Professional Documents
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m1-c Main Engine Manuals For Appendix
m1-c Main Engine Manuals For Appendix
ContentsforAppendix
1 空冷器 Charge Air Cooler
17 增压器 Turbocharger
凯络文换热器(中国)有限公司
凯络文增压空冷器是一种管片式热交换器。其
凯络文
凯络文
直接向德国凯络文公司购买,或向凯络文换热器(芜
湖)有限公司购买,也可以在我们世界各地的维修中
心购买。
The Kelvion charge air cooler is a finned tube heat exchanger. The
hot air flows through the fins on the outside of the tubes and the
cooling fluid flows through the tubes. The heat exchanger surface of
0
CONTENTS
1 Application............................................. 2
3 Construction............................................ 3
4 Installation............................................ 4
5 Operation............................................... 5
1
1 Application
This tuning gear is used for cranking the crankshafts of large low
Type M2QA132S6A V1
Insulation class F
Type M2QA132M6A V1
2
Rated speed 945r/min(1150 r/min)
Insulation class F
drives the speed reducer. On the output shaft is mounted a movable gear.
housings of the electric motor and the speed reducer are base-connected.
There are five holes on the speed reducer base for fixing the turning gear.
pipe and the switch is connected with the control circuit of center control
3
room. When the string-bar is on the outside position, the position switch
the starting air is cut off. So the diesel engine can’t be started up. But the
circuit is energized and the indicated light in the center control room is on.
You can start the turning gear. When the string-bar is on the inside
position, the indicated light in the center control room is off. Therefore,
40 ℃ ,flash point not lower than 220 ℃ ,cloud point not lower than
0℃,carbon residue not higher than 1.7% before adding additive and
mechanical impurity not higher than 0.02%). The quantity of gear oil
filled should be within sight through oil level dipstick glass. That is to say,
the oil level can’t be lower than the visible level range through the oil
level dipstick glass. It also can’t be higher than the visible level range
through the oil level dipstick glass. If so, drain the oil through the drain
port at the lower part of the speed reducer till the oil level requirement is
met. When the oil level is lower than the specified lower limit, add oil
promptly to the visible level range through the oil level dipstick glass.
engine (with the gear at the inner side position and without the
4
stirring-bar interlocking mechanism) and let the five holes in the base of
speed reducer correspond with those in the side plate of the engine. By
adjusting the left and right positions of the turning gear and the thickness
of the distance tube (i.e. gasket) under speed reducer, the turning gear
axis can be parallel with the crankshaft axis and the engagement
clearance between the gear and crankshaft gear within the requirements
and even contact of their gear surface can also be ensured. Then, tighten
the nuts of the four bolts for fixing turning gear with a tightening moment
of 500 Nm. After tightening, recheck the flank clearance of the gears. If it
After fixing the turning gear, mount the stirring-bar. Then connect it
with power supply and air line according to the special instruction for the
motor respectively. After this, check the switch circuit of the turning gear,
the position switch, the two-position three-way valve and starting pipe for
lubricating oil for the speed reducer as well as odor. Put it into application
mechanism and have the gears engaged correctly. After these, start the
WARNING:
When the gear moves to the inter side, it should not contact
with grease.
by the control press button. For the operation method, please refer
6.2 During lifting and installing, the electric motor is not allowed to be
collided.
6.3 The turning gear can be dismantled for check only when it is under
static condition, and the crankshaft gear and the gear are under
6
disengaged condition. It is not allowed to dismantle it for check
during operation.
6.4 Before removing the electric motor, disconnect the power supply
first. Then drain off the lubricating oil in the speed reducer.
6.5 There must be often remained some grease between the gear and the
6.6 For lifting purpose, a special lifting ring should be used. But do not
and handle.
6.7 Put a protecting shield on the electric motor to prevent it from water,
6.8 Renew the lubricating oil for the first time after 80 operating hours,
7
Connect the power
Common
Item Analysis Solvent
Breakdown
8
Open the chain driving
The
mechanism. Replace the
movable
Chain maybe damaged.
damaged chain with new
gear is not
ones.
3 turning
Common
Item Analysis Solvent
Breakdown
out. ones.
9
8 Operation of Manual Release Screw for Brake
There is manual release screw for brake just locating at the position of
loose. Twist the screw clockwise, the brake can be released and the
10
Sketch map for the Turning gear
11
SERIES
DRAWING NO PART NAME QTY MATERIAL
NO
1 CP23-10-00 Cover parts 1 Q235A
2 GB/T819.2-1997 M5×12 Bolt 8 8.8
3 CP23-02-01-02 Shaft 1 304
4 GB/T894.1-1986 18 Snap ring 2 65Mn
5 CP23-02-01-01 Move knob 2 45
6 GB/T70.1-2000 M6×40 Bolt 2 8.8
7 GB/T859-1987 6 Spring washer 18 65Mn
8 Three way valve 1
9 GB/T70.1-2000 M8×16 Bolt 8 8.8
10 GB/T859-1987 8 Spring washer 17 65Mn
11 GB/T288-1994 22217CC/W33 Bearing 1 G
12 CP23-09-01 Front end-cover 1 ZG270-500
13 GB/T120.2-2000 16×32-B Pin 3 30
14 GB/T 5783-2000 M12×40 Screw 4 8.8
15 GB/T859-1987 12 Spring washer 4 65Mn
16 GB/T97.1-1985 12 Washer 4 200HV
17 CP23-02-02-01-00 Support parts 1 Q235A
18 JB/T 7271.4-1994 BM16×63 Handle cover 1 PLASTIC
19 CP23-02-01-04-00 Stirring-bar parts 1 Q235A
20 GB/T70.1-2000 M5×16 Bolt 2 8.8
21 GB/T859-1987 5 Spring washer 2 65Mn
22 Position switch 1
23 CP23-02-01-06-00 Bolt set 1
24 GB/T117-2000 5×20 Pin 2 35
25 CP23-02-01-03 Stirring-bar support 1 QT500-7
26 GB/T70.1-2000 M8×25 Bolt 8 8.8
27 CP23-02-01-04-04 Knob 2 ZCuSn10Pb1
28 GB/T 894.1-1986 12 Snap ring 2 65Mn
29 CP23-05-03 Screw M18×1.5 3 Q235A
30 CP23-05-04 Gasket 3 T2
31 GB/T301-1995 51207 Bearing 1 E
32 CP23-08-05 Underside cover 1 20
33 CP23-08-11 Ring 1 45
34 GB/T276-1994 6308 Bearing 1 E
35 GB/T893.1-1986 90 Snap ring 1 65Mn
36 CP23-08-02 Worm 1 35CrMoA
37 GB/T 818-2000 M8×20 Bolt 4 8.8
38 CP23-05-05 Cover 1 Q235A
39 CP23-05-06 Looking window 1 glass
40 GB/T297-1994 33210 Bearing 1 G
41 CP23-08-04 Top cover 1 20
12
42 SN70-TC05007008 Seal 50×70×8 1 RUBBER
43 GB/T819.2-1997 M8×25 Bolt 6 8.8
44 CP23-05-01 Central support 1 ZG270-500
45 Motor 1
46 CP23-05-02 MIDDLE SUPPORT 1 ZG270-500
47 CP23-08-01 Worm wheel 1 ZCuAl10Fe3
48 GB/T292-1994 7020C Bearing 1 G
49 CP23-04-01 Back cover 1 Q235A
50 GB/T893.1-1986 78 Snap ring 1 65Mn
51 CP23-08-09 Ring 1 F4
52 CP23-03-01 Solar gear 1 35CrMoA
53 CP23-03-07 Ring 1 F4
54 CP23-03-03 Center shaft 3 40Cr
55 CP23-03-02 Planet frame cover 1 40Cr
56 GB/T288-1994 21307CC Bearing 3 G
57 CP23-03-04 Planet gear 3 35CrMoA
58 CP23-03-06 Ring gear 1 40Cr
59 CP23-06 Ring 1 ZG270-500
60 CP23-03-05 Planet frame 1 35CrMoA
61 GB/T70.1-2000 M10×35 Bolt 22 8.8
62 GB/T859-1987 10 Spring washer 22 65Mn
63 GB/T70.1-2000 M6×16 Bolt 16 8.8
64 CP23-09-02 Gear cover 1 Q235A
65 SN70-TC07510010 Seal 75×100×10 1 RUBBER
66 CP23-03-08 Key 2 40Cr
67 CP23-07 Gear 1 QT500-7
13
10 Wiring Drawing for E-motor
14
Sketch map for the fixing of the Turning gear
15
Instruction Book For
1
◆ 概述 ◆Introduction
◆ Space heater
◆ 空间加热
2
船用辅助鼓风机使用说明书
适用于分体式离心辅助鼓风机
上 海 齐 耀 系 统 工 程 有 限 公 司
QIYAO POWER SYSTEMS CO., LTD
1 概述
分体式船用辅助鼓风机,是一种电机直接带动叶轮的离心式风
机,用于 MDT、WIN GD、MHI 等各型船用柴油机的辅助进气。
2 结构
分体式船用辅助鼓风机按客户订货要求供货,主要结构有以下三
种(图 1):
图 1.a(单出口带蜗壳)
图 1.b(三出口) 图 1.c(不带蜗壳供货)
1—电机 2—气封 3—叶轮
4—壳体 5—进气锥弧管 6—排气孔
分体式船用辅助鼓风机的叶轮由轮毂直接安装在电机轴上,通过
平键联接,叶轮与进口集流管采用套口方式连接。密封采用进口具有
热弹性的 PS 气封。风机结构紧凑、密封优良,维修时无须拆开机壳
与柴油机的连接便可取出叶轮,维修方便。
产品制造、检验和试验均按照国家有关风机标准。性能符合要求,
工作可靠,运行平稳。
3 主要技术指标
1
3.1 性能参数与性能曲线:辅助鼓风机的性能是指订货图中选择的满
足主机需求的静压-流量要求,各型辅助鼓风机运行特性符合所需的
静压-流量(性能运行特性曲线举例示意如图 2),具体型号设计完全可
满足客户订货图中对性能的要求。
静压P(Pa)
6500
6000
5500
5000 A
4500
4000
3500
3000
2500
B
2000
1500
1000
流量m3/s
图 2(性能特性曲线举例)
3.2 安装尺寸(图 3)
辅助鼓风机的安装尺寸是指风机安装到主机相关管道的接口尺
寸,主要是进口锥管安装和风机出口法兰或壳体连接板二个安装面。
具体型号根据客户订货图要求设计,完全符合安装要求。
图 3.a(单出口带壳体)
图 3.b(三出口) 图 3.c(不带蜗壳供货)
2
4 使用、维护
4.1 安装、起吊风机时应使用设计的专用起吊孔,注意安全操作。
4.2 注意区分顺时针和逆时针的风机叶轮以及电机的接线,风机叶轮
旋转应与方向指示牌及壳体出风口一致。
4.3 使用中应注意:
4.3.1 监察风机的振动情况是否正常(v≤6.3mm/s),振动过大影响风机
寿命和性能,否则需修复叶轮平衡或更换新叶轮。
4.3.2 监察电机、电压、电流参数等是否正常,超过要求应停机检查,
进行必要的维护维修。
4.3.3 运行中检查各处是否有漏气、异响,如需要应检查和更换相关
密封件。
4.4 使用随机提供工具备件箱中的专用叶轮拆卸工具小心拆卸叶轮,
经修理的叶轮应进行动平衡校正或更换新的叶轮,以保证风机工
作平稳。
4.5 如需更换电机轴上的密封圈,注意按其说明,安装时涂适当润滑
油脂,安装方向正确,不可碰坏损伤。
5 工具备件清单
每套风机都会随机附带有一份相应的工具备件清单。
3
1 Application
The split-body type marine auxiliary blower is used for most models of
MDT、WIN GD、MHI diesel engine and so on.
2 Main construction
There are three types supplied by us according to the demands of clients
(see Fig. 1)
Fig. 1.b (type of three outlets) Fig. 1.c (type of without shell)
1——electric motor 2——PS-seal
3——impeller 4——auxiliary blower shell
5——air passing in tube 6——leaking out hole
These auxiliary blowers are composed of air passing in tube 5, blower shell
4, impeller 3, PS-seal 2, electric motor 1 and so on. The impeller is connected
with the shaft of electric motor through key directly, using PS-seal for sealing.
The characteristic of such construction is being high revolving speed, more
small external size and good command for sealing.
When maintain and check the auxiliary blower, it needn’t dismount it from
the diesel engine. It’s quite convenient to take out the impeller with the electric
motor together while maintaining and checking. They are according to certain
Blower Industry Standard of China when designing, manufacturing and doing
experiments. It has more advantages such as convenience for maintaining and
checking, reliable running and so on.
1
3 Main technical parameter
3.1. Function curve (see Fig. 2 for example)
The function of the blowers is designed according with the drawings
afforded by clients. The running character1curve is according with the
demands of main engine.
静压P(Pa)
6500
6000
5500
5000 A
4500
4000
3500
3000
2500 B
2000
1500
1000
1 2 3 4 5 6
流量m3/s
Fig. 3.b (type of three outlets) Fig. 3.( type of without shell)
2
4 Operation and maintenance
4.1. When lifting the auxiliary blower, please use the lifting hole being
specially designed.
4.2. When supplying the power source, please be attention that the
revolving direction should be the same as the direction plate.
4.3. Cautions:
4.3.1. Whether it is normal or not of vibration(v≤6.3mm/s). The old
impeller may be repaired or changed by a new one if the vibration is over
the demands.
4.3.2. Whether it is normal or not of motors’ rated voltage and current.
Otherwise it needs to be checked carefully.
4.3.3. Whether air leaking or not by checking the connect face and
leaking out hole. Otherwise some parts such as PS -seal need to be
changed.
4.4. Please dismount the impeller by special tools in spare parts box,
carefully mounting and dismounting PS-seal.
4.5. When change the PS-seal, please put some grease on it and don’t do
any damage to the sealing lip. To be sure that the installation direction of
seal is correct.
5. List of tools and spare parts
There are always some tools and spare parts in the spare box with
the equipment according to the list paper.
3
上 海 齐 耀 系 统 工 程 有 限 公 司
QIYAO POWER SYSTEMS Co., LTD
地址:上海市共青路 357 弄 1 号 邮政编码:200090
ADD:No.1 Lane 357 Gongqing Road,Shanghai,China(2009)
电话(Tel):021-65687121 传真(Fax):021-65680330
Instruction Book For
1
◆概述 ◆Introduction
2
Instruction Book For
1
◆概述 ◆Introduction
2
排气阀和阀座电动磨削机使用说明书
上 海 齐 耀 系 统 工 程 有 限 公 司
QIYAO POWER SYSTEMS Co., LTD
目 录
1 概述 ................................................................................................................... 3
1.1 产品信息 ..................................................................................................................................................... 3
1.2 制造商信息 ................................................................................................................................................. 3
1.3 安全事项 ..................................................................................................................................................... 3
2 产品介绍 ...................................................................................................... 4
2.1 产品技术参数 ............................................................................................................................................. 4
2.2 结构简介 ..................................................................................................................................................... 5
2.3 设备特点 ..................................................................................................................................................... 6
2.4 适用范围 ..................................................................................................................................................... 6
3 磨削机的安装 .................................................................................................. 6
3.1 安装地点的选择 ......................................................................................................................................... 6
3.2 电源连接 ..................................................................................................................................................... 7
4 磨削前的准备 .................................................................................................. 8
4.1 电控系统的检查 ......................................................................................................................................... 8
4.2 更换砂轮 ..................................................................................................................................................... 9
4.3 砂轮的修整 ................................................................................................................................................. 9
4.4 砂轮组件的平衡 ......................................................................................................................................... 9
4.5 砂轮罩壳的调整 ....................................................................................................................................... 10
4.6 磨削角度的调整 ....................................................................................................................................... 10
5 排气阀的磨削 ................................................................................................ 12
5.1 排气阀对中夹紧 ....................................................................................................................................... 12
5.2 磨头位置调整 ........................................................................................................................................... 12
5.3 磨削操作 ................................................................................................................................................... 12
6 排气阀座的磨削 ............................................................................................. 13
6.1 排气阀座对中夹紧 ................................................................................................................................... 13
6.2 磨头位置调整 ........................................................................................................................................... 14
6.3 磨削操作 ................................................................................................................................................... 14
7 磨削机的维护保养 ........................................................................................ 15
8 故障处理 ......................................................................................................... 15
9 随机工具及安装件 ........................................................................................ 15
1
contents
3 INSTALLATION ............................................................................................. 20
3.1 LOCATION OF THE EQUIPMENT .................................................................................................................... 20
3.2 ELECTRIC POWER CONNECTION .................................................................................................................. 21
5 VALVE GRINDING........................................................................................ 25
5.1 CENTERING OF THE VALVE SPINDLE............................................................................................................. 25
5.2 GRINDING HEAD POSITION .......................................................................................................................... 26
5.3 GRINDING OPERATION ................................................................................................................................. 26
7 MAINTENANCE ............................................................................................ 28
附录 APPENDIX ............................................................................................... 30
2
1 概述
1.1 产品信息
DM 系列排气阀和阀座磨削机是以电力为动力源的磨削加工设备,适用于各型柴油机排气阀与
阀座密封面的修复磨削。该磨削机结构简单可靠,磨削精度高,操作快捷方便,体积小巧。
本说明书适用于 DM 系列排气阀/排气阀座磨削机的使用及维护保养,文中的图表仅用于本文
的说明,保留对设备和技术资料进行更新和改进的权力。
1.2 制造商信息
设计制造:上海齐耀系统工程有限公司
电话:+86-21-65687121
传真:+86-21-65680330
1.3 安全事项
1.3.1 使用及维护保养人员应在使用或维护前仔细阅读和学习本手册,并遵守相关安全
规定。
1.3.2 安全措施与注意事项
运输:
运输及装卸时应注意安全。
必须使用安全合格的吊装工具与设备,吊装螺钉确保无损坏及安装紧固。
吊装时不允有人员许站在设备下。
使用:
检查砂轮型号正确且无损伤、裂纹等缺陷,检查裂纹的正确方法是:砂轮装好后,用一非金属
棒轻击砂轮每个面,无裂纹的砂轮应会发出清脆声音,否则会听到不正常的音调。
防止砂轮破损,砂轮应存放在常温干燥环境中,应保护不受潮及被液体、灰尘及杂物的污染,
否则会损伤砂轮并导致不平衡。
每次磨削前检查各部件的连接应牢固,而且运转正常方可进行磨削操作。特别是砂轮安装螺钉
必须紧固。
操作中如必要应使用防护镜、呼吸罩、耳塞等防护用品。
操作中应防止碰到高速旋转的磨削砂轮,与所有旋转件都应保持距离。
操作时不要穿着宽松衣饰(如领带,纱巾等),长发须注意防护以免卷入。
磨削中注意防止磨屑烫伤,并注意周围无易燃品,以防被磨削火花引燃。
其它注意事项:
不要用水清洁设备。
设备闲置或维修时应停掉设备和关闭电源。
3
操作中如遇意外情况,按下操作面板上的紧急停止键。
使用保险丝保护设备中各类电器。
1.3.3 安全说明及标识
安全说明包含在说明书各章节中,操作者应严格遵守,以免造成对人员、财物、环境等的损害。
安全标识包含如下几类:
危险!
