-
ltem ltem
ltem Description ltem Description
No. No.
Nut
Fitted bolt
Washer
Self-locking nut
Screw
Clamping arm
Screw
Potentiometer
Clamping arm, complete
Pull rod, complete
Bracket
Nut
Screw
Nut
Screw
P90619 Edition 0018

Arrangement of Angle Decoder Plate
BBW
P90503-0017
'3
A-A
-
169 1
When referring to this page, please quote Plate P90503 Edition 0017 Page 1 (2)
MAN B&W Diesel N S
Plate Arrangement of Angle Decoder
P90503-0017
Itern tern
ltem Description ltem Description
No. No.
Measuring instrument, axial vibration

jamper
Screw
4ngle encoder
-lousing
Screw
Shaft
ntermediate box
2oupling
lamper plate
:able ties
r001s
'acking
Screw
Spring lock
Spring pin
Shaft
'acking
Nasher
Shield
'acking
Page 2 (2) When referring to this page, please quote Plate P90503 Edition 001 7
MAN B&W Diesel N S
Plate
Test Equipment for Lubricator
90364-0004
019 5
020
\
r - - - - 1
I
I
1 I
I t e m No. Alternative Thread Type No.
032 G3/1"-IS0 228 1 533 391 015 [GUS)

081 W22x1/14" 1 533 391 014 (JAPI
152 G5/8-IS0 228 1 533 391 011 (GBI
164 W24.5~1/14" 1 533 391 012 [USA1
176 W23x1/14" 1 533 391 013 (KORI
W"21 .8xl/lA" 1 533 391 010 (Fl
P90364 Edition 0004

- \N B&W
*
;AN- AGE : 0063- 11:
REIdARKS
;PARE
DESCRIPTION SKETCH PLATE
No. UNIT
IORK I NC PACON
'T(I(G)
-
JBR l CATOR 2v.2
A T E NO. ADDED.
063-
01
0063-3202T
-
zv.2
A T E NO. ADOEO.
063-
02
063-
03
1063-
04
O19E I 7 17 0
0&5 1 2ZtE PLATE NO. ADDED. 2
20080 10s ggtz I Z2 1 ~ 1 ~ 0 3 . 0SKETCH.
4 SIN08 W 'T CORRECTED, PLATE NO. ADDED
200707 1 1
DATE DRAW CHI( ' D APP ' 0 DESCRIPTION OF REVISION R
HULL NO.
ENG l NE
TYPE I I
DESCR I P- No. MA 12-2254-0063-2
TlON CYL l NDER LUBR l CATOR
Doosan Engine Co. .Ltd.

REMARKS
PARE
No. UNIT
PACON
'TMG:
-
2v.2
.ATE NO. ADDED.
163-
04
-
2v.2
A T E NO. ADDED.
163-
06
-
2v.2
.ATE NO. ADOED.
163-
07
-
ev.2
LATE NO. ADDED.
063-
08
0063-32 11 s
-
ev.2
LATE NO. ADOED.
063-
09
-
I NE
TYPE
WMG 0063
Doc
DESCR IP- No
Doosan Engine Co.,Ltd.

-
OS,AN-
- PAGE : 0 0 6 3 - 3 1 3
IAT ' L
SF'ARE -
3 E40.
DESCR l PT lON SKETCH
UNIT
PLATE
PACON
'T(I(G)
-- - -
-RING FOR BETWEEN 1307-035 ,v.2
180 .ATE 1'10. ADDED.
V ITON
00163-
10
-- -
1307-035
L98
NBR
OC163-
11
3 -
0.001
-- -
1307-035 3v.2
329 LATE NO. ADDED.
O( 163-
12
-- -
"-1
L-
--
ENG I NE
NPE
'I,
\
DESCR I P-
Doc
No.
TlON
CYL l NDER LUBR l CATOR
Doosan Engine Co. ,Ltd.

REI~IAFW
;PARE
NO.
PACON
JSE
IR
20080918 0 013% 013% F i r s t issued.

DATE DRAW CHI( ' D APP ' D DESCR l PT l ON OF REV l S l ON
HULL NO.
ENG l NE
TYPE
6S50MC-C WSIIVIG 0044
Doc.
DESCR I P-
ENG l NECONTROLSYSTEM
NO. MA 12-2254-0044-0
T I ON
Doosan Engine Co. ,Ltd

PAGE : 0 0 6 3 - 1 1 3
;PARE
DESCRIPTION PLATE
No.
PACON
-
JBR I CATOR ?V. 1
'T
063-
01
063-
02
-
ILTER FOR BOOSTEF
PUMP
PRESSURE)
063-
03
-
ILTER FOR BOOSTEF ev. 1
PUMP 'T 0.660->0.665
SUCTION)
1063-
04
2008050e 019s 01YE 019E SlN.Ol.04-05.08W1T805SI(ETCHCORRECTED. 1

2007071 1 01 $2 g2E &!2$Z F i r s t issued. 0
DATE DRAlVN CHI< ' D APP ' D OESCR l PT l ON OF REV l S l ON R
HULL NO. HN. 1 0 1 7
ENG l NE
TYPE
6S70MC-C MSIMG 0063
Doc.
DESCR I P- No.
TlON CYL l NDER LUBR
. . l CATOR
. .. ..
.
,I .-. .. ..
,..:,~..:..... ,.. ..-
:.D@san
';.:.. ,
Eng i ne Co . ,L t d .
.
:;,~ .
DOOSAN-MAN B&W PAGE : 0063-213
PARE
SKETCH PLATE
No.
PACON
- - ," 1
1308-0 1C
013 '~'0.606-x.461
(ETCH
)O 1353->OO 1268
163-
05
-
)307-02:
-486
-
1307-02:
-342
-
-RING FOR 1307-02:
JBR I CATOR -271
-
1307-02:
-305
-
OESCR I P- No.
Doosan Eng i ne Co . ,L td .
PAGE : 0 0 6 3 - 3 1 3
PARE
SKETCH PLATE -
NO. UNIT
PACON
'T(I(G:
-
RING FOR BETWEEN )307-023
.UBR I CATOR AN0 187
.OU(
V l TON
-RING FOR 1307-023

dDUCT I VE SENSOR -474
1307-023
-329
OESCR I P- No
T I ON CYL l NDER LUBR l CATOR
Doosan Engine Co. , L t d .

MAT ' L REMARKS
;PARE
No.
ORK l NG PACON
-
JSE(3A)
IR
I
INTROL UN l T
344-
01
044-
02
-
!NSOR
3R
ICK-UP
044-
03
20070706 zyy 013% 013% F i r s t issued. 0
DATE DRAWN CHl'D APP ' D DESCR l PT ION OF REV l S l ON R

-
-
HULL NO.
ENG l NE
HN. 1022
TYPE
6S70MC-C MSIMG 0044
Doc.
DESCR IP- NO. MA 12-2424-0044-0
T I ON
ENG I NE CONTROL SYSTEM
Doosan Engine Co. ,Ltd.

