MAN Diesel & Turbo

Introduction
The Combustion Pressure Control for Barred Speed Range (CPC-BSR) is designed to avoid high
combustion pressures, when passing the barred speed range after installing Turbo Charger Cut Out
(TCCO). Higher combustion pressures can result in increased torsional stress in the intermediate and
propulsion shafts. Such consequences are to be avoided and therefore the installation of CPC-BSR is
necessary on some vessels after installation of TCCO.

CPC-BSR works by delaying the exhaust valve closing and thereby delaying the compression cycle.
This results in a lower compression pressure and thereby combustion pressure. The delayed closing is
only active in the barred speed range and thereby only has an effect on the engine, when passing the
critical RPM range.

The System
CPC-BSR works by reducing the clearance of the damper piston when closing the exhaust valve. This
delays the closing, which cause a delayed start of the compression cycle. Thereby the compression
pressure is reduced and results in a lower overall combustion pressure.

Below is a schematic drawing, which describes the changes to the exhaust valve oil cylinder to make this
possible.

The control box system is making sure the poppet valve is closed when running through the barred speed
range. Outside the barred speed range the poppet valve will be open, so the exhaust valve closing is as
under normal running conditions. Thereby the TCCO system can get full advantage of the increased
combustion pressure and the corresponding fuel oil savings.

To ensure that the poppet valve is activated in the barred speed range and reduce the torsional stress it is
monitored by the valve supervision box system. In case of failure the valve supervision will raise an alarm.
On next page there is a simplified overview of the system.
MAN Diesel & Turbo

System Overview
MAN Diesel & Turbo

Operation
The system will work automatically without any operation input from the crew. When TCCO is engaged a
switch will enable the CPC-BSR system as well.

In case of a system failure the system will raise an alarm, ie. if a solenoid valve is stuck in closed position
an alarm will indicate failure.

Troubleshooting
Below you will find trouble shooting guide for the CPC-BSR Mk. 2 applications.
CPC Components:
 Oil cylinder on each cylinder unit – modified for the CPC Flange(8872-2272-0007 / 164) 
 Actuator Piston complete – Modified for CPC  
 CPC Flange on the top of each oil cylinder(8872-2272-0007 / 284)  
 CPC valve installed into the CPC Flange(8872-2272-0007 / 056)  
 Supervision sensor –  integrated on top of the CPC valve(8872-2272-0007 / 056)  
 Junction box – installed to extend the supervision cable – coming from the super vision sensor 
going to the Control Box( See System Overview) 
 Control Box( See System Overview) 
 Valve Supervision Box ( See System Overview) 
 Tacho sensor installed at the engine fly wheel 
 TCCO switch installed at the turbo charger cutout valve – on the turbine side 
 Common CPC alarm connection to AMS 

Detection of CPC active:

1. The Turbo Charger cutout is active and the CPC‐BSR is enabled via an interlock switch mounted 
on the TC cutout swing gate valve on the Turbine side. Inside Control Box relay K3 diode is 
ignited switch on. 
2. The engine is running in the defined barred speed range [rpm low; rpm high]. 
3. The Tacho Sensor diode installed at the ME fly wheel – is flashing each time the notch on the fly 
wheel pass the sensor tip. 
4. Diodes on each the CPC valve power supply plug are ignited switch on the CPC block on the side 
of each oil cylinder. 
5. Inside CPC Control box the K1 and K2 powers the valves. The diodes are ignited.  
6. Inside CPC Control box ‐ The PLC display show the engine revolution – which is in the range  
[rpm_low; rpm_high] ‐/+ hysteresis of 2 rpm. 
7. Inside the CPC Valve supervision box ‐ a relay is installed for monitoring each valve. The diodes 
K1, K2, K3, K4, … Kn are ignited switch on. 

In general the monitoring system is only active under the following conditions:
 TC cutout is enabled and 
 Engine run in the barred speed range [rpm_low; rpm_high] +/‐ hysteresis of 2 rpm. 

 
MAN Diesel & Turbo
The monitoring system makes supervision of:
1. CPC valve position 
2. Power supply 
3. Tacho timeout  
4. PLC failure 
5. Wire break 

Either may trigger a common alarm – which may be directed to the AMS.
In case of a common alarm arises:
1) Open the CPC control box cabinets 
2) Check the tachometer – by diode on the sensor at the fly wheel. Check that the Tacho signal is 
available in the CPC Control box by reading the displays. The displays should show the engine 
RPM. If not – the Tacho sensor or the PLC may be damaged. 
3) If OK – make the following test: 
a. Start engine and run to just below the barred speed range with turbocharger cutout 
active. 
b. Station an observer to verify the diodes of K1 and K2 in the open CPC control box ignites 
and if K1,K2,K3,K4,… Kn in the Valve supervision box in the open Valve supervision box 
ignites, when passing the barred speed range. 
c. Station an observer on the top of engine to verify the diodes on the valve power supply 
plug. 
d. Accelerate the engine through the barred speed range. 
e. The observers check the diodes and ensure that everything is ignited as described in the 
chapter “Detection of CPC active”.  
f. In case that of one power supply diode is not ignited: check the power cable. Check the 
diode and plug on the valve. Try to interchange the valve. This may identify the failure. 
g. In case of supervision diode is not ignited: check the power cable. Check the diode and 
plug on the valve. Try to interchange the valve. This may identify the failure. 