可能造成严重人身伤害
乃至死亡的伤害。
警告!
可能造成财物或环境
损害。
注意!
要求正确使用设备,
否则可能有轻微伤害或
损失。
2 产品介绍
2.1 产品技术参数:
2.1.1 磨削精度:
径向跳动 ≤0.02mm
表面光洁度 Ra0.5μm
角度精度 ±1′
2.1.2 设备参数:
转盘转速 约 10 r/min
磨削砂轮尺寸 Φ150×13×Φ32
磨削砂轮转速 ≥4000r/min
电源总功率需求 1.1kW
4
2.2 结构简介
磨削机由六个部分构成:机座部件,主机体部件,传动部件,磨座部件,磨头部件和电控箱,
如图 1 所示。
2.2.1 机座部件
磨削机的支架,其底面安装防震垫以防止磨削机的震动。
2.2.2 主机体部件
主机体部件包含气阀稳定支架,主轴组件,机架组件,转盘,大带轮,气阀及阀座的对中夹紧
装置等,主要用于对中夹紧排气阀和阀座,并通过传动部件带动工件旋转。
2.2.3 传动部件
包括驱动马达、齿轮箱及小带轮,是把驱动马达的转速减速后通过皮带传动到主机体部件上带
动工件旋转,满足工件所需的转动速度。
2.2.4 磨座部件
磨座部件主要包括连接座,上、下导轨及角度调节装置等,主要用于对磨削砂轮的操作,是磨
削时保证砂轮进给的装置,并可以对磨削角度进行精确调节。
2.2.5 磨头部件
主要包括磨削马达、同步带轮组件及砂轮组件,通过磨削马达座与磨座部件上滑板相联接。
5
2.2.6 电控箱
磨削机动作的控制系统,整体置于磨座部件的连接座内,电控箱面板如图 2 所示(内部线路图
分别见附录 1)。
图 2 电控箱面板图
2.3 设备特点:
本磨削机为电动式,结构简单可靠,自动对中,防震,精度高,磨削排气阀座时无需拆除气阀
稳定支架,操作简便快捷。
2.4 适用范围:
本设备主要用于二冲程船用低速柴油机排气阀与阀座配合面磨损时的修复磨削(具体型号参考
附录 5)。
3 磨削机的安装
3.1 安装地点的选择
应考虑选取最经济有效的合适地点安装此设备。
该处应避免有强烈震动。
该处应方便吊装并有足够的操作空间。
参考磨削机认可的安装图纸要求,安装在
船内合适的地方(附录 5)。
为了防止磨削机的震动,把备件箱中的橡胶减
6
DM-3 型控制箱适用于除 DM35A 磨削机外其他型号电动磨削机。
具体电路图见说明书后附录。
所有型号磨削机设备带有相同的插座及插头(图 4),用户根据电源与设备距离选择
电源线长度进行连接(用户自备),安装完成后开启电源,检查电控箱面板上各开关控制
正常。
图 4 插座及插头
危险!
注意用电安全,在安装、维修时必须断开电源。
7
4 磨削前的准备
4.1 电控系统的检查:磨削操作前应检查电控系统的连接及面板上的各开关。
4.1.1 检查面板上各开关处于关闭状态。
4.1.2 打开电源,指示灯亮。
4.1.3 开启驱动马达开关,带动转盘旋转,检查转向为逆时针。
4.1.4 开启磨削马达开关,带动砂轮旋转,检查转向正确,开向磨气阀转向逆时针,开向磨阀座
时转向为顺时针。
4.1.5 按下急停键,设备应停转。
4.1.6 关上驱动马达及磨削马达开关,让急停键复位后关掉总电源。
4.2 更换砂轮(图 5)
磨削机上已装有一经过了平衡校正的砂轮组件。当需换上备用砂轮时,按如下步骤操作:
4.2.1 拆除磨削马达轴上的压紧螺栓。
4.2.2 使用备件箱中的拆卸螺钉取出砂轮组件。
4.2.3 用备件箱中二件砂轮拆卸扳手拆除盖板并取出旧砂轮,注意盖板是左旋螺纹。
4.2.4 同样用二件砂轮扳手装上新砂轮,应保证夹紧。注意新砂轮装入前应检查,不允许有裂纹
和破损。注意更换的新砂轮需按 4.3 修整,然后按 4.4 进行平衡后才能装机使用。
危险!
砂轮及砂轮组件在安装
时必须确保紧固。
图 5 砂轮组件
4.3 砂轮的修整(图 6)
新砂轮或旧砂轮外边缘有缺损或脏物污染时,应在平衡前修整对中,步骤如下:
4.3.1 砂轮装入砂轮组件后,先取出平衡块,用内六角螺钉安装紧固在磨削马达轴上。
4.3.2 从备件箱取出砂轮修整器装在上滑座的支架上,调好修整器的金刚石刀的切削点,
并紧固。每次切削量不大于 0.1mm(相当于金刚石刀往前转 1/8 转)。
4.3.3 开启磨削马达,前后缓慢移动砂轮进行修整,应多次修整至砂轮对中。
8
警告!
注意修整中的砂尘!
修整时切勿碰到旋转的砂轮!
图6 砂轮的修整
4.4 砂轮组件的平衡 (图 7)
砂轮修整对中后,应对砂轮组件进行平衡校正。步骤如下:
4.4.1 从工具备件箱中取出砂轮平衡器,从砂轮组件上取出一平衡块,把砂轮组件装入
砂轮平衡器轴上。
4.4.2 让砂轮自由转动,其静止位置即为重心向下的位置,划上记号。
4.4.3 参考记号,在合适位置放上平衡块。
4.4.4 调整各平衡块位置,自由转动砂轮,到砂轮可停在任何位置,说明平衡了。
4.4.5 如不校正平衡会导致震动而磨削效果不佳,如砂轮上不干净或残缺时,会导致同
样的问题,因此应当经常校正砂轮平衡。
注意!
震动及磨削不良也可
能是因为砂轮积尘、太
脏或砂轮不平衡!
因此应经常检查砂轮,
定期进行平衡校正。
图 7 砂轮平衡
9
4.5 砂轮罩壳的调整
砂轮罩壳缺口位置根据要磨削的零件来改变。磨削排气阀杆时,罩壳缺口朝上,磨削排气阀座
时,罩壳缺口朝下,调好后要把罩壳上的紧定螺钉支紧。
4.6 磨削角度的调整
磨削机磨削角的原始设计角度为 30°,刻度盘在角度调节螺钉上固定时,其“0”位应对准角
度指示箭头(如图 9 所示)。磨削排气阀座时角度为 30°,则不须再调,如根据阀杆和阀座图纸需要
调整角度时,调整是通过一个安装在上滑座的角度调整螺钉 M16×1.5 实现的,首先松开两侧的两
个紧固螺栓 M12,顺时针转动角度调节螺钉 M16×1.5,把上滑座抬高到所需角度(因机型而异),刻
度盘上每格为 1′,转动一圈即为 30′。角度调好后,扳紧并紧螺母 M16×1.5,并将两侧的两个
紧固螺栓 M12 用手旋紧(图 8、图 10)。
图 8 角度调节装置
10
图 9 磨阀座时角度调节螺钉与刻度盘的位置(因机型而异)
图 10 磨气阀时角度调节螺钉与刻度盘的位置示意(因机型而异)
11
5 排气阀的磨削
5.1 排气阀对中夹紧
5.1.1 根据柴油机制造商说明书中的要求对排气阀进行检查,如垂直度,同轴度要求等,
先行校正。
5.1.2 检查排气阀与对中夹紧相关的圆柱面、磨削面、检测面,应清洁且无毁损。
5.1.3 将排气阀缓慢放入对中组件中,用拨杆顺时针转动夹紧对中组件,使气阀夹紧对
中。
5.1.4 用手拧紧气阀稳定支架调节螺栓轻轻顶住阀杆,使阀杆磨削时不致晃动。
5.1.5 用百分表在阀杆外径无损面测量径向跳动应≤0.02,可通过轻微调节气阀稳定支架
调节螺栓达到,如图 11 所示。
图 11 排气阀的对中夹紧
5.2 磨头位置调整
按 4.5 说明调整砂轮罩壳缺口向上,以便用砂轮上边缘磨削排气阀。同时按 4.6 说明,调节和
查看角度刻度盘,抬高上滑座到所需角度(因机型而异)。
5.3 磨削操作:分为粗磨和精磨二步,以达到所需的光洁度与精度。
5.3.1 粗磨
1) 转动手柄,移动上、下滑板,使磨削砂轮尽量靠近待
磨削面,即将接触时停止进给。使用径向进给手轮使砂轮
进给到轻微接触待磨削面。(图 12)
图 12
2)使用磨削行程手轮使砂轮后退,先离开磨削面。
12
警告!
磨削操作中注意砂尘!
操作中切勿碰到旋转的砂轮!
图 13
4) 打开电源,开启驱动马达带动工件旋转,转盘为顺时针旋转,转速在 10r/min 左右。
5)开启磨削马达带动砂轮旋转,注意在控制箱面板上开关指向标识为“磨气阀”一侧(DM-2
型控制箱无须选择),砂轮应为逆时针旋转。
6)缓慢使用磨削行程手轮使上滑板前后进给,工件每转一圈,行程手轮大约进给 1/8 转。
7)可反复几次磨削,直至磨削表面光洁平整。
5.3.2 精磨
精磨前清除砂轮外圆表面及磨削面磨屑等垃圾,径向进给磨削深度大约 0.01mm,其余操作同
粗磨,直至磨削面光洁度达到要求为止,完成后清理磨削面,并关闭马达,切断电源。
6 排气阀座的磨削
6.1 排气阀座对中夹紧
6.1.1 检查阀座的支承面,对中夹紧面及检测面不得有破损,并清洁。
6.1.2 检查并清洁磨削机转盘上的各个定位销,其对应编号应与转盘上的编号一致。
6.1.3 各定位销的切口平面位置靠内,小心放入阀座,以定位销上平面支承阀座。
6.1.4 用拨杆转动偏心定位销,使各定位销上的标记线与转盘上的刻线对齐。
6.1.5 用百分表在阀座外径无损面测量径向跳动应≤0.02,检查阀座是否对中,可参照刻
线用拨杆左右均匀调节偏心定位销,使阀座对中夹紧,如图 14。
图 14 排气阀座的对中夹紧
13
6.2 磨头位置调整
按 4.5 说明调整砂轮罩壳缺口向下,以便用砂轮下边缘磨削排气阀座。同时按 4.6 说明,调节和
查看角度刻度盘,根据图纸角度要求调整角度。
6.3 磨削操作:分为粗磨和精磨二步,以达到所需的光洁度与精度。
6.3.1 粗磨
1) 转动手柄,移动上、下滑板,使磨削砂轮尽量靠近待磨削面,即将接触时停止进给。使用径
向进给手轮使砂轮进给到轻微接触待磨削面。(图 15)。
2)使用磨削行程手轮使砂轮后退,先离开磨削面。
图 15 图 16
5)开启磨削马达带动砂轮旋转,注意在控制箱面板上开关指向标识为“磨阀座”一侧,砂轮应
为顺时针旋转。
6)缓慢使用磨削行程手轮使上滑板前后进给,工件每转一圈,行程手轮大约进给 1/8 转。
7)可反复几次磨削,直至磨削表面光洁平整。
6.3.2 精磨
精磨前清除砂轮外圆表面及磨削面磨屑等垃圾,径向进给磨削深度大约 0.01mm,其余操作同
粗磨,直至磨削面光洁度达到要求为止,完成后清理磨削面,并关闭马达,切断电源。
警告!
磨削操作中注意砂尘!
操作中切勿碰到旋转的砂轮!
14
7 磨削机的维护保养
为确保良好的磨削效果及操作安全,应定期进行如下检查保养:
7.1 检查砂轮表面应清洁、无破损及其平衡性。
7.2 检查电控箱上所有开关应动作正常、灵活、可靠。
7.3 每年二次向传动部件的齿轮箱内添加润滑脂。
7.4 检查并保持上、下导轨的良好润滑状态及尽可能小的配合间隙。
7.5 磨削机每次使用后都必须关闭总电源,清洁设备并涂上一层防锈油膜,用防水塑料
布扎紧罩住设备以防灰尘和潮湿,确保设备安全及状态良好。
8 故障处理
故障描述 原因 处理措施
砂轮没修整 查看砂轮情况,精磨前应清洁或
修整砂轮
砂轮不平衡 当马达空转感到震动较大时,须
平衡校正砂轮
减小进刀量,按精磨要求进行精
磨削面不平整 终磨时进刀量太大 磨
上、下导轨松弛 调整斜块调节螺钉到合适间隙
气阀稳定支架调节螺栓设置不当 重新设置
9 随机工具及安装件(详见随机备件箱内清单)
磨削机工具备件箱中带有以下工具:
9.1 砂轮平衡器:用于对磨削砂轮组件进行平衡校正。
9.2 挠棒:又称拨杆,用于扳动阀座定位销及扳动排气阀对中组件和夹紧螺栓。
9.3 砂轮扳手:用于把砂轮装到砂轮组件中,或从砂轮组件中拆换砂轮时使用。
9.4 砂轮修整器:将该工具装到上滑座修整支架中,用于修整砂轮。
9.5 内六角扳手:用于设备维修维护时的拆装工作。
9.6 砂轮拆卸工具:用于砂轮维修维护时,方便从磨削机上拆卸下砂轮组件。
9.7 减震垫块:安装设备时装于设备底脚下,用于防震。
15
1GENERAL DESCRIPTION
This manual is intended primarily for the operator of the valve and valve seat grinding machine of the
type DM. The charts and drawings are used in this manual and may be changed in the future.
Telephone:+86-21-65687121 Fax:+86-21-65680330
1.3.1 This manual must be carefully studied before using the equipment. It will help you to
use the equipment to its full capacity and to avoid costly mistakes. All safety
instructions must be complied with. Failure to do so can result in serious injury or
damage to equipment and the environment.
Transportation:
Make sure the lifting eyebolts are undamaged and adequately fastened.
Operation:
Make sure the correct type of grinding wheel is used. Make sure the grinding wheel is not cracked by
performing the ring test: use a non-metallic implement, gently tap the wheel at each side while holding the
wheel in the center. An undamaged wheel will omit a clear tone. If cracked, there will be a dead tone.
When idle, or stored, all grinding wheels should be protected from the effects of moisture, humidity
and fluids, as these may be absorbed and cause the grinding wheel to become unbalanced.
Make sure the screw on the grinding wheel is fixed tightly before every operation.
Use safety goggles, breathing filter and hearing protection when the grinding machine is in operation
and while dressing the grinding wheel, if necessary.
Keep away from the rotating grinding wheel and other rotating parts.
Do not wear loose fitting clothing i.e. sleeves, ties or hair styles which may become entangled in the
machine.
Use proper protection against glowing grinding particles whilst grinding and keep inflammable
material at safe distance at all times.
16
Other warnings:
Always turn off the power switch when the operation is completed, or if the electric power supply is
interrupted when grinding. Beware of the wrong starting in the machine during maintenance.
2EQUIPMENT DESCRIPTION
2.1Technical information
Eccentricity ≤0.02mm
17
2.2 Equipment structure
The machine includes six parts, they are: framework assembly, main body, driving assembly,
grinding seat, grinding head and electric control system, see figure 1.
2.2.1Framework assembly is the support part of the grinding machine, there are four damping
pads at the feet of the framework assembly to prevent the shake while grinding.
2.2.2Main body
Main body includes stabilising support subassembly, main shaft subassembly, frame subassembly,
turntable, belt wheel , centring subassembly. They can drive the valve spindle and valve seat to rotate, as
well as centre the valve spindle and valve seat.
2.2.3 Driving assembly includes motor, gear box and belt wheel. They drives the main body
to rotate by driving motor.
2.2.4Grinding seat
rinding seat includes connecting seat, top slider, lower slider and angle adjuster etc. They can control
the position of the grinding head and regulate the angle accurately.