'3 Index
Operation
Commissioning
Maintenance
Components
- Wires 0 . 7 5 ' blue
- W i r e m a r k i n g l a b e l s Phoenix C o n t a c t PABA-15 HW
- A l l w i r e ends a r e f i t t e d w i t h coble F e r u i r e
N o t e added.
ilz4IPoqp 5 & 8 : ~,
MCU
u
SBU I
I
BCU
POWER
N o t e : LCD s i g n a l c o n n e c t i o n f o r
fixed p i t c h propeller plonts
with e l e c l r a n l c governor.
N
I : S l o w Down = L o a d Reduction
for stationary
plants
I I?
2-
I +24V-FILT I
I I
-X1 2 u OV I
I I
I
-1
I -
3 SPARE 1
SPARE 2
I
1
I I 4 c
UI I
I
I
I
I
1
I -
1 BCU-INCTRL
I
2 BCU-IN I
I I 7 -CTRL-GND I
I I
I I
1 1 I P ~OUTP I+ 1
I
PUMP OUT 1- I
P M P OUT 2+ 1
I
PUMP OUT 2- 1
I I
r-----------
&El 4
PUMP I N
PUMP I N
PUMP I N
PUMP I N
I
PUMP 2 OUT+ I
_ - _ - - J
OIL OIL THERMAL TELEGRAPH
l NDEX TEMP PRESS. FAIL POS.
r------------
A 1 I VE-OUT
I
COWON I
5
I I
TDC
TR l GG
IDC b l
IDC # 2
I I
I I FB
I
I I #A OUT I
#A OUT
I I
#B OUT #B OUT I
I I
I I
I SOL RET
# I A H RET
~ ~
RET
L RET I
I I I I
I
I
I
SOL # 2 B
FB 51 4
- SOL
FB
I
I +74V 5 t24V
FB
I
I #A OUT #A OUT {
# B OUT I
RET 1 R RET I
FB I
#A OUT #A OUT I
#B OUT # B OUT I
I
SOL # 2 A RET I
RET
RET I
SOL # 2 B I
FB I r-----------
In
I
#A OUT #A OUT I
#B OUT
I
RET 8 RET I
I I I
I
I
FB
I r----------- 7z
1P
I
#A OUT #A OUT I
# B OUT I
1 SOL SOL
# B OUT
RET RET
I
I
I RET RET I I
1
I
SOL SOL
I r_-_--------
I FB lrn
I +24V
I
ov I
I
#A OUT # A OUT I
# B OUT # B OUT I
I I I
RET RET I
I I I
I I I
I I I
I I I
I I I
I I I
I I I
I I I
SOL
RET
SOL
I
FB
I r-------
+24v
ov
#A OUT #A OUT
I I I #B OUT #B OUT I
I I I I
I I I RET RET I
I I I I
I I I
I I I
I I I
I I I
FB
# A OUT
#B OUT
#5A SOL
RE1
RET RET
#5B SOL
FB FB
+24V
FB
ov
#A OUT
t B OUT
RET
I I I
I I I
I I I
I I I
I I I I
I I I
#B OUT
. #6A SOL
RET 2 8 RET I
RET RET I
p=pqp
. #6B SOL
FB FB
+24V
FB
ov
#A OUT #A OUT
I I I #B OUT #B OUT
I I I I I
I I I RET RET
I I I I I
I I I
I I I
I I I
SOL
SOL
FB
#A OUT
#B OUT
RET
I r _ - _ _ _ - - - - - - _ l
z
1 0
=
I
I
I #A OUT #A OUT I
I I I
I #B OUT #B OUT I
I
I SOL #8A SOL
I RET RET I
I RET RET I
I SOL #8B SOL
I
I FB FB
I +24V
I FB
I
ov
#A OUT
I
I I I #B OUT
I
I I I
I RET
I I I
I I I
I I I
I I I
I I I
I I I
I I I
I I I FB
I
#A OUT #A OUT I
#B OUT #B OUT I
I
# g
SOL RET ~ w SOL
RET RET I
RET
. I I
SOL #9B 82 SOL
I r
m
FB 83 4 FB
FB
#A OUT
#B OUT #B OUT I
I
RET RET I
I I I
- Wirer 0.75' blue
- W i r e m a r k i n g l a b e l s P h o e n i x C o n t a c t PABA-15 HW
- A l l w i r e ends o r e f i t t e d w i t h c o b l e F e r u l r e
MCU
I
n FEU \
FJlO - -
-- m m
-
-
m
- _
m
-
*
FJ2 L L Lz;;::
7
mu
SBU
EFJZ~ PSu
I
SW3
a BCU
J31
0 1 1I - I mmm
- - FBU
FJlO 1-1
F3 - -
FJ2 - 'm
;m
-
_ - - ,
; - - - -
P. rn s
LL LL L i L L
8 : S l o w Dawn = L o a d R e d u c t i o n
for stationary
plants
COMUON
MCU
ALARM
r---------
P
MCU
POWER
FAIL
SBU
BCU
IN
CONTROL
r---------7
BCU
-
r - - - - - 7
BCU
POWER
FA1 L
I
I
I
BCU
r-----
MCU
FAIL
BCU
FAIL
- SLOW'
DOWN
I
I
I
I
I
I
I I I
J8 I I J31
I I I
I
Slow
down
I
I
SPARE 1 I
SPARE 2 1
BCU-INCTRL I
I I I
I BCU-IN I
XTRLLGND I
I I
I I
I I
I I
I I
I I BCU-IN I
XTRLLGND
I I I I
----------- -
",
IF
PUMP I N I + I
I
PUMP I N 1- I
PUMP I N 2+ I
I
PUMP I N 2 -
F 37
38
Corn
AUTO
BCU CONTROL I
~r-71
I
32
34
#2
0
0,
I
4
3
0
TH. F#Al I-L
TH.
TH. #2-
ACHl+
AGND
ACH1-
I
I SBU
I r----------
I I
I I
I I
I I
I
I
I
I
I
I
- SOL
FB . X'
I +24V 5 +24V
FB
I ov
I #A OUT #A OUT
I #B OUT
t B OUT
I
I RE 1 RE T
I I
I
I
I
I
I
I FB
I
I # A OUT
I #B OUT
1 S O L
I RET
I RET RET
I SOL
7
I
I FB 53 FB
I t24V 5 +24V
I
OV 6 OV I
I #A OUT #A OUT I
I I
I #B OUT #B OUT I
I I I
I I
I I I RET RET I
I I I
I
I I I I I I I
I I I I
I I I I
I I I I I
I I r-----------
I I lz
12
FB
I
#A OUT #A OUT I
#B OUT #B OUT I
I
RET RET I
RET RET I I
FB
#A OUT #A OUT
#B OUT #B OUT I
I
RE1 RET I
I
I
I
I -----------
1 0
I
I #A OUT #A OUT I
#B OUT 3 7 #B OUT I
I
RET RET I
I
L _ _ _ _ _ _ _ _ _ _ _ J
SOL I
FB
5 +24V
ov ov
#A OUT
#B OUT
RET
SOL
FB
5 t24V
F8
#A OUT #A OUT
#B OUT #B OUT
RET RET
SOL #
RET
6 A
64
~ - m S 0 1
RET
FB OUT
#A
#B OUT
RET
~ ~ q q
2
I r - - - - - - - - - - - 7
8
#A OUT
#B OUT
RET
12
I
I
I
I
I
z
I I
FB
#A OUT
#B OUT
RET
I n c a r e o f an u n e v e n number o f c y l i n d e r s
the feedback r i g n q l l o r the l a t e s t add
c y l i n d e r must b e um e d l o t h e n e r t e v e n
c y l i n d e r on t h e poard.
Ex. 7 c y l i n d e r s :
Jumoer b e t w e e n B C U / J l 6 : 4 a n d B C U / J 1 9 4 .
I I I I FB
I I
I I I #A OUT # A OUT I
I I I
I #B OUT # B OUT I
I SOL I
RET RE1 I
I
I I A I I
I SOL
I FB
I
I +24V
FB
I OV ov
I #A OUT
I I I I #B OUT
I I I !
I RET
I
I
#;::gT~l
I
I
I
I
I
I ;
I I
I I I FB
I I I #A OUT # A OUT
I
# B OUT # B OUT
RE1 RET
Sol I
FB 80 FB
+24V +24V
OV 6 OV I
#A OUT #A OUT I
I I I # B OUT I
I I I I
I I I RET RET I
I I I I I I
I I I
I I I
I I I
I I I
I I I I FB
I I I
I #A OUT
#B OUT
SOL * RET
~ Z A M J O L RET
RE1
SOL
FB 83 4 FB
+24V +24V
0 0 -- 1 OV ' 6 OV
o s 2
7 rO, I I
I I
? I I
- s I I
7
& E
a ? m I I
I
L _ - _ _ - _ _ - _ _ - _ - - _ - - - - - - J
I
L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J
- . I n c a s e o f a n uneven number o f c y l i n d e r s ,
i0- the feedback sign91 f o r the l a l e s t odd
c y l i n d e r musl b e urn ed t o \ h e n e x t e v e n
.;
c y l i n d e r pn the B h p o o r d .
E x . 7 cylinders:
Jumper b e t w e e n B C U / J 1 8 : 4 and B C U / J l 9 : 4 .
I
co
DD,_/m..l_,
8 D..,_,,,-
-7
#o.,~
0;
I,."..,&,w 8 1 .
YARD RELATED CABLING
LI I.,. 0 ,..,".*...I W,C ,.".*"...
ii.,.
ENGINE SIDE MOUNTED
l '.~. "."nb,
' p'.'
'''-1'
-
DRAWING NO.~O-GOMCIMC-4 I PAGE I 1
-C o-n t r- -
o l room
Engine room
ECR s i d e
N
- ote:
1) 440V//380V c o n n e c t i o n a c c o r d i n g t o
pump s t a t i o n s p e c i f i c a t i o n .
I
2 ) ~ o w e / r s u p p l y r e q u i r e m e n t s : 24VDC, ''1
Voltage t o be constant up t o 1 . 5 x I N
Brak!er s i z e 1 6 A .
I
3 ) TabqlI f o r 24V power c a b l e q u a d r a t e :
I
1.5 for 0 t o 25m
f o r 25 t o 70m
4.0
2/5 f o r 7 0 t o 150m
4 ) Opt ijona I
Twisted p a i r
p a i r i n d i v i d u a l l y screned
W-1 . . . .W-u
WP-B WP-A
I Per c y l i n d e r
CABLE w 4 t CABLE FERULES qs:' 2.
CABLE B':.llt I D TAGS S Y Y 2 .
CALBE!I A I W alt C A B L E MARKERE 39% X . n = Cvlinder no.1-7
-
IECR I j
I
11 COntoct l o be c l o l e d i n STOP p o n i t i o n .
2 ) Contoot to be closed i n ASTERN.
31 Relay L O be a c t i v a t e d and contact closed.