Other indication of failure:

As the monitoring system is only active through the barred speed range and with TCCO active
the following may not be detected:
1) Jammed CPC valve in closed position. 
2) Corroded CPC orifices 

Jammed CPC valve in closed position: This may be due to impurities in the oil – captured inside
the valve between housing and the poppet valve plunger. The jammed closed position will only
appear through the barred speed range – and is as such very unlikely. More likely is jammed
valve in open position – which will be detected by next passage of the barred speed range. The
jammed closed valve – will result in a reduced combustion pressure and is as such not dangerous
for the engine. The failure may be identified by exhaust gas deviations. The problem is rectified
by cleaning the valve or by replacement.

Corroded CPC orifices: this is very unlikely situation that the components inside the CPC block
are corroded by high pressure peaks in the hydraulic system. Such problem will most likely result
that the orifice inside the block is distorted. An increased of orifice area will allow the exhaust
valve to land faster to the exhaust valve seat. Such problem can be detected by unusual contact
MAN Diesel & Turbo
noise from the unit. Check the condition of the orifices inside the CPC blocks. In case the orifice
have indication of erosion – replace it by similar from spare parts kit. Contact maker.

In case that failure cannot be detected

Fail safe configuration is running with all Turbochargers engaged. Thus in case of failure that
cannot be rectified by crew – engage all turbochargers. The TC disengagement may wait to next
given opportunity.

Reduce the speed to just above the barred speed range (rpm high + 1rpm). Wait for stable vessel
speed and engine condition. Then reduce engine index - for a fast passage through the barred
speed range. Engage the Turbocharger again. The engine is again free to operate.

CPC-BSR Component list

PO item Plate-Edition Item Description
Mounting on oil cylinder
0010 8872-2272-0007 019 Piston actuator, complete
0020 8872-2272-0007 032 Flange
0030 8872-2272-0007 044 Orifice plug
0040 8872-2272-0007 056 Solenoid valve
0050 8872-2272-0007 068 Plug screw
0060 8872-2272-0007 081 Orifice plug
0070 8872-2272-0007 093 Plug screw
0080 8872-2272-0007 103 Orifice plug
0090 8872-2272-0007 115 Sealing ring
0100 8872-2272-0007 127 Sealing ring
0110 8872-2272-0007 139 Sealing ring
0120 8872-2272-0007 140 Orifice plug
0130 8872-2272-0007 152 Disc
0140 8872-2272-0007 176 Piston ring
0150 8872-2272-0007 260 Screw
0160 8872-2272-0007 272 Socket plug
0170 8872-2272-0007 284 Flange
CPC-BSR Control Box and Valve Supervision box
0180 8872-4772-0001 Control Box
0190 8872-4772-0002 Valve Supervision box
0200 Support bar
0210 Clamps
0220 Cyl. Screw
0230 Washer
RPM sensor
0240 RPM Sensor
0250 Junction Box
MAN Diesel & Turbo

Valve Supervision Connections

Connection Poppet valve to Valve Supervision box - Feedback signal
0260 Plug for proximity switch
0270 Cable
Connection to AMS system(Alarm)
0280 Cable
Connection(Power supply to Valve Supervision box)
0290 Cable (Power)
0300 Cable glands for power

Control Box Connection

Connection(TCCO signal)
0310 Cable to TCCO switch
Connection Poppet valve to Ecocam control box - Signal
0320 DIN power connectors for valve
0330 Cable (Actuation)
Connection(Power supply to Control Box)
0340 Cable (Power)
0280 Cable glands for power
Connection(RPM Junction box to control box)
0290 Cable
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8872-4772-0001

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Item No. Qty Item Designation

Special Instruction

012 - Row terminal

024 - Row terminal
036 - Converter
048 - Relay

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8872-4772-0002

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Item No. Qty Item Designation

Special Insruction

012 - Converter
024 - Circuit breaker
036 - End stop
061 - Row terminal
073 - Terminal
085 - Terminal
097 - Row terminal
107 - Terminal plate
119 - Terminal plate
120 - Relay module

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8872-2272-0007

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Item No. Qty Item Designation

Special Instruction

019 - Piston actuator, complete

032 - Flange
044 - Orifice plug
056 - Solenoid valve
068 - Plug screw
081 - Orifice plug
093 - Plug screw
103 - Orifice plug
115 - Sealing ring
127 - Sealing ring
139 - Sealing ring
140 - Orifice plug
152 - Disc
164 - Oil cylinder
176 - Piston ring
188 - Piston actuator
211 - Slide
223 - Piston
235 - Spring
247 - Disc
260 - Screw
272 - Socket plug
284 - Flange

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