18
2.2.5 Grinding head
Grinding head includes wheel subassembly, gear belt subassembly and grinding motor, connecting
with top slider of the grinding seat by the seat of the motor.
z The machine is controlled by the panel of the electric controlling box. (see figure 2 and
APPENDIX 1 )
2.3 Features:
The grinding machine is driven by electric power and easy to operate. It is of robust construction and
designed as a professional tool for grinding valve spindles and valve seats. Automatic centering and
insensibility to vibrations assures a high quality grinding result.
2.4 Application:
The grinding machine is available for use on two-stroke crosshead engine exhaust valves and valves
seats.
3 INSTALLATION
mount the machine on a suitable foundation according to the mounting drawing by us(appendix5)
Mount the grinding machine on the damping pads supplied in the spare box to prevent the vibrations
by 4 bolts of M20 (figure 3).
19
Figure 3
Model DM-3 control box is be applicable for other models except of DM35A grinder.
The detail electric diagrams are at the end of this book.(See appendix).
This machine equipped with plug and plug seat(Figure 4). Customer connects the cable by the distance
between the machine and the power. After installation, check the rotation of the grinding wheel and the
turntable.
Figure 4
CAUTION!
Be caution of unexpected start while connecting the cables.
20
4 GRINDING PREPARATIONS
4.1.2 Turn on the power switch. The dedicator on the panel should be on.
4.1.3 Turn on the switch of the driving motor, check the correct direction of the turntable.
4.1.4 Turn on the switch of the grinding motor, check the correct direction of the grinding
wheel.
4.1.5 After pushing down the “emergency button”, the equipment stops.
4.1.6 Turn off the switches of the driving motor and the grinding motor. Reset the
“emergency button”. Turn off the power.
4.2.2 Remove the complete assembly of grinding wheel and grinding wheel hub by pulling it
from the grinding motor shaft by the screw tool in the spare and tool box.
4.2.3 Split the grinding wheel hub into two halves using pin spanners from the spare and tool
box. The grinding wheel hub is left hand threaded.
4.2.4 Fix the new grinding wheel and tighten the hub using the two pin spanners. Make sure
that it is fixed tightly and check the new grinding wheel before replacing, no crack and
damage is allowed.
Danger!
The wheel and the
wheel subassembly
must be fixed tightly.
Figure 5
21
4.3 Dressing of grinding wheel (figure 6)
A new grinding wheel should be dressed until concentric before balancing.
4.3.1 Remove the balancing weights, fix the wheel subassembly on the shaft of the grinding
motor.
4.3.2 Get the dresser out of the spare box and set the dressing bracket. Adjust the diamond
cutting point and tighten the lock nut. Each cut should be 0.1mm in maximum (1/8 turn
of the screw).
4.3.3let the grinding motor run. Dress the wheel until concentric by slowly moving the
grinding wheel back and forth over the diamond cutting point.
Figure 6
Warning!
Be care of the dust while dressing!
Be care of the high speed wheel!
4.4.1 Get the wheel balancer out of the spare box. Remove the balancing weights firstly, and
mount the grinding wheel on the shaft of the balancer.
4.4.2 Let the wheel swing back and forth until it stays with its heaviest point downward.
Then mark this point with a marking pen.
4.4.4 Adjust weights symmetrically up or downward until the wheel stay put when placed in
any angular position. The grinding wheel is now balanced.
4.4.5 Vibrations and poor cutting performance could be caused either by a grinding wheel
clogged with dirt and residue, or by an unbalanced grinding wheel. Truing and
balancing should therefore be done regularly.
22
Emery wheel balancer
Figure 7
Caution!
Vibrations and bad grinding result may be these reasons
such as dust, dirty or unbalanced wheel!
Check the wheel subassembly regularly!
4.5 Adjusting of grinding wheel cover
The gap location of the grinding wheel cover is adjusted according to the valve or valve seat. While
grinding the valve, the gap is upward. On the other hand, while grinding the valve seat , the gap is
downward.
23
Figure 8
Figure 9
24
Figure 10
5 VALVE GRINDING
5.1.1 Before commencing work, check the valve spindle according to the instruction from the
engine manufacturer, such as coaxial degree, cylindrical degree ect. .
5.1.2 Check the valve spindle such as related grinding surface, inspecting surface.
5.1.3 Lower the valve stem slowly into the hole in the machine. Make the centering
subassembly to center the valve by using a regulating bar in the spare box.
5.1.4 Adjust the stabilizing bolts evenly against the valve stem and tighten slightly and
equally by hand, preventing the valve from vibration while grinding.
5.1.5 Check the dial gauge on the surface of valve spindle, insure the spindle center’s
deviation is less than 0.02 by adjusting the stabilizing bolts slightly. (See figure 11)
Figure 11
25
5.2 Grinding head position
Adjust the gap of the wheel cap upward according to item 4.5. And turn the grinding head to the angle
position required in the instruction from the engine manufacturer according to the item 4.6.
valve surface. Use the feeding wheel to guide the grinding wheel
3) A division responds cutting depth of 0.01mm, Feed upwards 3~6 divisions, about 0.03~0.06mm..
The cutting depth in prophase is more than in anaphase (figure13). Check the clearance between the slide
guide and the slider block after feeding.
figure13
4) Open the electrical power, start the driving motor on the controlling panel, and the turntable
should turn clockwise at the speed of about 10 rpm.
5) Start the grinding motor, the switch directs the “valve” on the panel of the controlling box, the
direction of the revolution should be anticlockwise.
6) Feed slowly with the hand wheel in the grinding route subassembly, approximately 1/8 turn per
round of the valve.
Clear the wheel before fine grinding. Feed upwards about depth 0.01mm, grind the valve surface
finely until the required surface finish. After grinding, clean the valve and shut off the power.
Warning!
Caution the dust during operation!
Do not touch the high speed wheel!
26
6 VALVE SEAT GRINDING
6.1.1 Before commencing work, check the valve seat according to the instruction from the
engine manufacturer, such as related grinding surface, inspecting surface.
6.1.2 Check these orientation pins on the turntable, be sure the serial number is accordant.
6.1.3 The gap on every pin is toward to the axis of the main body assembly. Put the valve
seat onto the top of these pins.
6.1.4 Turn around the pins with a Regulating bar in the spare box, make the marks both on
the pins and turntable accordant with each other.
6.1.5 Check the dial gauge on the surface of valve seat, insure the seat center’s deviation is
less than 0.03 by adjusting these pins slightly.( See figure 14)
Figure 14
6.2 Grinding head position
Adjust the gap of the wheel cap downward according to item 4.5. And turn the grinding head to the
angle position required in the instruction from the engine manufacturer according to the item 4.6. The
angle dial should be at the position “0”.
seat surface. Use the feeding wheel to guide the grinding wheel
3) A division responds cutting depth of 0.01mm, Feed upwards 3~6 divisions, about 0.03~0.06mm..
27
The cutting depth in prophase is more than in anaphase (figure16). Check the clearance between the slide
guide and the slider block after feeding.
figure16
4) Open the electrical power, start the driving motor and the turntable should turn clockwise at the
speed of about 10 rpm.
5) Start the grinding motor, the switch directs the “valve seat” on the panel of the controlling box,
the direction of the revolution should be clockwise.
6) Feed slowly with the hand wheel in the grinding route subassembly, approximately 1/8turn per
round of the valve.
Clear the wheel before fine grinding. Feed upwards about depth 0.01mm, grind the valve surface
finely until the required surface finish. After grinding, clean the valve seat and shut off the power.
Warning!
Caution the dust during operation!
Do not touch the high speed wheel!
7 MAINTENANCE
Check the following regularly in order to ensure a good grinding result and a safe operation:
28
8 TROUBLE SHOOTING
9.2 Regulating bar:used for turning the orientation pins or the centering subassembly for
valve
9.6 Tool for didmantling grinding wheel:1 pieces,used for taking-down the grinding wheel
from grinder.
9.7 Damping pad:installed for preventing the vibration on the foots of the machine .
29
附录 1 APPENDIX 1:DM-3 电控箱电路图 Electric diagram of DM-3 control box
30
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独立液压顶推支撑装置
认可资料
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目 录
INDEX
1、简介 Introduction ............................................................................................................ 3
2、安全 Safety .................................................................................................................... 4
3、技术参数 Technical description ...................................................................................... 5
4、系统组成 System parts ................................................................................................... 6
4.1 液压顶推支撑单元 Hydraulic top bracing unit .................................................. 6
4.2 运输用起吊工具 Lifting tools for transport. ....................................................... 6
4.3 正确定位安装法兰的安装工具 Fitting tool for correct positioning of mounting
flanges. .................................................................................................................. 7
4.4 电气控制箱 Electric control box. ...................................................................... 7
4.5 液压手摇泵 Hydraulic hand pump.................................................................... 7
4.6 其他工具及备品 Other spare parts & tools ....................................................... 7
5、工作原理 Working principle ........................................................................................... 8
6、控制系统 Control system............................................................................................... 9
7、操作 Operation ............................................................................................................. 11
8、安装 Installation ............................................................................................................ 12
8.1 准备 Preparation ........................................................................................... 12
8.2 安装法兰的安装 Installation of mounting flanges ........................................... 13
8.3 液压顶推支撑液压缸的安装 Installation of top bracing cylinders .................... 16
8.4 液压控制单元包括蓄能器的安装 Installation of hydraulic unit including oil
accumulator ......................................................................................................... 17
8.5 电气控制系统的安装 Installation of electric control system ............................ 18
8.6 液压顶推支撑的充油、补油及调整 Filling, refilling and adjustment of top bracing
............................................................................................................................ 18
9、服务和维护 service and maintenance .......................................................................... 20
9.1 备件 spare parts ............................................................................................ 20
9.2 服务检查 service inspection .......................................................................... 20
9.3 油压的控制 control of oil pressure ................................................................. 20
9.4 调节绿色位置带 Adjusting green position band ............................................. 21
9.5 推力杆不重合度 Distance rod alignment ........................................................ 21
9.6 更换密封件 Replacing sealing rings............................................................... 22
9.7 更换蓄能器 Replacing oil accumulator........................................................... 23
10、故障分析 Trouble shooting ........................................................................................ 25
11、图纸 Drawings ............................................................................................................ 26
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1、简介 Introduction
独立式主机液压顶支撑装置(以下简称液压顶推支撑)是安装在主机和船体结构之间(参
照液压顶推支撑布置图 HCHT26(40)-01),用来防止船体与主机之间产生共振,从而降低主
机振动所产生的影响一种减振装置。液压顶支撑使主机和船体之间由于主机热膨胀以及船舶
不同装载所产生的变形是柔性的。
Hydraulic top bracing stand-alone type of M/E(shortened form:Hydraulic top bracing)
are installed between the engine and the hull (refer to the arrangement diagram :
HCHT26(40 )-01 ), to detune the natural frequencies of the engine and thus lower the
impact of the vibrations. The hydraulic top bracing units are flexible to thermal expansion
of the engine and various loading conditions of the vessel.
标准安装方式是安装在主机的右侧;如果更方便的话,也可以安装在主机左侧,一般只
需安装在一侧即可。
The standard installation is on the starboard side of the engine, but port side
installation can alternatively be used if this is more convenient. Installation is only
necessary on one side.
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2、安全 Safety
液压顶推支撑的设计原理是通过液体产生压力来提供较大的机械力。工作过程处于高压
和较大机械作用的环境,一旦失去控制,就会对操作者和设备造成伤害和损失。因此,为了
安全起见,在使用设备之前必须彻底的了解设备是如何操作和控制的。
Hydraulic equipment is designed to accomplish work using liquid pressure to produce
a greater mechanical force. The operator is subject to hazards from high-pressure liquids
and large mechanical forces. Either of these forces, when out of control, have the
potential to cause enormous damage and great bodily injury. All safety devices should be
controlled and the operator should have a thorough knowledge of how the equipment
operates before the equipment is used
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液压顶推支撑外形尺寸参照图:HCHT26(40)-02
Outline dimensions please refer to diagram of hydraulic top bracing:HCHT26(40)-02
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液压顶推支撑系统主要由以下几部分组成:
The parts of the hydraulic top bracing system, shown on the following pages, are:
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mounting flanges.
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每套液压顶推支撑系统单元主要由一套液压缸单元和安装在液压缸本体上带有液压蓄
能器的液压控制单元组成。
Each top bracing unit consists of a single acting hydraulic cylinder and a hydraulic
control unit including an oil accumulator mounted directly on the cylinder house.
当主机运行时,顶推单元建立起压力,来降低主机的振动强度。当主机停车时,压力释
放至初始压力 7bar。
When the engine is running, the unit builds up a pressure on the engine in proportion
to the vibration lever. When the engine is at standstill, the pressure is released to the
nominal pressure, 7 bar.
当船体与主机之间距离变大时,液压缸液压 当船体与主机之间距离变小时,液压缸油压
油压下降,液压油从蓄能器流向液压缸。 力上升,单向阀阻止液压油进入蓄能器,如
When the distance between hull an engine 果压力达到最大设定值,此时安全阀打开,
increase, oil flows into the cylinder under 将油引至蓄能器,将主机震动控制在允许范
pressure from the oil accumulator. 围内。
When the distance between hull an engine
decreases, a non-return valve prevents
the oil form flowing back to the
accumulator and the pressure on the
engine rises, of the pressure reaches the
preset maximum value, the relief valve
allows the oil to flow back to the
accumulator, maintaining the force on the
engine and hull structure below the
specified level.
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当液压活塞处于正冲程,即主机与船体之间距离变大时,液压油从蓄能器通过单向阀流
向液压缸,当液压活塞处于负冲程,由于有单向阀作用,液压油缸内油压升高,阀块上的安
全阀将会打开,一般情况下,当主机缸径不大于 600mm 时,安全阀在 26bar 压力时打开,
当主机缸径大于 600mm 时,安全阀在 40bar 压力时打开,将油引至液压蓄能器,使得活
塞可以继续运动。在安全阀的低压侧,阀块上有一个 25bar 打开的安全阀。
During positive stroke of the hydraulic piston-when the distance between hull side
and engine side increases oil flows from the accumulator through the non-return valve to
the cylinder. On negative stroke, the piston provides a rising pressure in the cylinder due
to the non-return valve. A relief valve in the valve block opens at 26 bar, for engines with
bore≤600mm,or 40bar, for engines with bore >600mmand leads the oil back to the
accumulator, and thereby allows the piston to move in negative direction. On the
low-pressure side, a safety relief in the valve block opens at 25 bar.
通过电磁换向阀,可以释放液压缸内的压力。电磁阀打开时,液压缸与蓄能器直接相连,
此时液压缸单元不能建立压力。一般来说,当主机运行时,电磁阀断开;主机停止时,电磁
阀导通。
By means of a solenoid valve in a parallel pipe branch the pressure of the system can
be released. When the valve is open, the workspace is directly connected to the
accumulator and the top bracing cannot build up the pressure. Practically, the valve is
open when the engine is at standstill and closed when the engine is running.
液压顶推支撑系统单元原理图如下:
The hydraulic top bracing system unit working principle is as followed;
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7、操作 Operation
液压顶推支撑是自动运行的。但在测试和运行情况,也可以选择手动控制模式。运行模
式可以通过电气控制箱上选择开关进行选择,共有如下三种模式:
The hydraulic top bracing system is operated automatically. For test or service
purposes, manual control is also possible. The operation mode is selected at the control
panel, the three possible operation modes are:
1)自动:液压顶推支撑是通过“备车”和“完车”的车钟信号来自动控制的,这也是常规模式。
根据主机状态,液压顶推支撑将处于“运行”或“停止”,控制灯可以显示实际的运行情况。
AUTO: The top bracing system is controlled automatically by the engine telegraph order
“stand by” and “finish with engine”. This is the normal operation mode Depending on the
engine status; the top bracing will be “INSERVICE” or “OUT OF SERVICE”. The control
lamps indicate the actual state.
2)运行:液压顶推支撑系统处于运行状态且一直建有压力。此模式下电磁阀处于关闭状态,
当主机运行,系统建立压力。此模式仅仅用于调试或信号失灵的情况下。
IN SERVICE:The top bracing system is permanently active and pressurized. The
solenoid valve closes the pertaining pip branch and the top bracing cylinders builds up a
pressure when the engine is running. This mode should only be used in testing or by
failure in the control signal.
3)停止:液压顶推支撑处于停止状态,电磁阀导通,此时系统压力释放,大约维持在 7bar,
为了安全考虑,此模式仅仅运用于液压顶推支撑需要维修的时候。
OUT OF SERVICE :The top bracing system is not active. The solenoid valves are open
and the system pressure is released to approximately 7 bar. Due to safety precaution, this
mode should always be used when servicing the top bracing
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8、安装 Installation
液压顶推支撑正常工作的前提就是液压缸单元安装点的刚性要满足要求,如果不符合,
结构就必须给予加强。液压顶推支撑正确的正确安装包括:确定安装长度,以及两平行法兰
的平行度,其安装标准如下:
The top bracing will only work correctly if the supporting hull structure is sufficiently
rigid. When this is not the case, the structure should be sufficiently reinforced. It is
important that the top bracing be installed with correct build-in length and with parallel
flanges without misalignment.
顶撑的安装长度及两侧法兰的平行度,对顶撑的正常工作非常重要。要求:
安装长度公差:475+1/+3mm(参照 8.1.3),
安装平行度:≤1°(参照 8.1.3);
It is important that the top bracing be installed with correct build-in length and with
parallel flanges without misalignment. The parameters for the installation are:
Installation tolerance:493+1/+3mm(refer to 8.1.3);
Installation parallelism ≤1°(refer to 8.1.3)。
运行不重合度
Service misalignment
建议在主机工作一段时间后,在主机处于热态情况下对安装长度进行调整。
We recommend a re-adjustment of the top bracing cylinders shortly after installation,
at normal loading condition of the vessel and with warm engine.