* a n .u.iiiory b l o r a r l l l o r e running.
Relay: Yard w p p l y .
41 LCD input t o be p o t a n l i a l I r e s contact

o.an i n n ~ r m sl o n d i t i o n
NOTE:
1.Pf CABLE S P q t CABLE FERULE. ?B3 X .
2 . P f CABLE =Ed+ I D TAG+ r u u n .
3 . P f CALBE'I N Y 3 g d t CABLE MARKERS Y V Y n
NOTE :
1 . P f CABLE G F q t C A B L E FERULES Y82 R .
2.9f CABLE ZV4t I D TAG+ F Y Y R .
3 . 9 ~C A L B E ~ I A I ~ : I t4t CABLE MARKER= F Y Y
I +4 FB
1 +, tzrv FB
ow a j a
a +a ov
BN
BU
-.
415~
0"
E% .
out
I I
I I
ALCU
NOTE:
l.~f CABLE f E ' q l t CABLE FERULES q%P n .
2.e~ CABLE z e l t I D TAG+ r u g n .
3 . y ~CALBEv A I ~ XW t CABLE MARKER; P W 2
)RAWING NO. 70-98MC/MC-C PAGE 1
Y a r d power s y s t e m
- - - - 4-x 3 . S 1
Power Supply
t~ A C Z ~ O V I
I
I
-
Alpno ub. c o n l r c I
I ECR CONSOLE AUX BLOWER PANEL
4X3.5'
I I I I IL SIGNAL
-
I- I-
I I
I
I I
I I I
I I
I
pbp
11 4 4 0 ~ / 3 8 0 c~o n n e c t i o n a c c o r d i n g t o
station specification.
I
2 ) Ppwer s u p p l r e q u i r e m e n t s : 24VDC. 2E
V o l t a g e t o be c o n s t a n t u p t o 1 . 5 x IN
Blaker s i z e 16A.
31 l a b e l f o r 24V power c a b l e q u a d r a t e :
I
for 0 t o 25m
f o r 2 5 t o 70rn
4.0 f o r 7 0 t o 150m
1
41 0 t i o n a l .
51 Cpble: Twisted p a i r
I p a i r i n d i v i d u a l l y screned.
n = C y l i n d e r no
) R A W I N G NO. 70-98MC/MC-C PAGE 2
- Kdtios
connection
t o monitoring
system.
1 ) C o n t a c t t o b e c l o s e d i n STOP p o s i t i o n .
2 1 C o n t a c t t o b e c l o s e d i n ASTERN.
3 ) R e l a y t o b e a c t i v a t e d and c o n t a c t c l o s e d .
when a u x i l i a r y b l o w e r ( s 1 a r e r u n n i n g .
R e l a y : Yard supply.
4 ) LCD i n p u t t o be p o t e n t i a l f r e e c o n t a c t
open i n normal c o n d i t i o n .
IE: /
BLE ZV4t CABLE FERULE4 q?2 X.
B L E aeqt I D TAG+ w u a .
BLE7 AlWl *4t CABLE MARKER. ?YY 1
Starter :
1x2
r
3
,x,
4 Start t 2
Starter 1
I I
Intermediate box
I
Cab l s
TDC TRlGG
RD +24V
TRlGG
BU OV
TDC h N 7
Encoder
- BCU pick-up box
BN = t24V
BU = OV
BK = out
NOTE:
I.'€
2."
1
ABLE ze=it CABLE FERULE* Y ~ Y8 .
CABLE W = i t I D TAGS ? 4 Y 2 .
3 . P+ ~ABLE!I r l w t *-it CABLE MARKER* W Y 2
SOL t 7 B
FB
OV
SOL t 9 B
FB
+24V
ov
SOL t l l ~ l88 C 1-
SOL f f 1 2 A 92
RE.
SOL A128 94
Alpho Lubricator Control Unit

TO A L C U
ALCU
. .~
Inlocrnadlota L BK -
w = ov
out S ~ l o n o l dV a l r o
52
IAOUt 1+ 1
TO A L C U
11
1 4 1 rAout
2 4 2 Rat.
3 4 3 .B.Ut
4 4 4 FB
R o t . 2*2
*15V 3 h . l
FB
OV
1*1
5+5
JI
3 =I;-
SoI.nold va1.m
3+5 +21V rBout 1* 1

8 4 6 OV R a t . 2*2
+15V 3-3 4 3
FB 1-1
ov 5-5
BN - t15V
TO A L C U
TO A L C U
I n t o r m o d l a l ~L
12
,A~"tl+ 1
TO A L C U
@ -- - 1 4 1
J1
ZADYL
2 4 2 Rat.
- 3 4 3
-141
,Bout
FB
R s l . 2+2
+15V 3+3
FB
OV
J1
4-1
5+5 1
-5+5 -21V ,Bout 1-1
- 8 4 8 0V R a t . 2+2
r 1 5 v 3+3
FB 1-1
ov 5+5
TO A L C U --m%
DIRECT CONNECTION
BETWEEN INT.BOX B ALCU
12
,A.Ut 1- 1
R o t . 2-2
11 t 1 5 V 3+3
1 4 1 ~Aout FB 4+1
1 4 2 Rat. OV 5 h 5
3 4 3 ,BoUl
TO A L C U -i1%
4 1 FB 14 %
5 4 5 +24V asout 1- 1
0 4 8 OW R o t . 2-2
+ l J V 3*3
FB 4+4
OV 5-5
R4
ffl
-- ov
11%
I
BK = o u t
TO A L C U
4 FB
31 44 3+ ZBOUI
I4
Inl.,"mdl.ta
J2
, b u t 1* 1
bl
-~
Bl( = out
~
-
Solanold Valve
c~nnactol
><
TO A L C U
14
J1
1 ~Aout
2 4 2 Rat.
3 4 3 .8o"l
4 4 1 FB
Rmt. 2-2
+ 1 W 3+3
FB
PV
4-4
5-5
I4
3
5 4 5 +2,V l B ~ " tI+ 1
0 4 8 OV R e t . 2+2
r 1 5 V n-3
FB 4-4
ov 5-5
TO A L C U
Inlormodlate b
12
,lout l*
1
1
Rat. 2-2
dl * I 5 V 3-3
-1 4 1 zhul FB 4-4
@ - 2 4 2 Rat. ov 5*5
3 4 3 .8oul
TO A L C U e- -
.
x x . 1 4 4 4 FB I4
- 5 4 5 +24V lSDUt 1- 1
- 6 4 6 OV R a t . 2+2
+15V 3-3
FB 4-4
OV 5-5
J I
BN -- +l5V
I
ffl
BK - ov
out
TO A L C U +24v
BCU p i c k - u p box
I
Pick-UP 1
TO A L C U
PIsk-up 2
DIRECT CONNECTION
BETWEEN INT.BOX B ALCU
lndan Tronmmltlsr
2 4 4
TO A L C U 1 2 5
BOOSTER UNIT I
FOR ALPHA LUBRICATION SYSTEM i
Main Power : 3 x 440V. 60 Hz HAN YOUNG CO., LTD.

Drawing No. : HYCOI -200100-0 #780-1, Jangbang-ri, Hallim-myun, Kimhae-city,
Kyung-nam, Korea, 621-874
Pump Flow : 0.8 rn3/h
Tel : +82 55 346 3097-8 1 Fax. +82 55 343 3097
E-mail : polaris506@paran.com
Global Leader HAN YOUNG CO.,LTD BOOSTER UNIT FOR ALPHA LUBRICATION SYSTEM
Tel : +82 55 346 3097-8 Fax :+82 55 343 3097 CONTENTS
Page : 2 of 5
CONTENTS :
Before use andlor interference in the Booster Unit and/or

connected functions please read the entire manual.
1. TECHNICAL SPECIFICATIONS
2. DIRECTIONS FOR MAINTENANCE
3. GUIDELINES FOR TIGHTENING
4. PART LIST WITH HYDR. CIRCUIT
5. MAINTENANCE OF BOOSTER UNlT
Tel :+82 55 346 3097-8 Fax : +82 55 343 3097 TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS Page : 3 of 5

FOR BOOSTER UNlT FOR
ALPHA LUBRICATION SYSTEM
UNIT SIZE. According to order sheet.
VOLTAGE / FREQUENCY 3~440Vl60Hz/3x380V/ 50Hz
OIL TYPE SAE 50
Motor Motor
Type Flow Pump Motor Motor Mass Part No.
size speed voltage frequency size
1 0.4mS/h 4m 1700 RPM 440V 60 Hz 2.2 KW 275 kg 1890775-9
2 0.8m'lh 8m 1700 RPM 440V 60 Hz 2.2 KW 275 kg 1890776-0
3 1 1.3mn/h I 14m 1 1730 RPM I 440V 1 60 Hz 1 3.0 KW 1 275 k g 1 1890777-2
Pump Motor Motor Motor Motor
-Type Flow Mass Part No.
size speed voltage frequency size
4 0.4m'/h 5.5a 1410 RPM 380V 50 HZ 2.2 KW 275 kg 1890778-4
5 0.8m3/h 9.9m 1410 RPM 380V 50 Hz 2.2 KW 275 kg 1890779-6
6 1.3ma/h 16m 1440 RPM 380V 50 Hz 3.0 KW 275 k g 1890780-6
1. MAIN COMPONENTS
1.1 Circulating Pumps. Flow according to above scheme, m'/h per pump at 50
bar, 50cSt.
Max. viscosity 12cSt to 800 cSt at start-upI250cSt at 4
09:.
Make : Bosch
2 PCs self-priming displacement gear-see1 pumps, one
operating, one stand-by.
1.2 Electric motors See above scheme. B14NB3 flange.

3-Phase Squirrel cage induction motors. IP 55 Enclosure
according to IEC 34-5. Insulation class F.
Allow pumping up to 50 Bar.
1.3 Heater 500W, 1W/m at 3~440V60Hz

Thermostat 5'-85C 1109: fuse, pre-set to 409:
IP 54 Enclosure.
1.4 Pressure selling Pressure relief valve. Pre-set to 45 bar. Max set : 50
Bar
Cartridge valve M30x1.5.
1.5 Valve for & w e of filter element Pressure filter : Valve placed on front of Manifold.
Level horizontal : filtration.
Lever vertical : bypass ; element change possible.
Suction filter : Valve placed on pipe to pump.
Lever vertical : open.
Lever horizontal : suction closed ; element change
possible
Global Leader HAN YOUNG CO.,LTD BOOSTER ,MT FOR ALPHA LUBRICATION SYSTEM
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 TECHNICAL SPECIFICATIONS
Page : 4 of 5
2. CONTROL AUTOMATIC AND STARTERS
Motor starters for both Operating and stand-by motor

Contact for heater
Pressure transmitter
PTlOO sensor
3. INSTRUMENTS
3.1 Pressure gauge Gauge 0-100 Bar 063

Visual control of pressure setting.
3.2 Pressure Transducers Pressure transducer for alarm, low pressure.

4-20mA at range 0-100 bar. 24VDC supply.
3.3 Test point M16x2.0 test point for pressure setting
3.4 PTIOO sensor Standard PTIOO sensor. DIN Class 1. 2-wire
3.5 Filter indicator, suction filter Visual indicator for Filter change of suction filter.
Indicator -1.0 to +1.5 bar.
Recommended change of element at -0.25 Bar
3.6 Filter indicator, pressure filter Visual indicator for Filter change of pressure filter.
Pop-up indicator with manual reset.
Before filter change press at top control.
Remmmended change of element when indicator pops
UP.
4. MATERIALS
4.1 Steel All steel parts of St.37.2, sand blasted and painted.
Colour aocording to order spec or same to engine body.
4.2 Piping Tubes of Seamless carbon steel 8.354. DIN 2391
4.3 Fittings BsP thread(paralle1) accarding to DINIISO 228

Pipe fittings according to DIN 2353
4.4 Components All hydraulic components made for Oil.
4.5 Oil reservoir Tank : Drain plug 112"G.

Tray : Drain plug 318"G.
G10bd Leader HAN YOUNG CO.,LTD BOOSTER UNIT FOR ALPHA LUBRICATION SYSTEM
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 TECHNICAL SPECIFICATIONS
Page : 5 of 5
5. MAINTENANCE
5.1 Filter elements High pressure filter. When the filter indicator pops up the
element must be changed. Press on top of indicator to
verify that the element needs to be changed. If indicator
pops again up the element needs to be changed. After
changing, the indicator must be reset by pressing the top
of the indicator.
lnspection interval ; Daily.
Suction filters. When the indicator on side of the element

enters the red zone the element must be changed.
5.2 External leaks If any of the hydraulic components leaks, the seals for
this component should be changed.
lnspection interval ; Weekly.
If any unusual vibrations or noises occur this must be

investigated.
Tel ; +82 55 346 3097-8 Fax : +82 55 343 3097 DIRECTIONS FOR MAINTENANCE
Page : 1 of 3
DIRECTIONS F O R THE MAINTENANCE OF
HYDRAULIC SYSTEMS
Control Point. Control Interval
1.0 Mechanical Maintenance.
1.1 Pipe Assemblings. Every Month.

All screw connections have to be tightened-up. At the same time
they have to be controlled for leakages. In case of a leakage the
cause has to be found and corrected.
1.2 Tube Connections. Every Month.

All tube connections have to be inspected for leakages, and the
tubes have to be controlled. The tubes have to be intact without
any sign of mechanical wear or other faults in the tube surface.
Has such a fault been found, the tube may have to be replaced.
But at least it has to be considered, how the fault came into
existence, and it has to be secured that it will not be repeated.
Leaking tubes have to be replaced.
1.3 Screw Gaskets. Every Month.
All screw gaskets have to be tightened-up, and the parts that the
connection holds have to be inspected for leakages. The
tightening-up has to be effected in accordance with an accepted
standard.
1.4 Mechanical Securing of Hydraulic Components. Every Month.
All connections that hold, carry or suppon hydraulic components
have to be controlled. This is especially important where the
hydraulic components are parts that move or are subject to
vibrations. therefore also pipe and tube holders have to be
controlled.
1.5 Lubrication of Guides. Daily or in acwrdance
All guides have to be greased with fat or oil that is suited for the with the guidelines of
purpose. The guidelines of the supplier regarding frequency, fat/oil the supplier.
type, quantities and places have to be followed.
2.0 Hydraulic Maintenance.
2.1 Inspection of the Filter.

2.1.1 Fiters without Supervision. After 1 week. Thereaftel
With filters without supervision it is essential to pay thorough the condition has to be
-
attention to the reaulations for the inspection and to the intervals controlled every month.
of replacement.
2.1.2 Filters with Supervision. After 1 week.
When the indicator shows an excessive pressure, the element Then on indication.
have to be replaced.
2.1.3 Breathing Filters. Every 3 Month.
Have to be cleaned or replaced.
Global Leader HAN YOUNG CO..LTD BOOSTER UNIT FOR ALPHA LUBRICATION SYSTEM
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 DIRECTIONS FOR MAINTENANCE
Page : 2 of 3
DIRECTIONS FOR THE MAINTENANCE OF
HYDRAULIC SYSTEMS
2.2 The Hydraulic Fluid.
2.2.1 The Condition of the Hydraulic Fluid. After 1 month

The hydraulic fluid has to be controlled for dirt, water and other Hereafter every 6
impurities. In case that the fluid is considered to be not suitable, it months.
has to be replaced or cleaned. Depending on the impurity, the
system has to be found and repaired.
2.2.2 The Level of the Fluid. Daily. Before starting
The level of the fluid has to be controlled. Maybe the hydraulic to work the system.
fluid will have to be replenished.
2.2.3 The Working Temperature of the Hydraulic Fluid. Daily, when starting the
Once you have stared to work the system it is necessary that you system.
frequently control that the max, temperature of the fluid is not Then every 1 month.
exceeded.
2.3 Gaskets. Every year.
The gaskets have to be replaced. This goes for both sealing
gaskets between valves and for gaskets in assembling.
2.4 Cylinders. Every 3 month.
The cylinders have to be inspected for seizing on the tube and
around the stuffing box. The cylinders have to be cleaned around
the tube.
2.5 Settings of the Pressure. 1 st mntrol after 1 week
All pressure settings valves have to be controlled, reset if 2ndambdafter3months
necessary and then sealed. In case of resetting at pressure valve Then yearly.
the control interval has to start from the beginning.
2.6 Accumulators. I st control after 1 week.