8.1 准备 Preparation
8.1.1 检查所有零部件是否齐全和完好。
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8.1.2 检查液压顶推支撑安装点及其对应的船体侧结构或支撑在水平线上,并确保结构具有
液压缸单元安装所必须的刚性和强度。
Check at all top bracing positions that the hull side supporting structure is in line with a
cross girder or supported otherwise to insure necessary strength and rigidity of the
installation.
8.1.3 检查主机侧安装点的平面是否垂直于连接线,并检查安装点与船体侧结构之间的距离。
Check that the face of the engine fix point is cut perpendicular to the connection line.
Control the distance between the fix points.
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8.2.3 测量主机安装点与船体结构之间的距离和法兰不平行度。
Measure the gap and inclination between the hull fix point and the large mounting flange.
See the sketch below.
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8.2.3.1 如果安装长度不够,可通过对船体结构进行修整使之达到安装长度要求。
If the build-in length is too short for the tool to fit, extend the length by cutting or grinding
the hull fix point-alternatively the engine fix point.
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8.2.4 安装长度和平行度符合要求
Build-in length correct, parallelism correct
8.2.4.2 将焊接法兰点焊在船体安装点处。
Tack welds the flange to the hull fix point.
8.2.4.3 移除安装工具,完成焊接工作,为了减小变形,焊接时,应尽可能远离热源。
Remove the fitting tool and complete the welding job in order to minimize deformations. It
is recommended to apply as little heat as possible.
8.3.4 拆除靠近主机侧起吊工具上的螺栓,确保零件不散架。
Remove the bolt nearest to the engine fix point, making sure that the parts do not fall
apart.
8.3.5 为确保推力杆在水平和垂直方向成一条线,拧紧主机侧安装点的螺栓时可能需要松开
船体侧部分的螺栓做最后修正,最后拧紧所有八颗紧固螺栓(扭矩:200Nm)。
Tighten the bolts at the engine fix point making sure the distance rod is aligned in both
horizontal and vertical direction. It might be necessary to loosen the bolts at the hull part
for a final correction. Finally tighten all eight installation bolts (200Nm).
8.3.6 拆除起吊工具
Remove the transport brackets.
accumulator
8.4.1 确保液压控制单元的安装底座和安装表面都是干净并清洁的,液压控制单元和蓄能器
是整体起吊。
Ensure that the mounting base of the hydraulic unit and the mounting surface of the
hydraulic unit are clean and in good condition. The hydraulic unit and the oil accumulator
are delivered as one unit.
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Mount the hydraulic unit on the mounting base of the cylinder unit, Mount with 2×M12×50
and tighten the bolts(50Nm)
bracing
8.6.1 确保电气接线正确,且压力传感器及电磁阀已经连接到电气控制箱,且通电。
Check the electric line, make sure that it is correct, and the pressure transmitter and the
solenoid valve is connected to the electric control box,and power on.
8.6.2 将控制开关置于“停止”位置,此时电磁换向阀导通,工作压力释放至最小工作载荷。
Set the control switch ‘OUT OF SERVICE’. The solenoid valve is now open and the
hydraulic pressure is released to the minimum workload.
8.6.3.1 将空气排放软管与液压控制单元高处的测压接头相连,且将手摇泵软管与液压缸低
处的快速接头相连。
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Connect the air bleeding hose to the highest mounted minimizes coupling and the hose
from the hydraulic hand pump unit to the lowest mounted minimizes coupling.
8.6.3.2 打开空气排放软管上的阀,以便可以排出液压缸单元内的空气。
Open the valve on the air bleeding hose and bleed the top bracing system.
8.6.3.3 取下锁紧片,调节锁紧螺母,或利用手摇泵向液压缸单元内充油,直到推力杆上的
绿色位置带与缸体的边缘持平。
Unlock the locking patch, adjust the nut or pump oil into the top bracing system using the
hydraulic hand pump, that the green position band on the pressure rod is leveled with the
edge of the cylinder house.
8.6.3.4 紧固锁紧片。
Lock the locking patch.
8.6.3.5 确保排放软管上的球阀已打开,利用手摇泵向液压顶推支撑系统充油,
Make sure the ball valve on the bleeding hose is open. Filling the top bracing system
using the hydraulic hand pump.
8.6.3.6 持续充油,直到液压顶推支撑系统里所有的空气通过排放软管排出,当所有的空气
排出后,拆下排放软管并关闭阀。
Continue filling oil until all air has escaped from top bracing system through the bleeding
hose. When all air has escaped, disconnect the bleeding hose and close the valve.
8.6.3.8 拆开软管并检查推力杆上绿色位置带与缸体边缘持平。
Disconnect the hose and check that the green position band on the pressure rod is
leveled with the edge of the cylinder house.
8.6.3.9 安装并锁紧位于液压控制单元上测压接头盖子。
Mount and tighten the lid on the minimizes coupling located in the hydraulic control unit.
8.6.3.10 对其他液压顶推支撑液压缸单元重复以上顺序。
Repeat the procedure for the remaining hydraulic top bracing cylinders unit.
8.6.3.11 将电气控制箱上控制开关置于在“自动”位置上,液压顶推支撑系统准备就绪。
Set control switch in ‘AUTO’ position of the electric control box,the hydraulic top bracing
system is now ready.
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所有的备件必须按照所提供的图纸清点完毕,与单个活塞配套的一整套的密封圈和导向
环都在包含在标准交付里。
All spare parts should be ordered with reference to the supplying drawings. A set of
sealing rings and guide rings for one piston is included in the standard delivery.
9.2.1 每台液压顶推支撑单元应该在试航后进行检查,且从此以后必须进行定期检查。
Inspection of each top bracing unit should be carried out after sea-trial and
regularly of service hereafter.
9.4.1 推力杆上的绿色带正常情况下应该与缸体边缘持平。同时考虑到船体在各种负载条件
下会导致液压活塞偏出原始调整,在绿色和红色带之间的位置是可行的。然而,值得注意的
是液压顶推支撑不允许在处在红色带区域的情况下运行。
The green band on the distance rod should normally be in level with the edge of the
cylinder house. A position between the green and the red band may be acceptable,
having in mind that various loading conditions of the vessel will cause the hydraulic piston
to shift away from the original adjustment. However, it is important to note that the top
bracing shall never operate on the red band area.
建议在主机工作一段时间后,在主机处于热态情况下对安装长度机型调整。
We recommend a re-adjustment of the top bracing cylinders shortly after installation, at
normal loading condition of the vessel and with warm engine.
9.5.1 船体在各种负载条件下会导致船体侧和发动机侧产生位移。如果推力杆不重合度超过
10mm,顶推支撑应该被重新校准。校准应该在正常荷载和发动机启动的情况下进行。
Various loading conditions of the vessel may result in displacements between the hull side
and the engine side. If a misalignment of the distance rod exceeds 10mm , the top bracing
should be re-aligned. The alignment should be performed at normal loading condition and
with warm engine.
9.5.2 将电气控制箱上控制开关置于“停止”位置,电磁阀打开且系统压力被释放至最小工作
荷载 7bar,这个读数显示在压力表上。
Set the control switch ‘OUT OF SERVICE’. The solenoid valve is now open and the
pressure of the system is released to the minimum workload, 7bar, indicated on the
pressure gauge.
9.5.3 将空气排放软管与安装在最高处的测压接头连接,并将手摇泵的软管与安装在最低处
的接头连接。
Connect the air bleeding hose to the highest mounted minimizes coupling and the hose
from the hand pump unit to the lowest mounted minimizes coupling.
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9.5.6 按照 8.6.3.3 继续
Continue from 8.6.3.3.
9.6.2 打开手摇泵上的溢流阀,并将手摇泵软管与安装在最低处的接头连接,打开最低接头
处的截止阀卸去系统中的压力。
Open the overflow valve on the hand pump, connect the hand pump hose to the lowest
mounted minimizes coupling. Insure that the ball valve is pointing down in an oil can.
Open the ball valve to take off the pressure of the system.
9.6.3 拆下安装在最高处的测压接头并使系统中的油通过排放软管流出,断开电气控制,并
拆下液压控制单元,小心移除。
Remove the highest mounted minimizes coupling and let the oil in the system run out
through the bleeding hose. Disconnect the electric control system and dismount the
hydraulic control unit. Carefully lift the unit away.
9.6.4 安装两个运输用起吊工具
Mount the two lifting tools for transport.
9.6.6 移走液压缸单元并将缸体安装面朝下放置在一个干净的表面上。
Lift the top bracing unit and place it on a clean surface with the mounting face of the
cylinder house downwards.
9.6.7 拆下运输用起吊工具并小心移走发动机侧部件(法兰、推力杆及调节螺母)。
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Dismount the lifting tools for transport and carefully lift away the engine side parts (flange,
distance rod and adjusting nut).
9.6.8 移除橡皮保护罩和船侧的挡圈并移走推力杆。
Remove the rubber protect cover and the retaining rings at the hull side and lift away the
distance rod.
9.6.10 提出活塞并将其放在干净的表面上。
Lift the piston away and land it on a clean surface.
9.6.11 更换所有的导向环和密封圈。
All guide rings and sealing rings are should be replaced.
9.6.12 使用润滑油润滑球付的接触面,按拆卸的相反顺序进行组装。
Grease the contact surface of the spherical using molykote,assemble it according to the
opposition step of disassembly .
9.7.2 将电气控制箱上控制开关置于“停止”位置,电磁阀被打开且系统压力被释放至压力
表上显示的压力。
Set the control switch ‘OUT OF SERVICE’. The solenoid valve is now open and the
pressure of the system is released to the pressure shown on the pressure gauge.
9.7.3 打开手摇泵上的溢流阀,并将手摇泵软管与安装在最低处的接头连接,打开最低接头
处的截止阀卸去系统中的压力。
Open the overflow valve on the hand pump, connect the hand pump hose to the lowest
mounted minimizes coupling. Insure that the ball valve is pointing down in an oil can.
Open the ball valve to take off the pressure of the system.
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9.7.11 关闭阀 B
Close valve B.
9.7.12 等待 5 分钟让温度稳定下来。
Wait five minutes for the temperature to stabilize.
9.7.16 连接电气部分。
Connect the electric control system.
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11、图纸 Drawings
图号 名称
Drawing No. Title
液压顶推支撑布置图
HCHT26(40)-01
The arrangement diagram of hydraulic top bracing
液压顶推支撑外形尺寸图
HCHT26(40)-02
Outline dimensions diagram of hydraulic top bracing
液压顶推支撑焊接座板图
HCHT26(40)-02-01
Welding plate of hydraulic top bracing
液压顶推支撑系统图
HCHT26(40)-03
Hydraulic top bracing system diagram
电气控制箱外形图
HCHT26(40)-04
Electric control box outline diagram
电气控制箱原理图及外部接线图
HCHT26(40)-05
Electric wiring and connection diagram
压力传感器接线图
HCHT26(40)-05-01
Pressure transmitter wiring diagram
供货范围
HCHT26(40)-06
Scope of supply
工具清单
HCHT26(40)-07
Stool list
备件清单
HCHT26(40)-08
Spare parts list
液压手动泵
HCHT26(40)-09
Hydraulic hand pump
充气工具使用说明
HCHT26(40)-CQSM
Explanation of charge tool’s use
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User’s manual
User’s Manual
MMT330 Water in Oil Sensor
User’s manual for the MMT330 Water in Oil Sensor
P-MMT330/FE Rev. C 1
Water in Oil Sensor MMT330
Revisions
Document history
The information contained in this document is subject to change without prior notice.
Kongsberg Maritime AS shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or use of this
document.
© 2008 Kongsberg Maritime AS. All rights reserved. No part of this work covered by
the copyright hereon may be reproduced or otherwise copied without prior permission
from Kongsberg Maritime AS.
Kongsberg Maritime AS
NO-7005 Trondheim Telephone: +47 73 58 10 00
Norway Telefax: +47 73 58 10 01
www.kongsberg.com
E-mail: km.sales@kongsberg.com
2 P-MMT330/FE Rev. C
User’s manual
Table of contents
2 WARNING................................................................................................................ 6
4 INSTALLATION ................................................................................................... 14
4.1 Mounting the housing ...........................................................................................14
4.1.1 Standard mounting.................................................................................... 14
4.2 Wiring ...................................................................................................................14
4.3 Signal and power wiring for standard sensor .......................................................15
4.3.1 Procedure .................................................................................................. 15
4.4 Signal and power wiring for CAN based sensor ..................................................16
4.4.1 Procedure .................................................................................................. 16
4.5 Installing the sensor probe .................................................................................... 17
4.6 Ball valve installation ...........................................................................................18
4.6.1 Procedure for new installation .................................................................. 18
4.7 Installing probe without ball valve .......................................................................19
4.7.1 Procedure for new installation .................................................................. 19
4.8 Tightening the clasp nut .......................................................................................20
4.9 Alarm settings .......................................................................................................21
4.10 Water activity vs ppm, alarm limits...................................................................... 21
P-MMT330/FE Rev. C 3
Water in Oil Sensor MMT330
5 OPERATION.......................................................................................................... 22
5.1 General considerations .........................................................................................22
5.2 Using display / keypad (optional).........................................................................22
5.2.1 Basic display ............................................................................................. 22
5.2.2 Graphic history ......................................................................................... 23
5.2.3 Menus and navigation............................................................................... 25
5.3 Error states (for display option) ............................................................................ 29
8 APPENDIX ............................................................................................................. 35
8.1 MMT330 on MAN D&T 2-stroke engines...........................................................35
4 P-MMT330/FE Rev. C
User’s manual
1 GENERAL INFORMATION
This chapter provides general notes for the manual and the
product.
P-MMT330/FE Rev. C 5
Water in Oil Sensor MMT330
2 WARNING
Warning The equipment to which this manual applies must
only be used for the purpose it was designed.
Improper use or maintenance may cause damage
to the equipment and/or injury to personnel. The
user must be familiar with the content of the
appropriate manuals before attempting to work
or operate on the equipment.
6 P-MMT330/FE Rev. C
User’s manual
3 PRODUCT OVERVIEW
This chapter introduces the features, advantages, and the product
terminology of the HUMICAP® Water in Oil Sensor MMT330.
P-MMT330/FE Rev. C 7
Water in Oil Sensor MMT330
8 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 9
Water in Oil Sensor MMT330
0510-028
10 P-MMT330/FE Rev. C
User’s manual
3.5 Wiring
3.5.1 Cable bushings
A single electrical cable with screen and three to ten wires is
recommended for power and analogue/serial connections. The
cable diameter should be 8 to11 mm. The number of cable
bushings depends on the transmitter options. See the following
recommendations for the cable bushings:
0503-010
P-MMT330/FE Rev. C 11
Water in Oil Sensor MMT330
Dwg. 1
Dwg. 2
12 P-MMT330/FE Rev. C
User’s manual
3 Put the domed cap nut (item 1) and seal insert with contact
socket of the gland (item 2 and 3) onto the cable as shown
in the drawing.
4 Bend over the screen braiding or screen foil by about 90 ˚
(item 4).
5 Push the seal insert with the contact socket of the gland
(item 2 and 3) up the screen braiding or screen foil.
6 Mount lower part (item 5) on the housing.
7 Push the seal with the contact socket of the gland and
(item 2 and 3) flush into the lower part (item 5).
8 Fasten the domed cap nut (item 1) onto the lower part
(item 5).
P-MMT330/FE Rev. C 13
Water in Oil Sensor MMT330
4 INSTALLATION
This chapter provides you with information that is intended to
help you install the product.
0510-026
4.2 Wiring
A single electrical cable with a single screened cable with more
than three wires is recommended for power and analogue/serial
connections. The outside cable diameter should be 8 to 11 mm.
The number of cable bushings depends on the sensor options.
Note In case of high electric noise levels (for example, near a
powerful electric motor) in the operating environment, it is
recommended to make use of a shielded cable or keep the signal
cables in safe distance from other cables.
14 P-MMT330/FE Rev. C
User’s manual
R1/2" ISO7/1
Ch1+
For cable: Ø8-11 Ch1- 4 -20mA, temperature
To AMS Ch2+ Water activity (aw)
Ø13.5
Ch2- Water activity (aw)
Ø12
14
54 154
(Adjustment range)
5000 252
Notes:
1. DIP switch inside the transmitter is set according to
specification and shall NOT be changed.
2. The two WIO sensors 4-20 mA outputs are powered
internally in the sensor. Therefore "External Source" /
passive connection is to be used on AMS.
4.3.1 Procedure
Open the sensor cover by removing the four cover screws.
Insert the power supply wires and signal wires through the cable
bushing in the bottom of the sensor; see the grounding
instructions in the previous sections.
Connect the analogue output cables to the terminals:
Ch1 +, Ch1-, Ch2+, Ch2-. The two analogue -4 to 20 mA
outputs are powered from the sensor, and should be connected to
passive inputs on the automation system (AMS).
Connect the power supply wires to the connectors:
POWER 10...35V+ 24V~ (+) and (-) terminals.
Turn on the power. The indicator led on the cover is lit
continuously during normal operation.
Close the cover and tighten the cover screws. The sensor is
ready for use.
P-MMT330/FE Rev. C 15
Water in Oil Sensor MMT330
4.4.1 Procedure
Open the sensor cover by removing the four cover screws.
Insert the power supply wires and signal wires through the cable
bushing in the bottom of the sensor; see the grounding
instructions in the previous sections.
Connect CAN and Power terminals on terminal B.
Turn on the power. The indicator led on the cover is lit
continuously during normal operation.
Close the cover and tighten the cover screws. The sensor is
ready for use.
16 P-MMT330/FE Rev. C
User’s manual
45°
(ran
ge)
Recommended mounting
15
2
ISO228-G3/4
27
5
55
ISO228-G3/4
min. 36
min. 36
1
P-MMT330/FE Rev. C 17
Water in Oil Sensor MMT330
18 P-MMT330/FE Rev. C
User’s manual
Note If you push the probe too hard without using the handle, you
may damage the cable.