The muzzle pressure has to be examined and the accumulator has 2ndamtrdafter3mMlths
to be visually controlled for defects. In case that the muzzle Then yearly.
pressure has to be reset, or it becomes necessary to replenish,
the control interval has to start from the befinning.
2.7 Flow Settings. 1 st control after I week

Flow valves has to be examined and reset if necessary, and then 2nd mnbd after 3 mdx
sealed. In the case of a resetting the control interval has to start Then yearly.
from the beginning.
1
G/oba/ Leader HAN YOUNG CO.,LTD BOOSTER UNIT FOR ALPHA LUBRICATION SYSTEM
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 DIRECTIONS FOR MAINTENANCE
Page : 3 of 3
DIRECTIONS FOR THE MAINTENANCE OF
HYDRAULIC SYSTEMS
3.0 Others.
3.1 Safety. )aily-Before starting the
All functions of safety have to be controlled. The re-starting ystem
procedure has to be followed.
3.2 Cableing. Iaily-Before starting the

Electrical wiring to and from the control panel have to be iystem
controlled. It has to be secured that the wires are properly
protected and in a perfect condition. In the of doubts the wires
have to be replaced.
3.3 Valve functions. laily-Before starting the

All valve functions have to be controlled in order to secure a ;ystern
correct functioning.
3.4 Cleaning. laily-Before starting the

The area around the machine has to be dean and free of objects iystem
that may be of hindrance for the movements of the machine.
Likewise the area has to be free of objects that may present
danger to an operator.
3.5 Emergency stop. laily-Before starting the

Every emergency stop button have to be tested. Is one of the system
buttons defect, the machine is not to be worked until the button
has been put right or the defect has been repaired in another
satisfactory way.
3.6 Leakage. laily-Before starting the

A control has to be carried through regarding leaking oil. In the System
case of leakage, they have to be repaired as soon as possible.
-1
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 GUIDELINES FOR TIGHTENING
Guidelines for Tightening of Bolt connections Page : 1 of 1
Tube Thread Thread Series
1
Light
5
Heavy
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 PART LIST
Page : 1 of 3
PART LlST
TYPE 2, Bccrn, 60Hz
Part No. : 1890776-0
40LK-28-100KM
6 1 2,00 ICoupling, motor I NJ 028 124/30B-281-17 1
15 1.00 Minimess M16x2.0 DEMA3 114"G

Tel : +82 55 346 3097-8 Fax : i82 55 343 3097 PART LIST
Page : 2 of 3
PART LlST
TYPE 2, 8ccm, 60Hz
Part No. : 1890776-0
'0s Pcs. Description Trade No. Type Remarks
16 1,00 Ball valve, manifold mounted R 0 106024 DN 20;PN500;6 STK M I 0
17 l,00 Check valve IM 200014 D06B2H-7.5N
1 8 I T o L [ ~ r e A u r efilter
18 1 1.00 1 Element f. pressure filter
-tt----
18
19
1 1
20
1.00
1,00
1,00
Clogging indicator visual
Pressure relief valve
Thermostat
B0
002 012 1
I
15-50 Bar; M30x1.5
NIS 220216 3/4"G, 45'C

Set 45 Bar
21 l,00 Check valve DE 87410001 D06B2H-1.ON
22 (
-
1,OO (Plug
-
I DVSTl (112"G med packing 1
23 1,00 Heating element 92201904
500W. 1w/cm2, 3x400VAC E&VAc160H;
Coupling box for heater DE-VI 211~ Set 40'C
23 1.00 19900471
24 1 1.OO 1 Plug I DVSTl (1"G med packing I
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 PART LIST
HYDR.CIRCUIT OF CYL.LUB.BOOSTER UNIT Page : 3 of 3

I MAINTENANCE OF BOOSTER UNIT FOR
II
1 ALPHA LUBRICATION SYSTEM
HAN YOUNG CO., LTD.

#780-1, Jangbang-ri, Hallim-myun, Kimhae-city,
Kyung-nam, Korea, 621-874
Tel : +82 55 346 3097-8 / Fax. +82 55 343 3097
E-mail : polaris506@paran.mm
Tel : M2 55 346 3097-8 Fak' : +82 55 343 3097 CONTENTS
Contents :
1. Identification of Block Componen*-- -3
2. Changing the Pressure Filter Element 6
3. Changing the Suction Filter Element 8
4. Setting the Pressure 9
5. Changing the Pressure Transducer 10
6. Changing the Pressure Gauge 11
Page 2 of 11
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 IDENTIFICATION OF BLOCK COMPONENTS
1. Identification of Block Components
Components can only be removed while both motors are not running, unless
otherwise stated.
I I
7. 2 : Diagram of hydraulic system
Page 3 of 11
Numbers in boxes refer to

diagram in Fig. 2
Fig, 3 ; Top view
Fig. Lower view
Fig. Front view
Page 4 of 11
Global Leader HAN YOUNG CO.,LTD BOOSTER UNIT FOR ALPHA LUBRICATIONSYSTEM
Fig. 6 : Side view
Page 5 of 11
Tel : +82 55 346 3097-8 Fax : i82 55 343 3097 IDENTIFICATION OF BLOCK COMPONENTS
2. Changing the Pressure Filter Element
Fig. 7 : Location of pressure filter
Fig. 7 shows lever for shut-off valve in operation mode (horizontal).

The shut off valve must be closed before changing the filter element.
Procedure for changing the pressure filter element :
t
1. Turn lever up ( vertical) thereby closing
the valve and bypassing the filter. Fig. 8
Fig. Shut-off level in closed

position (verticao
Page 6 of 11
2. Unscrew the filterbowl by turning

clockwise (CW)
Key with : KW30.
Fig. 9.
3. Remove element and replace. Fig. 10.
4. Check condition of O-ring. Replace

if necessary.
5. Remount filterbowl. Turn counter-clockwise

(CCW).
Fig. 10 : Replacement of filterbowl
6. Reset filter indicator. Fig. 11.
7. Set lever position to 'openl(+horizontal)

shut off valve.
Fig. 11 : Reset filter indicator
Page 7 of 11
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 CHANGING THE SUCTION FILTER ELEMENT
~ i g 12
. : Location of suction filters
The suction filters are duplicated.

The element can be replaced only when the suction filter is in operation.
Procedure for replacement of the suction filter :
1. Make sure the suction filter you want to

replace is not in operation.
Unscrew filter top CCW. Key with : KW30.

Fig. 13.
2. Remove element and replace. Fig. 14.
3. Check condition of O-ring. Replace

if necessary.
4. Remount filterbowl. Turn CW.
Fig. 14 : Replacement of sucbbn filter

Page 8 of 11
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 CHANGING THE PRESSURE TRANSDUCER
4. Setting the Pressure
Fig. 15 :
Location pressure relief valve
The pressure relief valve is preset to 45 bar.

Procedure for setting the pressure :
1. Remove plastic cap. Fig. 16.
Fig. 16 :Plastic cap being removed
2. Turn lock nut CCW, KW19, to loosen.

Fig. 17.
3. With screwdriver, turn screw CW to raise

pressure, CCW to lower pressure.
4. Turn lock nut CW to tighten.
5. Replace plastic cap.