P-MMT330/FE Rev. C 19
Water in Oil Sensor MMT330
0505-276
20 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 21
Water in Oil Sensor MMT330
5 OPERATION
Note If the sensor shows high water activity and the sensor for test is
put into a container with new still oil, it may take up to 10
minutes for the sensor to stabilize and show correct water
content.
22 P-MMT330/FE Rev. C
User’s manual
0706-046
Figure 12. Basic display
P-MMT330/FE Rev. C 23
Water in Oil Sensor MMT330
24 P-MMT330/FE Rev. C
User’s manual
The time displayed below the graph is adjusted with the current
time offset of the transmitter. If you change the transmitter's date
and time settings, the displayed timestamps in the history graph
changes accordingly.
Message Interpretation
Power outage Power failure (also marked with a dashed,
vertical line)
No data Quantity has not been selected for the display
Device failure General device failure
T meas. failure Temperature measurement/sensor failure
RH meas. failure Moisture measurement/sensor failure
Adj. mode active Adjustment mode active (data recorded in the
adjustment mode are not displayed)
A question mark after the time tells you that at least one power
failure (a dashed vertical line) has occurred after the chosen
moment. In this case, the exact time difference between the
present and the cursor position is not exactly known.
P-MMT330/FE Rev. C 25
Water in Oil Sensor MMT330
0706-208, 0706-048
Figure 15. Main menus
Some menu items, such as Date and time in the System menu,
are only shown if supported by the transmitter and the installed
options.
26 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 27
Water in Oil Sensor MMT330
28 P-MMT330/FE Rev. C
User’s manual
Note The transmitter automatically overwrites the old data when the
memory is full, so manual deletion of the recorded files is not
necessary in normal use.
To delete the data files using the keypad/display:
1 Press any of the arrow buttons to open the MAIN MENU.
2 Select System by pressing the ► arrow button.
3 Select Clear graph memories by pressing the CLEAR
button. Press the YES button to confirm the selection.
Caution This function clears the entire data history of the
transmitter, including all graphs and the content of the
optional datalogger module.
5.2.3.9 Undelete
Similarly to the DELETE command, the UNDELETE
command is used without any arguments. It will recover all
deleted data that has not yet been overwritten.
P-MMT330/FE Rev. C 29
Water in Oil Sensor MMT330
30 P-MMT330/FE Rev. C
User’s manual
6.1 Calibration
Normally the sensor shall not be calibrated or adjusted.
6.2.1 Cleaning
Clean the sensor enclosure by use of a soft, lint-free cloth
moistened with mild detergent.
Clean the sensor before storing the MMT330 probe and before
calibration. For cleaning the probe you need instrument air and
heptane (C7H16) liquid. Use instrument air for drying to prevent
oxidation of the oil on the sensor. The oxidation of the oil on the
sensor can cause extended response time or drifting.
1 Blow the probe with instrument air (with filter attached) to
remove any remains of the oil.
2 Immerse the probe into heptane liquid and rinse out the oil
(for 1 minute maximum).
3 Dry the probe by use of instrument air. In case you are
going to calibrate the probe, remove the filter and dry the
sensor with instrument air. Check that the sensor is clean.
P-MMT330/FE Rev. C 31
Water in Oil Sensor MMT330
32 P-MMT330/FE Rev. C
User’s manual
6.5 Test
6.5.1 Test of sensor alarm
To verify that the sensor is able to give alarm if the procedure is
as follows:
1. Connect the sensor to the system via the 4-20 mA outputs.
Set the alarm limits in the system.
(awHigh = 0.50, awHigh High = 0.90)
2. Disconnect the sensor tip from the oil tube.
3. Put the sensor tip into a can of clean water.
4. Wait until alarm is given on the system (may take up to 3
minutes)
5. Put the sensor tip back in place.
Note! After the sensor tip has been exposed to water, it may take
several minutes before the sensor output signal is back to normal
reading, up to 5 minutes in oil, 30 minutes or more if the sensor
is left in free air.
P-MMT330/FE Rev. C 33
Water in Oil Sensor MMT330
7 TECHNICAL SUPPORT
For technical questions, contact the KONGSBERG technical
support:
E-mail km.support@kongsberg.com
Phone 24 hours +47 815 35 355
NOTE Make sure that the unit is returned in one piece. Probe
with cable is part of the instrument and can NOT be cut,
shortened or disconnected from the electronics. Such
actions will make the unit irrepairable. It is also woid the
warranty.
34 P-MMT330/FE Rev. C
User’s manual
8 APPENDIX
P-MMT330/FE Rev. C 35
Water in Oil Sensor MMT330
Cleaning:
The MMT330 sensor probe should be cleaned
36 P-MMT330/FE Rev. C
User’s manual
a. Dismount the sensor probe. Clean and dry the probe, then leave
it in open air close to a calibrated Hygrometer. Compare the
readings. The aw value is equivalent to the relative humidity of
the air. E.g. If relative humidity of the air is 40% the aw reading
should be 0.4.
Calibration
When found inaccurate the WIO sensor is in need of calibration.
There are three lternatives:
1. Vessel to keep spare sensor onboard for rotation. (return to
maker for calibration)
2. Owner to keep spare sensor for rotation. (return to maker for
calibration)
3. On-site calibration (use calibration tool)
http://www.vaisala.com/
aw = p / p0 (0..1) where
P-MMT330/FE Rev. C 37
Water in Oil Sensor MMT330
NOTE 1: The oils ability to dissolve water changes with the age
and quality of the oil. Pollution will also change this. The
relation between water activity and absolute water content
(ppm) is therefore under constant change. A ppm. conversion
(from aw) require frequent calibrations against oil
properties/quality while the water activity measurement remains
reliable regardless of this. I.e. Regardless of the saturation point
of the fluid the aw reading will always provide a true indication
of risk of free water formation.
38 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 39
Water in Oil Sensor MMT330
40 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 41
Water in Oil Sensor MMT330
42 P-MMT330/FE Rev. C
User’s manual
P-MMT330/FE Rev. C 43
Kongsberg BWCM 600
Condition Monitoring System
Operator Manual - MAN Diesel
390250/B
September 2017 © Kongsberg Maritime AS
Document history
Document number: 390250 / Revision B
Rev. A February 2014 First version.
Added information on standard K-Chief functions, Bearing Wear
Rev. B September 2017
Service, Engine Monitoring log and Troubleshooting
The reader
This operator manual is intended as a reference manual for the system operator.
Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.
Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.
Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com
Kongsberg Maritime AS
www.kongsberg.com
Operator Manual - MAN Diesel
Table of contents
Glossary..................................................................................................................5
1 SYSTEM DESCRIPTION .................................................... 7
1.1 System functionality...............................................................................................7
1.2 Home view..............................................................................................................8
1.3 Engine Monitoring..................................................................................................8
1.4 Rapid Wear ...........................................................................................................10
1.5 Slow Wear.............................................................................................................15
1.6 Bearing Wear Service ...........................................................................................20
1.6.1 Learning Mode ........................................................................................ 20
1.6.2 Readjust .................................................................................................. 24
1.7 Engine monitoring Log.........................................................................................27
1.7.1 Event log................................................................................................. 27
1.7.2 Class Report ............................................................................................ 29
1.7.3 Long term trend log.................................................................................. 31
2 USER INTERFACE........................................................... 32
2.1 Help ......................................................................................................................32
2.1.1 Context-sensitive help .............................................................................. 32
2.2 Top bar functionality ............................................................................................33
2.2.1 Top bar layout.......................................................................................... 33
2.2.2 Alarm information and handling ............................................................... 34
2.2.3 Toolbar compartment layout ..................................................................... 38
2.2.4 Menu button and menu structure ............................................................... 39
2.3 Alarm side bar functionality .................................................................................42
2.3.1 Alarm presentation................................................................................... 42
2.3.2 Alarm handling........................................................................................ 44
2.4 Tabular views........................................................................................................46
2.4.1 Common functionality.............................................................................. 46
2.4.2 Active alarms view .................................................................................. 50
2.4.3 Alarm history view .................................................................................. 52
2.4.4 Tag summary view ................................................................................... 54
2.4.5 Event history view ................................................................................... 56
2.4.6 Inhibit tags view ...................................................................................... 58
2.4.7 Offscan tags view..................................................................................... 60
2.4.8 Counters list ............................................................................................ 62
2.5 Trend views ..........................................................................................................64
2.6 System tools..........................................................................................................69
2.6.1 Print........................................................................................................ 70
2.6.2 Report Manager ....................................................................................... 72
2.6.3 Date and time adjustment ......................................................................... 75
390250/B 3
Kongsberg BWCM 600
4 390250/B
Operator Manual - MAN Diesel
Glossary
BW Bearing Wear
BWCM Bearing Wear Condition Monitoring
BWS Bearing Wear Service
CP Control Panel
DPU Distributed Processing Unit
LOS Local Operator Station
OS Operator Station
PSS11 Bearing Wear sensor
SCU Segment Controller Unit
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System description
1 System description
Learning Mode
Each engine and each measuring point (i.e. sensor) responds differently to the effect
of changing RPM; and the distance measured varies with the RPM. At the start-up of
each installation the system must “learn” this trough a pre-defined “learning period”.
The period consists of 2 separate steps that can/will be conducted by either yard/maker
or the end user with the BWS application
The BWS application is located under Tools and Bearing Wear View menu
Rough Learning
The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the rough compensation is
made to the system the alarms are activated.
500 Hour Learning
During 500 hours the system gathers data and calculates an average compensation value
for every RPM. When 1000 BW values corresponding to 1000 engine revolutions has
been sampled for a compensation level this level is valid and downloaded to the SCU, a
valid compensation level is then updated each 50 hours; the accuracy of the system will
increase until 500 hour of logging is done and the system is in Normal operation
Normal operation
After the Learning Mode the system will monitor the wear down of the bearings and
logging long trend and event data for later retrieval. During maintenance of the engine
and the system itself there are some situations that require the attention of the user.
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The Home view is used to give the operator direct access to the contents of the BWCM
600 system.
Access to the Home view is possible by clicking the Home button on the top bar.
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System description
Alarm indication
All bearing shells for a cylinder will indicate alarm and need to be checked for damage
or wear
• Bearing shell — Gray = Normal
• Bearing shell — Red = Alarm
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System description
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• Single Rapid
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System description
Running status
Mimic text BWCM running status Action
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern
Engine stopped BWCM stopped
Engine running direction BWCM stopped BWCM stopped because
unknown engine running direction is
unknown for the system
Mode status
Different modes are used to deactivate/activate alarms
Mimic text State Action
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active
and logging data for 2nd
and 3rd compensation point
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Alarm limits
To avoid false Bearing Wear alarms, the Rapid Wear is build up with dynamics alarm
limits. Dependent upon engine speed changes, the system will increase alarm limits
accordingly. The alarm limits are specified by MAN Diesel & Turbo and is set as default.
Single Sensor value
TAG name TAG description Basic value Max value
SR_ALIM SINGLE RAPID 0.4 0.8 (1.2)
ALARM LIMIT
Cylinder Sum value
TAG name TAG description Basic value Max value
CR_ALIM CYLINDER 0.18 (0.2) 0.36 (0.6)
RAPID ALARM
LIMIT
Main Bearing Sum value
TAG name TAG description Basic value Max value
TCR_ALIM TWIN CYLINDER 0.55 1.1 (1.65)
ALARM LIMIT
Note
The alarm limits in ( ) is for Mk9 and Mk10 engine with 60 bore or larger
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System description
Note
Follow engine manufacture instruction to check the bearings
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System description
• Devation
Sensor Deviation Fore and Aft value is Sensor value subtracted average value of all
other sensor values to remove change in engine frame due to temperature changes
Cylinder Deviation value is average of Fore and Aft Sensor value in same cylinder
subtracted average value of all other sensor values to remove change in engine frame
due to temperature changes and load conditions
• Sensor value
Prewarning value is the latest average value for Sensor Deviation in the long term log
Running status
Mimic text BWCM running status Action
Engine running Ahead BWCM running Engine protected by alarms
Engine running Astern BWCM stopped BWCM stopped because
engine running astern
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Mode status
Different modes are used to handle alarm levels
Mimic text State Action
Not Compensated Learning not started Alarms inhibited
IDC Checking installation Alarms inhibited
distance of sensor
Preliminary Rough Rough Learning started Alarms inhibited
Learning and logging data for 1st
compensation point
Rough Learning Rough Learning running Alarms active, High alarm
and logging data for 2nd limit level
and 3rd compensation point
500 Hour Preliminary 500 Hour Learning running Alarms active, High alarm
Learning limit level
500 Hour Learning 500 Hour Learning running Alarms active, High alarm
and curve deviation check limit level
started
Normal Learning Mode done Alarms active, Normal
alarm limit level
Alarm limits
To avoid unnecessary/false bearing wear alarms the Slow Wear is build up with two set of
alarm limits, dependent upon Mode the alarm limit level is set.
Sensor value
Tag name: CYLxx_BWS-y
State LL L H HH
Normal – 0.7 – 0.5 0.5 0.7
Learning - 0.9 - 0.8 0.8 0.9
Sensor Deviation value
Tagname: SNSxx_y_DEV
State LL L H HH
Normal - 0.5 - 0.4 0.4 0.5
Learning - 0.7 - 0.5 0.5 0.7
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System description
Note
The alarm limits for Slow Wear values is indicated in the bargraph
Note
Follow engine manufacture instruction to check the bearings
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Readjust
Used when system is in Normal mode after learning to zero adjust the sensor if it has
been changed or removed/reinstalled for a bearing check/overhaul
Alarm test
• Alarm test will activate alarm output used for horn and light
• Slowdown test will active slowdown output to engine
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System description
User level
• User level to Start Learning: Chief or higher
• User level to Start new Learning: Master
Sensor Select
• Sensor selected for Learning
Time line
• Gray when engine is stopped
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IDC
Installation Distance Control is used to control the installation distance of the sensors in
BDC; if the sensor is outside the installation distance limit the sensor has to be adjusted
to correct installation distance before the Learning process can continue
When IDC values are accepted a IDC Repot is generated to document the
installation distance on the sensors, the report can be copied from the system by
running Full backup in System →Backup →Maintenance. IDC Report is located in
\ROS\Config\BWS\BW-Engine1\IDC in the backup Zip file
• IDC index: If same letter index is set on both sensors in same cylinder it indicates
that the correct node id is set on the sensors; if there are different letter index in same
cylinder it indicates the sensor has wrong node id and the sensor should be checked if
it has corrected node id regarding to serial number/installation position
Note
Only available when IDC is used with the turning gear
• IDC [mm]: Displays the installation distance of the sensor, sensor shall be adjusted to
a installation distance of 3 ±1 mm from the cross-head when the cylinder is in BDC
– Installation distance rang limit when engine is stopped: 2 — 4.5 mm
– Installation distance rang limit when engine is running: 1.8 — 4.5 mm
Sensor outside correct installation distance
If value is outside installation distance when the values are accepted the sensors that
are not correct installed will be listed. Adjust these sensors to the correct installation
distance of 3 ±1 mm from the cross-head when the cylinder is in BDC and then click
Restart IDC to do the check again
Rough Learning
The purpose of the Rough Learning is to within a short period gather enough data to
calculate a rough RPM compensation for the system. After the first rough compensation
point is made to the system the alarms are activated.
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System description
Rough Learning will measure 3 compensation points to give the system a rough engine
speed compensation; the engine speed is divided in to 3 ranges and a compensation point
is logged in each range, these 3 Rough compensation points are spaced by minimum
20% of the RPM range. The Rough learning compensation is logged automatically, and
the engine can be used normally when logging compensation data.
When a compensation point in one engine speed range are logged close to an other range,
the requirement for 20% spacing between the compensation points will affect the size of
the other range. This is indicated by a dark grey area and a new range limit in green.
How-to
1 Set user access to Chief or a higher level
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5 If there are sensors outside specified installation range, adjust the sensors to correct
installation distance and click Restart IDC
6 Learning will continue automatically and the engine can be operated normally
Note
If Learning have completed and ended up with bad compensations; a new Learning
period can be started by setting user level to Master or higher and click the Start new
Learning button, and then follow How-to
1.6.2 Readjust
Readjust is used when system is in Normal mode to zero adjust the sensor that have been
changed due to a sensor failure or removed/reinstalled for a bearing check/overhaul
Readjust type
Short Readjust:
Will be running for 50 hours to log average offset, and will be running if the sensor
failure date is not set.
Typical used when:
• Sensor have been removed/reinstalled without engine has been running
• Changed sensor that has failed/broken without engine has been running
Long Readjust:
Will check long term log for wear before sensor failed and then run for 500 hours to
add average offset and wear to sensor value. Long Readjust function is automatically
activated when failure date for sensor is set in Start process
Typical used when:
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System description
User level
• User level to Start: Chief or higher
• User level to Start new Readjust: Master
Sensor Select
• Sensor selected for Readjust
IDC
Installation Distance Control is used to control the installation distance of the sensors in
BDC; if the sensor is outside the installation distance limit the sensor has to be adjusted
to correct installation distance before the Readjust process can continue
When IDC values are accepted a IDC Repot is generated to document the
installation distance on the sensors, the report can be copied from the system by
running Full backup in System →Backup →Maintenance. IDC Report is located in
\ROS\Config\BWS\BW-Engine1\IDC in the backup Zip file
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• IDC [mm]: Displays the installation distance of the sensor, sensor shall be adjusted to
a installation distance of 3 ±1 mm from the cross-head when the cylinder is in BDC
– Installation distance rang limit when engine is stopped: 2 — 4.5 mm
– Installation distance rang limit when engine is running: 1.8 — 4.5 mm
Sensor outside correct installation distance
If value is outside installation distance when the values are accepted the sensors that
are not correct installed will be listed. Adjust these sensors to the correct installation
distance of 3 ±1 mm from the cross-head when the cylinder is in BDC and then click
Restart IDC to do the check again
How-to
1 Set user access to Chief or at a higher level
2 Select sensor to be Readjusted
3 Click Start
4 If engine has been running with failed sensor, set the date when the sensor failed by
clicking on the calender symbol and select date in the pop-up. If engine have not
been running with failed sensor, continue without setting any date. Then click Next
5 When status states Turn engine turn engine two revolutions on turn gear and click
Accept values button
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System description
Note
If engine is running IDC will be done automatically
6 If there are sensors outside specified installation range, adjust the sensors to correct
installation distance and click Restart IDC
7 Readjust will continue automatically and the engine can be operated normally
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History
Show all events and alarms stored in file
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System description
• None
• Alarm
• Info
• Error
• Warning
Status log
Status for each cylinder to give a quick overview
Gives a overview if there has been a event or alarm on the cylinder with date and time
when the status has been set.
• Normal: Is set when Learning mode is finished
• Prewarning: A Prewarning has been activated and this can indicate that a wear has
started
• Alarm: There has been an alarm on this cylinder
• Unknown: Readjust on both sensors in the cylinder has been done at the same time;
initial reference point for the cylinder is lost
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2 User Interface
2.1 Help
2.1.1 Context-sensitive help
Context-sensitive help is provided for the following items:
• Tabular views
• Operator dialogues
• Mimic’s
The context-sensitive help provides help linked to the current state of the system. If for
example accessing context-sensitive help when the Alarm history view is the active view,
the intended use of that specific view is explained.
Context–sensitive help is accessed by pressing the Help button or Help tab page
present on all tabular views and operator dialogues.
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User Interface
The top bar and alarm lines will always be accessible. Hence it is not possible to cover
the top bar by for example dialogues.
The product name is displayed in the lower left corner of the top bar. Date and time is
displayed to the right of the product name.
System status
The top left corner of the screen shows system status is information, such as the name of
the Operator Station, user modes, special modes and so on. Other system information is
available in the system status extension. The system status area is expanded by clicking
the chevron button.
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System status
Product version of the K-Chief system can be found by selecting Menu→System→About.
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Alarm status
The Alarm status button shows the importance of the alarm. This is indicated by
the colour of the button. Note that the button will always be flashing, as only
unacknowledged alarms are presented.
The alarm state is also displayed (high/low etc.). The alarms in the top bar are
time-stamped, but date is not given, as these are running alarms.
See on page for presentation of all alarm states.
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Note that this information pop-up window will not cover the top bar or the alarm side
bar. Clicking anywhere on the screen will close the pop-up window.
Note that such a view might not be available for all alarms.
The behaviour of the short-cut button is as follows:
• If no process view is available, the button is greyed.
• If one process view is available, clicking the button jumps to that view.
• If more than one process view is available, clicking the button automatically jumps
to the view of most relevance.
The colour of the number is the colour of the most important unacknowledged alarm in
the system at the present time. An icon on the button will indicate if the list can expand
downwards. When the list is expanded, the icon changes to indicate that clicking the
button again will collapse the list.
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Alarm acknowledge
Alarms may be acknowledged in several ways. The most common methods are:
• Clicking the ACK short-cut button in the top bar. This acknowledges all alarms visible
in the alarm compartment and in the Active Alarms view.
• Clicking on the visible alarm status button in the top bar. This acknowledges the
single alarm selected.
• Using the Menu button by selecting Menu→Alarms→Acknowledge.
It is also possible to silence the buzzer using the Alarms>Sound off button on the Watch
Call panel.
This stops the sound on the CRP and on related DPU relays.
The Sound off button can also be pressed on the TCP. (Note that this depends on the
Touch Control Panel hardware version.)
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Figure 17 Toolbar
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Split view / full view Toggle between split view mode and full screen
mode.
The menu categories are by default hidden, but clicking the Menu button will expose
the menu categories just below the top bar. The menu categories are distributed in two
even rows.
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Note
If space allows it, the menu categories will be shown on the screen all the time.
When one of the menu categories is selected, its complete sub-menu appears.
Note
For larger display resolution, only the complete menu is visible.
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Menu operation
There is a clear visual indication of which menu category is open at any time. When the
menu is open, all menu categories are visible at all times. Consequently, menu selection
in the top row will not cover the lower row.
If the operator by a user context has temporarily deactivated a menu category or
command, these are visibly disabled, but not removed.
Some command may be grouped. These groups are visually supported in the menu area.
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Figure 18 Alarm side bar layout The alarm group button is coloured red
or magenta when there are one or more
active alarms in the group.
The alarm group button is coloured
yellow or light yellow in case of
warnings or if only local acknowledge
is possible. Actual acknowledge must
be done at the default location.
The alarm group button is coloured
grey if there are no active alarms in the
group or if responsibility for alarms is
on another location (for example cargo
alarms in the ECR).
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When clicking an alarm group, the list of active alarms will pop-up in a dedicated
secondary window.
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Selecting Show all tags in group will open the Tag summary view for the alarms in this
group.
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Emergency alarm,
Alarm,
Warning,
Info,
Alternatively it is possible to acknowledge all visible alarms in the alarm group, by
means of dedicated button.
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The operator can set the columns to “best fit” by double-clicking on the header right edge
of the column heading.
Selected rows in the tabular view are displayed with maximum contrast and visibility.
Rows not selected are shaded.
Scrolling buttons
The total number of alarm items listed in the view is displayed on the view header.
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If more than one page is necessary to display all items, use the ▲ (up) or ▼ (down)
buttons to go backwards or forwards in the list. The PAGE UP and PAGE DOWN buttons
on the Control Room Panel can also be used for this purpose.
Use the Top or Bottom buttons to go to the very first or last item on the list.
Note
On touch devices view can be scrolled horizontally and vertically by finger slide
View options
The Options button is used to customize which optional columns to be displayed or
hidden. Two options are available:
• Optional columns: Select or deselect singular columns using the check boxes (actual
columns selectable being dependent on the active view)
• Restore default layout: Restore to factory settings
The following example shows selectable columns for the Tag summary view.
Columns adjustments
Columns can be relocated by “drag and drop”
The column width can be adjusted by moving the border line between the column
headers.
If the text in the cell is not fully visible , tooltip provides full text when mouse pointer is
over the cell.
Note
The Status column cannot be relocated. It is always in the utmost left position.
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Data filtering
Operator can filter the data to limit the number of rows in the view.
Filtering is enabled by right-clicking on the requested column header and selecting
filter. On screen keyboard may be used to type the filter values. Some columns do
not contain filters.
Note
If the Operator station is equipped with TCP (touch control panel), the on screen
keyboard appears on TCP instead of main display.
Data sorting
The tabular view can be sorted in all columns. This is done by clicking on the requested
column header. Sorte column is highlighted in light yellow colour.
Context menu
Context menu is may be different for each tabular view. It depends on functionality
of each view.
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• Send to custom views— single or multiple tags can be sent to custom view. Multi
select can be done by mouse drag over the multiple rows.
• Select all — select all tags in the view.
Note
On touch devices use “touch and hold” to activate context menu.
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— Emergency alarm,
— Alarm,
— Warning,
— Info,
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View columns
The Active alarms view holds the following columns:
1 Status: The importance of the alarm is indicated using a dedicated colour and
a letter on the button.
2 Short-cut button to relevant process view.
This button is greyed if no such view is available.
3 Time: The time stamp of the alarm (local time).
Tip
Extend the column width to see both time and date.
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Purpose
The Alarm history view is used to display the following alarms:
• Active acknowledged alarms
• Active unacknowledged alarms
• Acknowledged alarms returned to normal
• Unacknowledged alarms returned to normal
• Local time change events
This is the main view for investigation of the history of all alarm events in the system.
The view is event based, so every event has a time stamp in both local and UTC time.
Alarm history view holds the last 30 days alarm entries ( software version 12.14 or newer
). In older OS software versions Alarm history shows up to 2000 last entries.
The list of alarms is synchronized between stations.
Alarm history is event based. Every entry represents one time-stamped event.
Symbols used in the Alarm history view:
Note
Symbol colour depends on alarm importance level.
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View columns
The Alarm history view holds the following columns:
1 Short-cut button to relevant process view. Button is grayed out when view is not
available
2 Time: The time stamp of the alarm (local time).
Tip
Extend the column width to see the date.
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View columns
The Tag summary view holds set of default and optional columns. The optional columns
are shown (or hidden) on demand by clicking the Option button in the top right corner
of the view and then selecting the Optional column dialogue to enable (or disable)
additional columns.
The columns are by default shown in following order:
1 Short-cut button to relevant process view.
This button is greyed if no such view is available.
2 Device no: Numbered identification of the device.
3 Device type: Identification of the device type.
4 Channel: Internal DPU or SYS channel number.
5 Channel type: Channel type (field, software or system).
6 Tag: A unique tag identifier.
7 Description: Detailed description of the alarm tag.
8 Value: Measured value scaled to Engineering unit.
The value is at any time updated with the real time value.
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View columns
The Event history view has following columns:
1 Short-cut button to relevant process view.
2 Event type: Description of what type of event is recorded.
3 Event sub-type: Next level description of event type.
4 UTC time: The time stamp in Coordinated Universal Time (UTC).
5 Local time: The time stamp of the alarm (local time).
Tip
Extend the column width to see the date.
6 Source: Description of what is the source of the event (for example Operator
Station, DPU, SYS).
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View columns
The Inhibit tags view holds the following columns:
1 Short-cut button to relevant process view.
2 Time: The time stamp of the alarm (local time).
3 UTC time: The time stamp in Coordinated Universal Time (UTC).
4 Tag: A unique tag identifier.
5 Description: Detailed description of the alarm tag.
6 Function: Short code describing the function of the tag.
7 Alarm state: Description of alarm condition (system alarm, field alarm etc.).
8 Value: Measured value scaled to Engineering unit.
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Purpose
To avoid unnecessary alarms, some alarms are not checked for alarm situations (offscan
alarms). The Overridden tags view is used to display these alarms.
Note that offscan alarms are visually highlighted by a light blue background colour. This
applies only when the alarm tag is represented in a tabular view.
Column properties
All columns can be relocated by the drag-and-drop function.
Data in the columns can be sorted in ascending or descending order by clicking on the
corresponding column header.
Note
Sorted data will be highlighted in a light yellow colour.
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View columns
The Overridden tags view holds the following columns:
1 Short-cut button to relevant process view.
This button is greyed if no such view is available.
2 Tag: A unique tag identifier.
3 Description: Detailed description of the alarm tag.
4 Function: Short code describing the function of the tag.
5 Alarm state: Description of alarm condition (system alarm, field alarm etc.).
6 Value: Measured value scaled to Engineering unit.
The value is at any time updated with the real time value.
7 Engineering unit: Unit of measurement.
8 Limit LL: Signal limit for low-low alarm.
9 Limit L: Signal limit for low alarm.
10 Limit H: Signal limit for high alarm.
11 Limit HH: Signal limit for high-high alarm.
12 Alarm group: The alarm group to which the alarm is connected.
If data is not defined for a tag, the corresponding field is left blank.
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Column properties
Data in the columns can be sorted in ascending or descending order by clicking on the
corresponding column header.
Note
Sorted data will be highlighted in a light yellow colour.
View columns
The Counters list holds the following columns:
• Short-cut button to relevant process view.
This button is greyed if no such view is available.
• Tag: A unique code describing an alarm tag.
• System: Displays system name.
• Description: Detailed description of the alarm tag.
• State: Displays running state (Running/Stopped or Flow/No flow).
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Active tags
Each tag logged in the view is represented by an information field above the trend plots,
showing tag name and colour representation.
For a given tag, clicking on the colour symbol will highlight its trend plot in the display
by using a bolder line. In addition alarm limits for the tag is shown, if relevant.
Which tag is highlighted is easily seen by its rectangular colour symbol changing form.
Interpolation
All plots are interpolated by default. User can turn off interpolation by right click on the
tag or from tag manager in the trend view.
Tag manager
The Tag manager is used to select which data to be shown by the current Trend view.
The Tag manager dialogue is opened by clicking the Tag manager button in the upper
right corner of the display.
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Add tag
A new tag can be added to a Trend view using the Add tags button inside the Tag
manager view.
This opens the Add tag to Trend view dialogue.
The list of available tags may contain thousand of items. Search functionality is therefore
implemented to help the operator to restrict the number of items listed.
• Alarm group: Search for tags belonging to a specific alarm group.
• Tag: Search by tag name (phrase 'contains', 'starts with', 'ends with', 'equals')
• Description: Search by tag description (phrase 'contains', 'starts with', 'ends with',
'equals')
After selecting the requested tag from the list, the Add tag button or just double clicking
the tag, places the new tag on the view. The new tag is automatically placed at the
bottom of the list.
It is also possible to add tags directly from the process view. Right clicking on the tag
you want to add will give you the option to add it to a trend view.
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Remove tag
Still inside the Tag manager view you mark the tag to be removed and click the Remove
tag button.
The lower part of the Tools and options area holds the following functionality:
• Live/Static view: Select live view or a time span in the past.
• Forward/backward buttons: Move forward and backward in time in the static view.
• Zoom buttons: x button zooms the time, y button zooms the engineering unit span.
Reset scale gets you back to default scale.
Note
It is also possible to zoom by pressing and holding the centre trackball button while
moving the trackball. The cursor must be situated on the relevant axis.
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View area
This area is used to display the trend plots. Up to eight plots can be monitored
simultaneously. The plots are recognizable by each one being assigned a unique colour.
The colour scheme is also shown in the Tag details area.
One vertical value scale is displayed for each alarm tag. The colour of the scale is
identical with the colour of the plot belonging to it. The button at the top of the scale
indicates the scale mode.
There are three different modes available for the value scale:
• Default scale : In this mode, range high and range low tag values are used for
the value scale.
• Auto mode : In this mode, the value scale is automatically adjusted for the plot to
fit the maximum scale range.
• Manual mode : In this mode, the value scale can be adjusted manually by the
operator. Values can even be set to exceed engineering high and engineering low
values.
The mode for a particular scale can be edited by clicking on the relevant button. This
opens the following dialogue:
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Note
Scale can be also adjusted by trackerball drag and drop .
Hold the mouse over the scale and push the centre button
on the trackball, move the trackball in the relevant direction
to get the scale wanted.
Topics
• Print on page 70
• Report Manager on page 72
• Date and time adjustment on page 75
• User access on page 77
• Database backup on page 80
• Software versions log on page 81
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2.6.1 Print
Purpose
The purpose of the Print dialogue is to print or save selected system data. It is possible to
print both process views and list views.
The printing function is activated by clicking the Print button in the top bar.
This opens the basic print dialogue.
The print header is automatically generated, and includes information on ship, operator,
report type, time and date, as following.
Vessel: M/S Explorer Kongsberg Maritime K-Chief 600
IMO: 12355474556 Printed by: Chief 12 dec. 2009 08:12
UTC
Active alarms report Page 1 of 23
Options
• Name: Select a printer from the list of printers available.
Network printers can be selected from the list.
Depending on project configuration it may also be possible to print to K-Chief 600
PDF printer
• Status: Displays status information for the selected the printer.
• Orientation: Select page orientation.
• Copies: Select the number of copies to be printed.
Print
• Screenshot: Select print of process view.
• View: Select print of list view.
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User Interface
Time reference
• UTC: Tabular view data and header will use UTC time reference
• View: Tabular view data and header will use Local time reference
Page range
• All: Print all pages.
• Current page: Print only the current page.
• Page: Print range of pages in format “1st page— last page” , for exmple: 5–20
Footer
Customized footer text may be printed at the bottom of the printout.
Print preview
Print preview enables the operator to see the page before it is printed.
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After inserting a USB memory stick, the requested document can be exported by
selecting it from the list and then clicking the Send to USB button.
It is recommended to click the Release USB drive button before removing the USB
memory stick.
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User Interface
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Kongsberg BWCM 600
• Time reference
Select UTC or Local time.
• Device: Select printer from the drop-down list.
The built-in K-Chief 600 PDF printer or any external printer connected to the OS
network can be selected.
• Interval: Select predefined print interval from the drop-down list.
Selectable print intervals are: 1 hour, 3 hours, 6 hours, 12 hours, 1 day, 1 week,
1 month.
Alarm events are printed continuously by aggregating data and printing full pages
• Starting: Select start date and time for the print job
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User Interface
UTC
This field displays UTC date and time.
To compensate computer time drift. UTC time may also be adjusted if necessary. This
can be adjusted with 1 second steps.
Note
Log on as Master user to change UTC time
Local
This field displays local date and time.
Offset adjustment
Local time can be adjusted only if the system is not synchronized with master clock.
This field holds the following information and buttons:
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If the master clock only provides UTC date, local time settings are still available for
adjustments.
Seconds are always synchronized with UTC time.
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User Interface
Purpose
The purpose of the User access dialogue is to manage BWCM 600 users and user
properties. Typical tasks are set default user, add/remove users, manage user passwords
and so on.
The following table presents the user groups defined in the BWCM 600 system. If
defining a new user, he must be set as member of one of the predefined user groups.