Fig. 17 : Loosening the nut-screw
Page 9 of 11
Tel : +82 55 346 3097-8 Fax : +82 55 343 3097 CHANGING THE PRESSURE TRANSDUCER
5. Changing the Pressure Transducer
While changing the transducer the signal

is not active.
-~
Fig. 18 : Lomtion of pressure transducer

with needle valve shown
Procedure for changing the pressure transducer :
1. Close the needle valve by turning CW,

thereby isolating the transmitter.
Fig. 19.
Fig. 19 :Needle valve being dosed
2. The transducer can now be replaced,

KW27.
Fig. 20.
3. After replacement, open the needle valve

by turning CCW.
Fig. 20 :Replacement of transducer
Page 10 of 11
Tel : +82 55 346 3097-8 Fax : +82 343 3097 CHANGING THE PRESSURE GAUGE
6. Changing the Pressure Gauge
Fig. 21 : Location of pressure gauge with needle valve shown
While changing the pressure gauge the signal is not active.
Procedure for changing the pressure gauge :
1. Close the needle valve by turning CW,

thereby isolating the pressure gauge.
2. The pressure gauge can now be replaced,

W18. Fig. 22.
After replacement, open the needle valve by

turning CCW.
Fig. 2.2 :Replacement of pressure gauge
Page 11 of 11
CONTROL BOX FOR BOOSTER UNIT
( Hun Young Co.,Ltd 1
1( Jel : ++82 55 346 3097-8
Fax : ++82 55 343 3007
E-mail : polaris506@oran.com~
Customer : DOOSAN ENGINE

Supply : 3 X 440VAC PE 6 0 H z+
Project Title Dmv. Checked. Approved date'

BOOSTER UNIT CONTROL BOX TITLE COVER 08.04.03.
Model no Dmwing no LWH LWH PCJ Poge $HYC HAN YOUNG
TYPE 2 HYC01-400501-0 1 of 10
Checked. Approved
Project Ttle Draw. 08.04.03.
BOOSTER UNIT CONTROL BOX CONTENTS Page
$HYC HAN YOUNG
Drawing no LWH LWH PCJ 2 of 10
Model no
TYPE 2 HYC01-400501-0
ALPHA LUB. PUMP STARTER 1 ALPHA LUB. PUMP STARTER 2
4S8 5H2 4H7 5T2 6S8 7H2 6H7 772
TEMPERATURE 5A7
Project litle Dmw. Checked. Approved 08.04.03.

BOOSTER UNIT CONTROL BOX ELECTICAL BOX LAYOUT
Page
$HYC HAN YOUNG
Model no Dmwing no LWH LWH PCJ
3 of 1 0
TYPE 2 HYC01-400501-0
Local
off
Remote
24V DC
CONTROL
VOLTAGE ON
SUPPLY HEATER
3 X 440 VAC
BHYC
Title dote'
Project Dmw. Checked. Approved
BOOSTER UNIT CONTROL BOX MAIN VOLTAGE - STARTER 1 08.04.03.
LWH PCJ page
HAN YOUNG
Model no Dmwing no LWH
TYPE 2 HYC01-400501-0 4 of 10
I
OMC I THERMAL CONTROL PRESSURE DlSP TEMPERATURE DlSP RUNNING

ovoc
RUNNING PUMP HOURME7ER

RUNNING OVERLOAD VOLTAGE
FAIL
Project Title Draw. Checked. Approved

BOOSTER UNIT CONTROL BOX CONTROL VOLTAGE - STARTER 1 08.04.03.
PCJ Page
$HYC HAN YOUNG
Model no ~ m w i n gno LWH LWH
TYPE 2 HYC01-400501-0 5 of 1 0
24V DC
CONTROL
VOLTAGE ON
SUPPLY
3 X 4 4 0 VAC
Ttle date'
Project Dmw. Checked. Approved
BOOSTER UNIT CONTROL BOX MAIN VOLTAGE - STARTER 2
$HYC MA! YOUNG
LW H LWH PCJ Page
Model no Drawing no
TYPE 2 HYC01-400501-0 6 of 1 0
OVDC
PUMP THERMAL CONTROL DlSP DlSP RUNNING

RUNNING HOURMETER
RUNNING OVERLOAD VOLTAGE
FAIL
'"'
BHYC
Project Title dote'
Drov. Checked. Approved
BOOSTER UNIT CONTROL BOX CONTROL VOLTAGE - STARTER 2 08.04.03.
Model no Drawing no LWH LWH PCJ Page HAN YOUNG
NPE 2 HYC01-400501-0 7 of 10
'UMP
TARTER 2
IER. BLOCK
Project Title Drov. Checked. Approved dote'

BOOSTER UNIT CONTROL BOX TERMINAL BLOCK 08.04.03.
Model no Dmwing no LWH LWH PCJ page $HYC HAN YOUNG
TYPE 2 HYC01-400501-0 8 of 1 0
PARTS LIST - STARTER 1
POS' I DESCRIPTION NPE I Q'TY I MAKER
4S1 Main Switch MLD-063P 1 KACON
I 4F2 I Thermal Circuit Breaker I C60N-3P (3P 4A) I 1 I SCHNEIDER I

4F5 Thermal Circuit Breaker C60N-1P ( 1 P 2A) 1 SCHNEIDER
4F6 Thermal Circuit Breaker C6ON-1P (1P 2A) 1 SCHNEIOER
4K5 Reloy HMX40 AC440V Coil 1 HYUNDAI
4KB Contoctor HIMC-12G DC24V Coil 1 HYUNDAI
404 Thermal Circuit Breoker HITHZZK 13A 1 HYUNDAI
4P4 Ampere Meter W-S72A4 0-lOA 1 WES
4K10 Relay & Socket LY4N DC24V Coil 1 HONMWELL
4H7 White Lomp URPFB022 WHITE 1 HANYOUNG
5H2 Green Lamp URPFB022 GREEN 1 HANYOUNG
I URSS320 I 1 I HANYOUNG I
1 5T2 ( Hour meter I LUN-HR I 1 I AUTONICS I
I 1x2 I Terminol - Control voltage I 1 22 1 I
XO Terminal - Main voltage 12
Project
BHYC
Title Dmv. Chocked. Approved Rev' dote'
BOOSTER UNIT CONTROL BOX PARTS LIST - STARTER 1 08.04.03.
Model no Drawing no LWH LWH PCJ Page HAN 'fO"NG
TYPE 2 HYC01-400501-0 9 of 1 0
PARTS LlST - STARTER 2
I POS' I DESCRIPTION I TYPE I Q I MAKER I
1 6S1 I Main Switch I MLD-O63P I 1 I KACON I
1 6F5 I Thermal Circuit Breaker 1 CGON-1P (1P 2A) 1 1 1 SCHNEIDER 1
6K5 Relay HMX40 AC440V Coil 1 HYUNDAI
6K8 Contactor HIMC-12G DC24V Coil 1 HYUNDAI
6Q4 Thermal Circuit Breaker HiTH22K 13A 1 HYUNDAI
6P4 Ampere Meter WY-S72M 0-1OA 1 WYES
6K10 Relay & Socket LY4N DC24V Coil 1 HONEWELL
6H7 White Lomp URPF8022 WHITE 1 HANYOUNG
7H2 Green Lamp URPFB022 GREEN 1 HANYOUNG
I URSS320 I 1 I HANYOUNG I
-
( 2x2 ( Terminal - Control voltage 1 1 l5 1

I XO I Terminal - Main voltage I I s I I
Project iWe Dmw. Checked. Approved Rev' date.

BOOSTER UNIT CONTROL BOX PARTS LIST - STARTER 2 08.04.03.
Model no wowing no LWH LWH PCJ Poge $Hyc HAN YOUNG
TYPE 2 HYC01-400501-0 1 0 of 1 0
POWER SUPPLY (UPS)
MODEL: SPS-222
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
SAMHOI INDUSTRIAL CO., LTD.

ADD: 257-1 1 An-dong, Gim hae-city, Gyungnam , Korea
TEL: 82-55-321 -0578
FAX: 82-55-321-0573
WEB: www.shico.co.kr
POWER SUPPLY(SPS-222)
3
CONTENTS
PAGE
1. BEFORE INSTALLATION 2
2. DESCRIPTION 3
3. SPECIFICATION 4
4. DIMENSION 5
5. ELECTRICAL DIAGRAM 6
3 6. CONNECTION DIAGRAM 7
7. OPERATION 8
8. MAINTENANCE MANUAL 10
9. SOLUTION 12
"
x- 1
I SAMHD l I NDUSTR IAL CD. ,LTD .
-3
BEFORE INSTALLATION
Please give attention to following instructions before set up.
1 . You have to avoid below environments.
g L~
High or Low Temperature
*F Snow, Rain or Humidity
Electromagnetic Wave
kP&
2. Do not disassemble.
3. Power must be off when you start installing.
1
.-
II .
SAMHO l l NDUSTRI A L CO. LTD .
A
DESCRIPTION
1. This manual describes POWER SUPPLY(M0DEL: SPS-222) that supplies
stable direct current in case of power outage. uninterruptible power supply
2. Standard Application
-K.S: Korea Standards
-ANSI: American National Standards Institute
-1EEE: Institute of Electrical and Electronic Engineers
-IEC: International Electrical Commission
-Manufacturer's Standard
3. Environment
3.1 Temperature: 0-40'C
-? 3.2 Relative Humidity: less than 90%
8
3.3 Place: Indoor
4. Components
4.1 Main lnner Entry Board (PART NO. SPP-001) 1 SET
4.1.1 Power Supply SMPS (Model: SPP-0011) 1 EA
4.1.2 SMPS for Battery Charge (Model: SPP-0012) 1 EA
4.1.3 Master Power Control Board (Model: SPP-0013) 1 EA
4.1.4 Fan (Model: SPP-0014) 1 EA
4.1.5 Diode Board (Model: SPP-0015) 1 EA
4.1.6 Shunt 30A150mV (Model: SPP-0016) 1 EA
4.2 Front Display Board Assembly (PART NO. SPP-002) 1 SET

4.2.1 Test & LED Alarm Display PCB (Model: SPP-0021) 1 EA
4.2.2 AC Voltmeter 0-300V AC (Model: SPP-0022) 1 EA
i
/~1 4.2.3 Square DC Voltmeter 0-50V DC
4.2.4 Square DC Currentmeter
(Model: SPP-0023)
(Model: SPP-0024)
1
1
EA
EA
4.2.5 Key Lock (Model: SPP-0025) 1 EA
4.3 Door lnner Front Switch

& Terminal Board Assembly (PART NO. SPP-003) 1 SET
4.3.1 Main Power Circuit Breaker 2P6A (Model: SPP-0031) 1 EA
4.3.2 Battery Power Circuit Breaker 1 P20A (Model: SPP-0032) 1 EA
4.3.3 Load Circuit Breaker 1 P20A (Model: SPP-0033) 1 EA
4.3.4 Thermal 4Q (Model: SPP-0034) 15 EA
4.4 Battery 12Vl12AH (PART NO. SPP-004) 1 SET
>
: .-
111 SAMHO I INDUSTRIAL CO. ,LTD.
'3 -
SPECIFICATION
1. MODEL: SPS-222
2. MAKER: SAMHOI INDUSTRIAL CO.,LTD
3. INPUT: 100-240V AC50/60Hz 8.2A
4. OUTPUT: 26.9V DC NORMAL Max.12A
OVER CURRENT PROTECTION: 22.2A
5. BATTERY BACK-UP TIME: 12A in 30min
6. WEIGHT: 40Kg
7 . CLEARANCE: 180 x 50mm or more
8. DIMENSION(W x H x D): 400 x 500 x 210mm
9. FITTING: 360mm x 440mrn(Hole: 010)
10. CABLE ENTRANCE: TRAY-BRACKET
1 1 . CONNECTION DIAGRAM: See page 7
12. MATERIAL: SS400 2.0t
13. COLOR: MAKER STANDARD
14. HlGH ALARM: DC 28V
15. LOW ALARM: DC 24V
16. TRIP ALARM: DC 22V
17. ALARMS AS POTENTIAL FREE CONTACTS
LOW VOLTAGE: Under 18V DC
HlGH VOLTAGE: Over 32V DC
18. PROTECTION
LOW VOLTAGE: 18V DC
HlGH VOLTAGE: 32V DC
19. SYSTEM TYPE: FLOATING DC SYSTEM
20. PROTECTION CIRCUIT
OVER CURRENT PROTECTION: Works at over185% of Rating
and Auto recovery
OVER VOLTAGE PROTECTION: 1 1 5 ~ 1 4 0 %limited output voltage
-~1
'
IV SAMHO l INDUSTRIAL CO . ,LTD .

3
DIMENSION
1-.
t-
*
a-
0-
POWR K I T h C L
z
h n M , - - n
3.
--rn
U O CURlWT
q
--.=
OUTPUT WCT
C- .
r
+
POWER SUPPLY
for ALPHA LUBRICATOR
FRONT VIEW SIDE VIEW
BOTTOM VIEW
J
'--
V SAMHO l INDUSTRIAL CO. ,LTD.

ELECTRICAL DIAGRAM
MAIN POWER
EXT DC 24V IN
MCU POWER
BCU POWER
FLOW POWER
MCU POWER
BCU POWER
FLOW POWER
COMMON M A R M
1
L
VI SAMHO I I NDUSTR IAL CO . ,LTD.

CONNECTION DIAGRAM
YARD SUPPLY
\ MAIN POWER
3
EARTH
EMERGENCY
POWER SUPPLY
1 ) BYPASS POWER
+ POWERA
+ POWERB 1
& 1
FOR
CONTROL SYSTEM
- POWERA
UPS
FAILURE ALARM
TEST BOARD
a
4
a
!c +
NO -
} TEST ALARM
'L
-3
VII .
SAMHO I I NDUSTR IAL CO . LTO.
POWER SUPPLY (SPS-222)
OPERATION
As steady DC providing instrument, it is urgent power supply for power
outage supplying DC 24V from DC 24V battery without interruption. All the
Power switches are off when it is first delivered.
If the switches are on, it can cause danger by DC voltage

or the battery life might be shortened.
1 . How to operate
1 . I Open the door and put the Main power, Battery and Load switches ON.
1.2 Check if sqiremeter (V, A, DCV) indicates normal value.
1.3 Batteries are recharged continuously and automatically while Battery
switch is ON. Recharging will be finished if Battery power is DC 26.9V. If
not, it keeps on recharging.
1.4 It is designed to supply urgent power from rechargeable battery when
AC power is out.
1.5 Supplying duration is 30 minutes with DC 24V, but it can be shorter or
longer according to supplying capacity.
2. Output control
Do not control by yourself because it is settled before delivery.
If DC power always remain either under 26.9V or over 2.69V. you can
control Voltage by adjusting volume after linking the DC voltmeter to Red.
Black test jack on the Test Board respectively. You should make sure that
TOGGLE switch keeps Normal position.
3. Common Alarm Output

Alarm Relay is available when abnormal voltage occurs.
Terminal No.17-NO
Terminal No.18-COM
Terminal No.19-NC
Alarm
HIGH VOLTAGE over 29.OV
LOW VOLTAGE under 23.OV
LOAD TRIP under 22.OV
1
,-
Vlll SAMHO l INDUSTRIAL CO. ,LTD .

--I
-
4. Test Alarm Indication
CHECK switch always should keep Normal position and TEST LED should b e
off. It is ~ o s s i b l eto set UD Alarm in which the user wants by converting
CHECK-NORMAL switch output into Test Mode.
NORMAL ---> TERMINAL N0.37 (NC)

COM ---> TERMINAL N0.38 (COM)
TEST ---> TERMINAL N0.39 (NO)
5. Alarm Test
You can check Power supply by Toggle switch
NOTE! Before conducting this function, you should inform

7 person who may concern. After Check Mode is finished, it
-
should return to Normal Mode.
1) Connect DC voltmeter to Test Point Jack.
2) Turn the switch Test mode, and you can see TEST LED is on
3) Turning the Volume counter clock wise(to the left), LOW BATTERY LED
and LOAD TRlP LED will be on. Next, check followings with turning the
Volume clock wise(to the right) slowly.
a. check if LOAD TRlP LED is off at DC%22.OV of voltmeter.

b. check if LOW BATTERY LED is off at DCk23.OV of voltmeter.
c. check if HlGH BATTERY LED is on at DC+29.OV of voltmeter
4) As you are turning the Volume slowly counter clock wise slowly, check
again if HlGH BATTERY LED is off at DC+29.OV, LOW BATTERY LED is on
at DCe23.OV. LOAD TRlP LED is on at DC=22.OV.
5) Change the Normal-Check switch to Normal Mode. With the Main Power
switch and Battery switch on, turn off Main Power switch. Then, Power LED
will be off and Module LED will be on.
1
T~~
~
IX SAMHO I I NDUSTR IAL CO . ,LTD .