User groups
Task Guest User Power user Administrator Administrator
description Master Kongsberg
View all tabular Yes Yes Yes Yes Yes
and process
views, and
dialogues
Access KM Help Yes Yes Yes Yes Yes
Add tags to No Yes Yes Yes Yes
Trend and
Custom views
Print No Yes Yes Yes Yes
Acknowledge No Yes Yes Yes Yes
alarms
Report Manager No No Yes Yes Yes
operations
Restart or No No Yes Yes Yes
shutdown
Operator Station
Offscan tags No No Yes Yes Yes
Lap counter reset No No Yes Yes Yes
Change tag No No Yes Yes Yes
parameters
Add and delete No No No Yes Yes
users
Set UTC time No No No Yes Yes
Total counter No No No Yes Yes
reset
Full system No No No No Yes
access
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Figure 35 User The dialogue offers two methods for changing the user:
access dialogue (basic)
• Pressing the Change user button: This may change to any
user defined by the system. The user is selected from the
drop-down list in the combo box and the corresponding
password must be entered.
• Pressing the Change to default user button: This will
change to the default user, as defined in the extended
operator dialogue.
Note
By default the password is always equal to the user name
(not case sensitive). Each user can change its own password.
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User Interface
The extended operator dialogue is used to manage users and user properties. This
dialogue holds two tabs:
• Users, with the following functions:
– Add user: creates new user. By default user will belong to “Users” group and have
same password as its user name ( password is not case sensitive )
– Remove user: deletes selected user
– Remove user: deletes selected user
– Password: each user can change its own password, Master logged on user can
reset any password.
– Group: assign group for each user name. Group determines privileges of the user.
– Timeout: in case of user inactivity, the system will automatically change to default
user. Time in minutes. 0 = timeout disabled. All users can change their own
password. Master user can change passwords without knowing the old one.
• Stations, with the following function:
– Master user can set default user for each Operator Station. Operator station will
log on automatically to this user upon reboot. This is user account used by Change
to default user button
Note
'Kongsberg' user is for internal Kongsberg Maritime use only.
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Purpose
The purpose of the Database backup dialogue is to make it possible to take backup
configuration database, settings and log files.
This operation is only available for Power users or higher.
The dialogue is opened by selecting Menu→System→Maintenance→Backup.
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User Interface
Purpose
The purpose:
• Give an overview or current software versions of all hardware and software
components.
• Track software changes and upgrades.
• Track hardware changes by serial number tracking
The view is opened by selecting Menu→System→Software versions log.
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3 System procedures
3.1 View
To accommodate for different light conditions in the operator's work space, the graphics
on the screen can be changed to one of the pre-defined color palettes under Display Mode.
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System procedures
Note
On Control Panel the Night palette can get to dark to see function in bright ambient
light conditions, so to get out of Night palette press and hold in top-right corner to
change palette
How-to
1 Click the Menu button in the top bar.
2 Click View.
• A drop-down list is displayed.
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3 Select the wanted Display mode, Day, Dusk or Night by clicking the corresponding
text.
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System procedures
• Screen lock
2 Click System.
3 Click Change user in the drop-down list.
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System procedures
5 Right click the line with the unit you want to replace to get access to the Start scan
button.
6 Click Start scan.
7 Click the line holding the serial number for the new DPU, and click OK.
• The unit will be loaded with the relevant node address, software and
automatically configured. The process may take a few minutes.
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4 Operational procedures
How-to
1 Go to BWS →Alarm test
2 To activate test:
a Click button for the test that shall start
b Click Yes on warning
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Operational procedures
Expected result
• Alarm Test: Horn and light to be activated
• Slowdown Test: Slowdown of engine to be activated
WARNING
Do not activate Slowdown Release test when engine is running
because this will cause the engine to Slowdown
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Generate Report
a Open Home view or Navigation line
b Go to Bearing Wear →Engine Monitoring Log →Class Report
c Select time period for the report in Select time
d Click Generate Report button
e Report is ready when status is Report generated C:\Ros\PdsLog\BWLog\Xml
Reports\.........
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g When status is Backup completed successfully click Release USB button and
remove USB drive
Note
For information about report file see Class Report file on page 30
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Operational procedures
This procedure must be followed when a sensor needs to be replaced during the Learning
Mode. Installation distance of the sensor is likely to change when a sensor is exchanged;
zero point need to be adjusted and Learning Mode need to be restarted to avoid offsets on
the compensation data.
Scope of work
• Replacement the defect sensor
• Set node id
• Restart of Learning Mode
How-to
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”
4 Safely remove all tools and the broken sensor from the crank case.
5 Go to K-Chief 600 OS
a Set user access to Chief or a higher level
b Open Menu →Tools →DPU Replacement and select sensor to be replaced with
new one
See DPU Replacement on page 86
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g If there are sensors outside specified installation range adjust the sensors to
correct installation distance and click Restart IDC
Scope of work
• Replacement the defect sensor
• Set node id
• Start of Readjust
Procedure
1 Remove defect sensor(s)
2 Install the new sensor(s) according to the installation manual.
a Use a dial gauge to ensure that the x-head is in BDC
b Use the 3 mm feeler gauge to ensure correct distance between sensor and guide
shoe
c Make sure not to turn the sensor as the nuts are tightened. This will alter the
distance
d Tighten the nuts with correct torque
3 Reconnect cable to sensor connector
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Operational procedures
Note
Do not tighten the connectors too hard. Tighten by using fingers, then 1/8 turn extra
by use of pliers. You will feel “an extra click”
4 Safely remove all tools and the broken sensor from the crank case.
5 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> DPU Replacement and select sensor to be replaced
with new one
See DPU Replacement on page 86
c Open Menu —> Tools —> BWS —> Readjust
d Select the sensors that is replaced
e Click Start
f Click Next in Select data view without setting date
g When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
h If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC
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How-to
1 Do bearing overhaul according to engine makers requirements
2 Go to K-Chief 600 OS
a Set user access to Chief or a higher level
f If there are sensors outside specified installation range adjust the sensors to
correct installation distance and click Restart IDC
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Operational procedures
How-to
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).
WARNING
DO NOT remove the sensor from the brackets
Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position
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4 Reinstall bracket with sensor(s) in it’s former position regarding to marks made
before bracket was removed
Note
Make sure that each bracket with sensors is reinstalled in the SAME POSITION as
before, then further adjustment of sensor position can be avoided
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Operational procedures
5 Go to K-Chief 600 OS
a Set user access to Chief or a higher level
f If there are sensors outside specified installation range adjust the sensors to
correct installation distance and click Restart IDC
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• Overhaul
• Start the Readjust procedure
Procedure:
1 Do bearing overhaul according to engine makers requirements
2 Go the K-Chief 600 OS
a Set user access to Chief or higher level
b Open Menu —> Tools —> BWS —> Readjust
c Select the sensors that is affected by the overhaul
d Click Start
e Click Next in Select data view without setting date
f When status states Turn engine turn engine two revolutions on turn gear and
click Accept values button
g If there are sensors outside specified installation range adjust sensors to correct
installation distance and click Restart IDC
Case B — Scope of work:
• Removal of the Bearing Wear Sensor and bracket
• Overhaul
• Reinstallation of sensor and bracket
• Start the readjust procedure
Procedure:
1 Carefully mark the position of the bracket so that it can reinstalled in the same
position.
2 Remove bracket with sensor(s).
WARNING
DO NOT remove the sensor from the brackets
Note
Shall be reinstalled in the same cylinder and cylinder position, so mark the bracket
with cylinder number and position
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5 Troubleshooting
5.1 BW values
Problem Probable cause Solution
Alarm is activated on Bad compensation data on Restart Learning
specific engine speed levels a engine speed level
and return to normal when
engine speed is changed
Alarm from one sensor in a Sensor failure 1 Check
cylinder due to high or low
CYLxx_RAW—y
value from around ±1 mm
value(xx = cylinder
number and y =
cylinder position
where 1 = Fore and 2
= Aft)
2 If value is around ±3
mm replace the sensor
regarding to mounting
instruction and on
page
Slow Wear
Problem Probable cause Solution
High or low value around Sensor failure
1 Check
±3 mm after sensors has
CYLxx_RAW—y
passed IDC in Learning
value(xx = cylinder
number and y =
cylinder position
where 1 = Fore and 2
= Aft)
2 If value is around ±3
mm replace the sensor
regarding to mounting
instruction and on
page
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Troubleshooting
Rapid Wear
Problem Probable cause Solution
False alarm in beginning of Value changed due to RPM Change engine speed and
Learning period range is linear compensated check if value return to
between two measured normal, if the value returns
points to normal this will improve
when compensation values
is logged for the RPM
range.
5.2 Communication
Problem Probable cause Solution
Communication alarm on Loose connector
1 Check connectors
some sensors. for the sensor giving
Tag name: DPUxxyyCOM alarm
(xx = segment number and
yy = node id) 2 Fasten loose connector
Note
Turn the nut by hand until
stop and then turn a extra
30° or with 0.7 Nm torque
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Troubleshooting
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Index
A DPU N
Acknowledge, 37, 44 Replace, 86 Night palette
Active alarms, 50 bright light conditions, 83
Active alarms columns, 51 E
Active alarms view, 50
Engine Monitoring, 8 O
Add tag
Engine monitoring log
Trend view, 66 Overridden tags, 60
Class Report, 29
Alarm and Monitoring Overridden tags view, 60
Event log, 27
System
Status view, 29
Change user, 85
Event history, 56 P
Replace DPU, 86
Event history view, 56
Alarm handling, 44 Palettes
Event log, 27
Alarm history, 52 Day, 82
Alarm history symbols, 52 Dusk, 82
Alarm history view, 52 H Night, 82
Alarm presentation, 42 Password, 78
Help, 49
Alarm side bar, 42 Print, 70
Context-sensitive help, 32
Alarm side bar Options, 70
Home view, 8
functionality, 42 Print scheduler, 72
How-to
Alarm state, 50 Printing, 70
Alarm test, 88
Alarm test, 88
Bearing Check after
Alarms, 34
Seatrial, 95 R
Acknowledge, 37
Bearing Check during
Sound off, 37 Rapid Wear, 10
Learning Mode, 95
Bearing Check during Remove tag
B Normal Mode, 99 Trend view, 67
Bearing Overhaul during Replace DPU
Backup, 80 Learning Mode, 95 Alarm and Monitoring
Bearing Check after Bearing Overhaul during System, 86
Seatrial, 95 Normal Mode, 99 Report explorer, 72
Bearing Check during Class Report, 90 Report manager
Learning Mode, 95 Display Mode, 83 New print job, 72
Bearing Check during Sensor replacement Print scheduler, 72
Normal Mode, 99 during Learning Mode, 92 Report explorer, 72
Bearing Overhaul during Sensor replacement Report Manager, 72
Learning Mode, 95 during Normal Mode, 94 Restore layout, 47
Bearing Overhaul during Slowdown test, 88
Normal Mode, 99
Bearing Wear Service, 20 S
Learning Mode, 20 I Scaling
Readjust, 24 Inhibit tags, 58 Trend view, 68
Inhibit tags view, 58 Sensor replacement during
C Learning Mode, 92
Sensor replacement during
Change user, 85 L Normal Mode, 94
Class Report, 29 Layout Side bar, 42
Class Report file, 30 Top bar, 33 Slow Wear, 15
How-to, 90 Trend view, 64 Slowdown test, 88
Context menu, 48 Learning Software versions log, 81
Counter, 62 500 Hour learning, 20 Sorting, 48
Counters list, 62 Rough learning, 20 Sorting of data, 48
Edit, 63 Local time, 75 Sound, 37
Status view, 29
System functionality, 7
D M Bearing Wear Service, 20
Database backup, 80 Master clock, 75 Engine Monitoring, 8
Date and time adjustment, 75 Menu Home view, 8
Default password, 78 Top bar, 39 Rapid Wear, 10
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T
Tabular view
Active alarms, 50
Alarm history, 52
Counters list, 62
Event history, 56
Filtering, 48
Inhibit tags, 58
Overridden tags, 60
Tag summary, 54
Tabular views, 46
Tag manager
Trend view, 65
Tag summary, 54
Tag summary view, 54
Time offset adjustment, 75
Toolbar, 38
Tools and options
Trend view, 65
Top bar
Alarm handling, 34
Alarm information, 34
Layout, 33
Menu button, 39
Menu structure, 39
Toolbar compartment
layout, 38
Trend view, 64
Add tag, 66
Layout, 64
Remove tag, 67
Scaling, 68
Tag manager, 65
Tools and options, 65
View area, 68
Troubleshooting, 102
U
User access, 77
Extended operator
dialogue, 78
User groups, 77
User interface
Alarm side bar, 42
Tabular view, 46
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©2017 Kongsberg Maritime
®
INSTALLATION,
OPERATION AND
MAINTENANCE
MANUAL
59812-K007
The information contained in this manual is the property of Kidde Products Limited and may not be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor stored
in any retrieval system or any nature without the express written authority of Kidde Products Limited.
3 MAINTENANCE ...........................................................................................................60
3.1 ROUTINE MAINTENANCE 60
3.2 DETECTOR HEAD REPLACEMENT 61
3.3 DETECTOR HEAD REFURBISHMENT 62
3.4 FAN REPLACEMENT 65
3.5 CABLE REPLACEMENT 65
3.6 CONTROL UNIT MEMBRANE 66
3.7 CONTROL UNIT PCB REPLACEMENT 66
3.8 DECOMMISSIONING 66
6 CATERPILLAR DETECTORS
6.1 53836- K269-03 C/W SHORT SAMPLE PIPE 95
53836-K269-02 C/W STANDARD SAMPLE PIPE 96
1. Kidde Products Ltd (KPL) warrants, for a period of 3 years from the handover of the new vessel
which is installed with KPL Oil Mist Detector (OMD) system to the system owner, and for a period
(*)
of 2 years from the commissioning date of a retro fitted Mk7 Oil Mist Detector (OMD) system, that
any component forming part of the original OMD system manufactured by or supplied by KPL shall
be free from defects in workmanship or materials during normal usage (the “OMD System
Warranty”). If any such component does not conform to this warranty KPL will, at its sole
discretion and its cost, either repair or replace such component. Installation of the repaired /
replacement parts is not covered under the OMD System Warranty. Components replaced or
repaired under the terms of the OMD System Warranty shall continue to have the benefit of the
unexpired portion of the OMD System Warranty, unless that unexpired portion is less than 12
months, in which case the repaired / replacement parts shall have the benefit of a 12 month
warranty against defects in workmanship or materials during normal usage starting on the date of
delivery. OMD’s supplied as spares shall be warranted in accordance with paragraph 2 below
only.
2. KPL warrants for a period of 12 months from delivery that individual OMD’s supplied as spares
shall be free from defects in workmanship or materials during normal usage.
f. any modifications to or installations performed on the OMD’s and/or OMD system outside
the scope of normal routine maintenance or running repairs without the express prior
written approval of KPL;
g. deterioration, staining or corrosion of parts which will occur due to normal exposure and
usage;
h. alleged defects not materially affecting the quality or proper functioning of the OMD
system.
7. The Warranties can be transferred to any new owner of the OMD system provided KPL is
informed in writing within 30 days of the transfer. The OMD System Warranty cannot be
transferred to another KPL OMD system.
8. Save to the extent amended by the provisions set out above, KPL’s standard terms and conditions
of sale shall apply.
1.1 INTRODUCTION
High temperatures, in excess of 200ºC that occur on bearing surfaces under initial failure
conditions, can lead to a rapid generation of oil vapour When the hot vapour contacts the
relatively cooler atmosphere of the crankcase it condenses into a fine mist, with typical particle
sizes of around 0.5 to 5 microns in diameter. When the density of these particles reaches
between 30 to 50 mg/I (Milligrams per litre), depending upon the type of oil, an explosive
condition exists.
Main Bearing
Bottom End
Bearing
Remote Display
Unit
1.2 DESCRIPTION
The system comprises three main components (refer to Figure 3):
Detectors 53836-K269 (with base) / 53836-K272 (replacement head)
53836-269-01 (Short sample pipe)
Control Unit 53836-K270 (With Membrane)
53836-K276 (Without Membrane)
Remote Display Unit 53836-K271
And connecting cables
Control Unit to Detector cable (Straight) 43682-K286-XX
Control Unit to Detector cable (Right Angle) 43682-K285-XX
The Graviner Mk 7 OMD system can comprise up to 100 detectors directly mounted on the
crankcases of up to 10 engines, allowing both main propulsion and auxiliary generators to be
monitored at the same time.
Each detector communicates electronically over a serial data link via the engine mounted
Control Unit with the Remote Display Unit designed to be mounted within the Engine Control
Room. This eliminates the need to enter the machinery space in alarm conditions.
Control Unit
Enclosure Rating IP65
Material Aluminium
Max detector inputs 10
Alarm Ranges
Pre Alarm 0.5mg/l to 1.2mg/l (adjustable) (Default 0.9mg/l)
Engine Slow/Shutdown Alarm 1.3mg/l to 2.4mg/l (adjustable) (Default 1.8mg/l)
Backup Alarm 3.0mg/l (fixed)
Alarm Philosophy
The system has 3 separate alarm levels as detailed below
1. Pre Alarm- This indicates that the oil mist levels are increasing in a particular crank
space and that investigation should be undertaken. This alarm will not operate the
slowdown/shutdown relays.
2. Engine Slow/Shutdown Alarm - When any detector reaches this threshold then the
slowdown/shutdown relay will be operated if they are connected.
3. Back Up Alarm - In the event of a failure of either the Pre Alarm or High Alarm, then
the Back Up Alarm will operate, but it will not operate the slowdown/shutdown relay.
This is an additional functional precaution added by Kidde Products Ltd which can be
connected in any way the customer requires. This is usually connected to a warning
beacon or siren; however the customer may choose to connect the relay to another
device or the engine slowdown or shutdown circuitry.
On receipt of either a Pre Alarm or High Alarm the engine should, unless connected to a
slowdown/shutdown relay, be stopped if safe to do so and allowed to cool down so that the
background oil mist levels reduce before entering the engine room.