"3
MAINTENANCE MANUAL
1. Check if all inside switches of the panel are off.
No.1 (Main switch), No.2 (Batt switch), No.3 (MCU switch)
No.4 (BCU switch)
Check NORMAL-CHECK switch of the interior test board indicates Normal.
2. Supply AC220V 10 at TERMINAL No.1,2
3. Main SWITCH ON
A. Check if OUTPUT VOLTAGE is DC 27 Volt.
If it is not DC27 Volt, refer to Check-A.
'3 B. Check if POWER LED is ON and AC VOLTMETER is right.

(The power of POWER LED is DC 27 Volt.)
If it is not normal, refer to Check-A.
C. Check if internal FAN MOTOR operates.

If it does not operate, refer to Check-A.
D. Check the LED for battery charger of internal test board is Green.
If is not OFF or indicates other color, refer to Check-B.
4. BATT SWITCH (No.2) ON

Color of the LED for battery charger of internal test board is changeable.
Refer to Check-B except change of color of the LED.
5. MCU SWITCH (No.3) ON

You can see DC 27 Volt at TERMINAL No.6(POSITIVE), No.11 (NEGATIVE).
3 Refer to Check-C when a problem occurs.
6. BCU SWITCH(No.4) ON
You can see DC 27 Volt at TERMINAL No.7(POSITIVE), No.l2(NEGATIVE).
Refer to Check-C when a problem occurs.
7. Off the main switch(No.1) if there is no problem by until 6.

A. Module LED will be on and will be changed by operation of battery.
Common Alarm will be dried contact out.(Terminal No.17, 18 will be
on.)
B. At this time, DC Output Volt of front side shall fall about DC 24 Volt.
If there is any problem refer to Check-D.
8. MAIN SWITCH ON
:;I
X SAMHO I I NOUSTR IAL CO . ,LTD .
9. LOAD CURRENT METER on the front side shows sum current MCU
POWER and BCU POWER.
If there is any problem, refer to Check-D.
10. Connect Digital Volt Meter at Test jack of internal Test board.
If there is any problem, refer to references of circuit board.
1 1 . Change Normal-Check switch of internal Test board to Check.

A. LED for Test will be on and Terminal No.38, 39 will be contact out.
6. When you regulate the volume, turn it from left(CCW) to right(CW)
slowly. Regarding the instruction of the voltmeter, you will see the LOAD
TRIP LED is OFF over DC 22.OV, the LOW BATT LED is OFF over D C
23.8V, and HlGH BATT LED is ON over DC 28V.
C. Even if one of the LED of LOAD TRIP, LOW BATT and HlGH BATT is
ON, Common Alarm will be dried contact out .(Terminal No.17, 18 is on.)
Refer to the references of circuit board if there is any problem.
12. Convert NORMAL-CHECK switch of internal test board to 'Normal'

Off all the switches inside the panel.
)
i
XI .
SWHO I INDUSTRIAL CO. LTD.
/.\
SOLUTION
Check-A
1. Check if AC voltage is being supplied.
2. Check the operation of the Main switch(No.1).
3. Open the cover of Test board and check if output voltage of SMPS i s
DC 27V and DC 5V.
4. See' if internal wiring is loose
5. L and N on the right-upper side are for AC Voltmeter, L1 and N are

'7 linked to FAN through LINE FUSE.
6. Check Voltmeter
7. Refer to references of circuit board if there is any problem in LED f o ~

battery charger.
Check-I3
1. If Battery switch(No.2) is off and also the voltage of BTA of switch and
NE of Terminal Block (No.5, No.1 1, No.12) is over, DC 22V, battery is
normal. If voltage is not normal, battery has problem itself. Internal battery
needs to be checked.
2. Check if cable is connected with battery.
3. Check Battery switch(No.2).

3
4. Refer to references of circuit in the case of problem of PCB(printed
circuit board).
Check-C
1. Check each switch(MCU, BCU).
2. Check if wiring is loose.
Check-D
1. Check a related LED.
2. Check the connection of HEROSE CONNECTOR is right.
3. See the cable connected to SHUNT if any problem of indication
XI1 SAMHO l INDUSTRIAL CO. ,LTD.

'>
Ampermeter, is found.
4. Check the wiring of connector on the back of front panel.
5. Test Ampermeter with FS(Full Scale) DC 50mV.
6. Refer to references of circuit board unless you can solve problems.
Circuit Board References (PCB)
Notice: This is only for electric engineers.

Refer to electric circuit diagram.
1. See if the connection of all connectors are connected to PCB exactly.
2. Check the activation of 2N3055 connected to CON B Connector of PCB.
3. Connect Minus cable of Tester to the terminal NE.
4. Check if voltage of SMPS has been supplied to CON B Connector.

(DC 27V, DC 5V)
5. Turn Volume of POT 5 and POT A to FCW with Battery switch off
6. Adjust POT 4 for voltage of NE and BTB to be 26.9V
7. Adjust POT 5 so that Battery Switches (between ETA and BTB) have
approximately 1.5 Amper.
8. Turn Battery switch on.
9. In order color of Battery Charge LED changes about the 26.1V of the NE
and the BTB you can regulate POT A (Charge V Control).
p,j
{
=
%
Xlll SAMHO l l NDUSTR l A L CO. ,LTD.

MAN Diesel service letter provides guidelines for cylinder lubrication

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MAN Diesel service letter provides guidelines for cylinder lubrication

Uploaded by

Copyright:

Available Formats

Search

Service Letter SL07-479lHRR

Specific Cylinder Oil Dosages

ACC Cylinder Lubrication, January 2007

Average Cylinder Oil Consumption

SULPHUR 2006. source DNV Pelroleurn Services

Fig. 2: Sulphur c o n t e n t 2006

Operating o n low sulphur fuels

Questions or comments regarding this SL should be directed to our Operation Dept.

Guiding Cylinder Oil Feed Rates

Standard EN 70 cylinder oil I BN 40 cylinder oil

Minimum feed rate

Maximum feed rate

Part-load control Proportional to indicated engine load

First 5 hours: 1.7 glkWh

Running-in new rings in

During starting, manoeuvring and load changes, the feed rate

1 Adjusting Alpha Lub. using ACC, BN40 Cylinder Oil

Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil

ACC Running-in Schedule

rate factor reduction curve(glkWhlS%)

0 500 1000 1500 2000 2500 3000 3500 4000

* A :Adjustment to be carried out / C: Check the condition / R: Parts to be redaced

1. Replacement of injection quill on cylinder liner.

SEAL OF PUMP FOR BOOST PUMP

1 REPLACEMENT OF INJECTION QUILL 1 1 I J I

1 ACCUMULATOR ON LUBRICATOR (SMALL) I d I d I d I

.:SOLENOI&VALVEON ~ I J B # @.. ~ T O R .. ....: : ~ , . . .d -. d d

I PICK UP SENSOR - FLY WHEEL SIDE I d I d I d I

REPLACEMENT OF INJECTION QUILL d

Alpha Lubricator System

MAN Diesel & Turbo

2. Operation of the System

3. HMI-Panel and Configuration of MCU

Description of HMI Panel

Table of Contents Page

Injection rate with BCU in control 56

Alpha Lubricator - Alarm Handling and Trouble Shooting Guide 66

5.3.7 Alarm 35 - BCU alive signal missing

Alarm 49 - Stand-by pump is running

Appendix 1 Function of the LEDs in the Intermediate Box

Appendix 3 Replacement of MCU, BCU, SBU Boards

Appendix 4 Service Letter -SL09-507lHRR - Cylinder Oil Feed Rate

Appendix 5 ALCU signal description

Appendix 6 Back-up Control Unit - BCU

ACC Adaptive Cylinder oil Control

ALCU Alpha Lubricator Control Unit

AMS Engine alarm System

BCU Backup Control Unit

ECR Engine Control Room

FBU Fuse Board Unit

FPGA Fast Programmable Graphic Array

HMI Human Machine Interface

Lcd Load change dependent

LED Light Emitting Diode

MCU Master Control Unit

MEP Mean Effective Pressure

PCB Printed Circuit Board

RPM Revolutions Per Minute

SBU Switch Board Unit

TDC Top Dead Centre

UPS Uninterruptable Power Supply

lump station and si panels