When the oil mist levels have returned to normal then the Accept and Reset buttons can be
operated from the Control Unit membrane if fitted or alternatively form the Remote Display Unit
and the system will then return to normal operation.
Event Log
All alarms, faults and events are recorded in an Event Log which is date and time stamped and
will indicate the type of event which enables analysis of the events at a later time. The Event
Log has a capacity of 1024 events and is a rolling buffer.
Pre-Alarm
Engine
Slow/Shutdown
Alarm
Backup-alarm
Fault
The Control Unit 53836-K270 (53836-K270-01 Caterpillar only) or 53836-K276 is designed for
on-engine mounting and it is recommended that the Control Unit is installed as near to the
centre of the engine as possible to minimise detector cable lengths.
Mounting is via the four M6 locating holes in the box. Sufficient space must be left around the
Control Unit to allow access to the cable glands and the routing of the cables and to facilitate
easy access to all aspects of the Control Unit.
Each detector is mounted to an individual crankcase via a ¾ inch BSP threaded hole.
Ensure all detectors fitted to the engine are locked tightly in place by means of the lock nut
supplied.
It is recommended that the detector be located at the upper part of the crankcase wall not in
the direct line of the oil throw. On smaller engines it is permissible to mount the detector on the
crankcase door if desired or as installation dictates, subject to vibration levels.
The detector must be fitted at a maximum of plus or minus 20 degrees from the vertical.
Horizontally the detector must be mounted level or with the detector body inclined towards the
engine to ensure oil drainage. Refer to Figure 10, and Figure 11.
Please ensure that Detector 1 is connected to position 1 on the Control Unit, Detector 2 to
position 2. Repeat for all Detectors fitted.
Each detector must be connected to the Control Unit by way of a supplied detector cable.
Refer Figure 12.
Ensure that the cables are run in a suitable cable tray and clipped at regular intervals to
ensure they cannot be subjected to mechanical damage caused by vibration.
o
Cable Length 90 Connector Straight Connector
m Part No. Part No.
1.0 43682-K285-1.0 43682-K286-1.0
1.5 43682-K285-1.5 43682-K286-1.5
2.0 43682-K285-2.0 43682-K286-2.0
2.5 43682-K285-2.5 43682-K286-2.5
3.0 43682-K285-3.0 43682-K286-3.0
3.5 43682-K285-3.5 43682-K286-3.5
4.0 43682-K285-4.0 43682-K286-4.0
4.5 43682-K285-4.5 43682-K286-4.5
5.0 43682-K285-5.0 43682-K286-5.0
5.5 43682-K285-5.5 43682-K286-5.5
6.0 43682-K285-6.0 43682-K286-6.0
6.5 43682-K285-6.5 43682-K286-6.5
7.0 43682-K285-7.0 43682-K286-7.0
7.5 43682-K285-7.5 43682-K286-7.5
8.0 43682-K285-8.0 43682-K286-8.0
8.5 43682-K285-8.5 43682-K286-8.5
9.0 43682-K285-9.0 43682-K286-9.0
9.5 43682-K285-9.5 43682-K286-9.5
10.0 43682-K285-10.0 43682-K286-10.0
10.5 43682-K285-10.5 43682-K286-10.5
11.0 43682-K285-11.0 43682-K286-11.0
11.5 43682-K285-11.5 43682-K286-11.5
12.0 43682-K285-12.0 43682-K286-12.0
12.5 43682-K285-12.5 43682-K286-12.5
15.0 43682-K285-15.0 43682-K286-15.0
17.5 43682-K285-17.5 43682-K286-17.5
20.0 43682-K285-20.0 43682-K286-20.0
22.5 43682-K285-22.5 43682-K286-22.5
25.0 43682-K285-25.0 43682-K286-25.0
For flush mounting details see below and Figure 15 and Figure 16.
For bulk head mounting details see Figure 17.
Cables should be segregated from high voltage cables and follow good installation
practice
2
Cable type-2 Cores + Earth, CSA 2.5mm (50/0.25mm), flexible stranded bare copper
conductors, low smoke halogen free insulation, cores laid up, braided screen, low smoke
halogen free sheath – grey, outside diameter 9.8mm, operating temperature 0ºC + 80ºC.
Suggested cables
2
Lapp Kabel CY cable 3 core 2.5mm
2
Prysmian LSM-HF 3 core 2.5mm
2
Helkama LKAM-HF 3 core 2.5mm
Modbus
Cable type – Individually screened 2 pair data cable, 24AWG, low capacitance, low smoke
halogen free. Outer diameter 7mm (max)
Cables should be segregated from high voltage cables and follow good installation
practice
Suggested cables
FS Cables 2402PIFFH
Beldon 9729
Helkama RFE-HF(i) 2x2x0.75
Jinro 60V RCOP(IS)
The above cable should be used to connect between the Control Units and either the ships
AMS system or the Remote Display Unit.
Relay Outputs
The relay outputs are rated at 30v DC at 1amps.
2
2 Cores + Earth, CSA 2.5mm (50/0.25mm), flexible stranded bare copper conductors, low
smoke halogen free insulation, cores laid up, braided screen, low smoke halogen free sheath
– grey, outside diameter 9.8mm, operating temperature 0oC + 80oC.
Cables should be segregated from high voltage cables and follow good installation
practice
Approved cables
2
Lapp Kabel CY cable 3 core 2.5mm
2
Prysmian LSM-HF 3 core 2.5mm
2
Helkama LKAM-HF 3 core 2.5mm
USB Connection
Refer Figure 18 for connection location.
Modbus
Connector
End of Line
Jumper
USB
Connection
Relay Output
Connectors
24v DC input
Connector
Cables should be segregated from high voltage cables and follow good installation
practice
Suggested cables
2
Lapp Kabel 1.5mm Ölflex Classic 110CH - 10035068
2
Prysmian LSM-HF 3 core 1.5mm
2
Helkama LKAM-HF 3 core 1.5mm
Cables should be segregated from high voltage cables and follow good installation
practice
Suggested cables
FS Cables 2402PIFFH
Beldon 9729
Helkama RFE-HF(i) 2x2x0.75
Jinro 60V RCOP(IS)
The above cable should be used to connect between the control unit and either the ships AMS
system or the Remote Display Unit
NOTES
1. A & B Connections to use RED BLACK pair
GND connection to use BLACK wire from WHITE BLACK pair.
Trim WHITE wire.
24v DC
Connector Modbus
Connector
Exposed screen
Feed the cable into the control unit via a metal IP65 EMC gland supplied, ensuring that the
metal prongs make contact with the exposed cable screen as shown below.
Cable gland
Earthing Prongs
Press ‘OK’
Press ‘OK’.
Figure 34 will then be displayed.
To change the Time & Date press
‘Set Time / Date
Press ‘OK’.
Figure 34 will then be displayed.
To save the event Log press ‘Save
Logs’
Press ‘OK’.
Figure 50 will then be displayed.
Press ‘Back’ to return to Figure 49.
Repeat setting Detector settings for
the number of Detectors connected.
NOTE – The Reset button must be pressed within 5sec of pressing the Accept button
Press ‘Accept’ button for a minimum of 1sec Press ‘Reset’ button for a minimum of 1sec
c. The current Modbus address of the Control Unit will now be flashing (1sec on, 1sec off) (Refer
Figure 54)
d. Press the numerical button required until the Green LED above the pressed button flashes. (ie
For Modbus address 03, press No. 3 button(Refer Figure 54)
NOTE – The numerical button must be pressed within 10sec of pressing the Reset
button
Repeat the above for the number of Control Units installed per system.
After the addresses have been changed, please ensure that the EOL jumpers are fitted to the last
Control Unit, all other Control Units need to have the EOL jumpers removed.
Refer Figure 18 for EOL jumper positions.
NOTE – The Control Units 24Vdc Power Supply needs to be removed for a period of 10sec and
re-applied to ensure Modbus address changes are recognized on the Modbus network.
Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need to be
programmed to detect the required number of engines on the system (refer Section 2.9.1.4)
USB USB
Connection Connection
c. Connect the other end of the USB Lead to a USB socket on your computer (refer Figure 56)
Repeat the above for the number of Control Units installed per system.
After the address’s have been changed, please ensure that the EOL jumpers are fitted to the last
Control Unit, all other Control Units need to have the EOL jumpers removed.
Refer Figure 18 for EOL jumper positions.
NOTE – The Control Units 24Vdc Power Supply needs to be removed for a period of 10sec and
re-applied to ensure Modbus address changes are recognized on the Modbus network.
Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need to be
programmed to detect the required number of engines on the system (refer Section 2.9.1.4)
Press ‘OK’
Note: Isolation of the output relays (Pre Alarm and Slow/Shutdown Relays) is
required before commencing the smoke alarm test. If the Back-up Alarm Relay
is connected to the engine slowdown or shutdown system this should be
disconnected.
Warning: Carrying out this test without isolation or disconnection of the output
relays will cause the engine slowdown or shutdown system to operate if
connected.
a. Cut a length of wick approximately 30 mm long. Assemble the smoke tester by pushing
the wick into the wick holder fitted with the pipette bulb. Press the nylon pipe into the pipe
connector (refer to Figure 65).
Pipette Bulb
Wick Holder
Wick
Pipe Connector
Nylon Pipe
b. Push the nylon pipe of the smoke tester into the connector on the side of the detector
base body (refer to Figure 66).
c. Dip the wick into the bottle of smoke oil and reseal the bottle firmly
Note: Only a small quantity of oil is required.
d. Ignite the wick of the smoke tester and blow out the flame. Squeeze the pipette bulb to
keep the wick smoking.
Note: Care to be taken with this activity at all times.
e. While the wick is still smouldering, insert it into the pipe connector and squeeze the
pipette bulb.
f. Observe the wick is still smouldering, insert nylon pipe into the pipe connector of the
detector and squeeze the pipette bulb.
g. After tests are completed the Detector Peak Level readings should be erased. This can be
done via the Engine Menu using Clear Peak. (refer Figure 46)
h. To release the pipe from the connector, press in the metal collar on the end of the
connector at the same time as pulling the pipe out
i. Remove the nylon pipe from the pipe connector for stowage purposes.
j. The wick is reusable and can be left in the wick holder. Fully extinguish the wick after use
at all times.
k. Refer to the Material Safety Data Sheet in the event of health or safety issues.
To prevent the possible activation of the Back-up Alarm Relay disconnect the cable from the
top of the detector unit.
Press ‘OK’
Press ‘OK’
You will be returned to Figure 70.
To Isolate the Pre-Alarm Relay, press
‘Isolate’
Press ‘OK’
Press ‘OK’
You will be returned to Figure 70.
To Isolate the Slowdown/Shutdown
Relay, press ‘Isolate’
To De-Isolate the
Slowdown/Shutdown relay, press the
‘De-Isolate’ button.
Press ‘OK’
You will be returned to Figure 70.
Press ‘Exit’ to return to Figure 69.
Press ‘Exit’ to return to Engine 1
overview screen (Figure 68).
Press ‘Menu’
Press ‘Isolate’
Press ‘OK’
You will be returned to Figure 88.
Press ‘Back’ button to return to Figure 87.
Press ‘Back’ button to return to Engine 1
overview screen (Figure 86).
Press ‘Back’ button to return to Engines
overview screen.
Note: With the detector isolated the Back-up Alarm Relay may be activated if the oil mist level
increases above 3mg/l or light is introduced in to the detector. To prevent the possible
activation of the Back-up Alarm Relay disconnect the cable from the top of the detector unit.
Press ‘OK’
You will be returned to Figure 97.
To Test the Fault Relay, press the ‘0’
button.
Press ‘OK’
You will be returned to Figure 97.
To Test the Backup Alarm, press the
‘Test’ button.
Note – This is a software test only.
Press ‘OK’
You will be returned to Figure 97.
To Test the Optics, press the ‘Test’
button.
Press ‘OK’
You will be returned to Figure 97.
Press ‘Exit’ to return to Engine 1
overview.
Note - This will also reset all Tests.
Press ‘Accept’
Press ‘OK’
Press ‘OK’
You will now return to Figure 96.
Press the ‘Back’ button to return to
Engine Overview, Figure 95.
The Event Log enables the user to interrogate the past 1024 events and can be accessed via
the menus below. The Event Log is a rolling buffer and when the events exceed 1024 then the
oldest event is dropped off the Event Log.
To access the Event Log from Figure 96, press ‘Event Log’ button.
Note - If there are no Events matching your search then this screen will be blank.
3. Using a 4mm hexagon key, unscrew 2 off screws from the underside of the detector head
(refer to Figure 119). The screws are self-retaining.
4. Remove and invert the top part of the detector head. Examine the base moulding seal and
replace if damaged or perished (refer to Figure 121).
Screw Removal
One Fixing
Screw
Fan Retaining
Plug
3.8 DECOMMISSIONING
All the components of the Graviner Mk7 OMD system must be disposed of as
electrical/electronic equipment waste. i.e. using waste disposal methods in accordance with
current local waste disposal regulations.
4.1 GENERAL
The table below lists a series of failure modes and the likely faults that would be indicated
should that failure mode appear. Also listed are Actions, numbered 1 to 15, which should be
followed if the associated fault appears. On the following pages, Actions 1 to 15 are shown as
flow charts which will assist with fault finding on the Graviner Mk7 OMD system
Supply Failure
Control Unit Power indicator is off All Control Unit LED’s off 1.
Membrane failure
Control Unit fault Control Unit fault LED on. Control Unit fault 2.
No indication on the
All detector Power On (Green) detectors.
Control Unit fuse.
indicators on the Control Unit are Control Unit fault LED on, all 3.
off. Detectors disconnected.
detector fault LED’s flashing
1sec on 1sec off
No indication on the
Short circuit in Detector
detectors.
All detector Power On (Green) Cable
Control Unit fault LED on, all 13.
indicators are off. Component Failure in
detector fault LED’s flashing
Detector
1sec on 1sec off
Control Unit Power indicator is off Communications fault with Supply Failure 6.
the engine indicated on the
Remote Display
No indication on the
detectors.
Control Unit fault LED on, all
All detector Power On (Green) Detectors disconnected.
detector fault LED’s flashing
indicators on the Control Unit are 3.
1sec on 1sec off Power Supply failure
off.
Remote Display indicates
communications fault on all
detectors for that engine.
Detector LED fault. Detector fault LED on Detector sample area 10.
Modbus communications
cable fault
Remote Display indicates a Remote Display indicates a
communications fault on all communications fault on all End of line termination 12
engines engines incorrect.
Remote Display failure
No indication on the
detectors.
Control Unit fault LED on, all Short circuit in Detector
All detector Power On (Green) detector fault LED’s flashing Cable
13
indicators are off. 1sec on 1sec off Component Failure in
Remote Display indicates Detector
communications fault on all
detectors for that engine.
No Is 24v present
at the supply
input terminals
(TB1)
Yes
No Is 24v supply
between 18 –
31.2v
No Do all of the
membrane LED’s
operate correctly
Yes
No Are all
connections
made correctly
Yes
No On power up are
the detector
power LED’s on
Yes
No
Does the
Yes communications
fault move with
the cable
No
No Is the fan
operating
correctly
Yes
Yes
Replace the
detector End
No Is 24v present
at the supply
input terminals
(TB1)
Is the 24v
No Yes
input power
supply cable
connected
correctly
Yes
No Do all of the
LED’s operate
correctly?
Yes
Replace the
Control Unit
PCB
No
Replace the
End Detector
Yes
Optics test
passed?
No
Replace the
End Detector
No Does the
watchdog fault
reoccur?
Yes
Replace the
End Detector
Are all
No
connections
made
correctly?
Yes
Correct the
connections
Press the Acknowledge key f or 1
second
No
Are all of the
Control Units
addressed
correctly?
No
No
Are the
No
connections
made
correctly?
No
Is the Control
Unit addressed
correctly?
No
Are the Control
Units
addressed
correctly?
Detector Spares
Item Description Part No.
Detector Complete 53836-K269
Detector Complete (Short Sample Pipe) 53836-K269-01
1 Detector Head Assembly 53836-K272
2 Fan Assembly (1 Screw) D5622-005-02
Fan Assembly (2 Screw) 53569-K005
3 Base Unit sub-Assembly D5622-101
4 Connector Push In 21888-K073
5 Base moulding O Ring C1513-802
Cable Assemblies
90º Connector
43682-K285-1.0 1.0m Cable with 90° Connector 1.0 Metres
43682-K285-1.5 1.5m Cable with 90° Connector 1.5 Metres
43682-K285-2.0 2.0m Cable with 90° Connector 2.0 Metres
43682-K285-2.5 2.5m Cable with 90° Connector 2.5 Metres
43682-K285-3.0 3.0m Cable with 90° Connector 3.0 Metres
43682-K285-3.5 3.5m Cable with 90° Connector 3.5 Metres
43682-K285-4.0 4.0m Cable with 90° Connector 4.0 Metres
43682-K285-4.5 4.5m Cable with 90° Connector 4.5 Metres
43682-K285-5.0 5.0m Cable with 90° Connector 5.0 Metres
43682-K285-5.5 5.5m Cable with 90° Connector 5.5 Metres
43682-K285-6.0 6.0m Cable with 90° Connector 6.0 Metres
43682-K285-6.5 6.5m Cable with 90° Connector 6.5 Metres
43682-K285-7.0 7.0m Cable with 90° Connector 7.0 Metres
43682-K285-7.5 7.5m Cable with 90° Connector 7.5 Metres
43682-K285-8.0 8.0m Cable with 90° Connector 8.0 Metres
43682-K285-8.5 8.5m Cable with 90° Connector 8.5 Metres
43682-K285-9.0 9.0m Cable with 90° Connector 9.0 Metres
43682-K285-9.5 9.5m Cable with 90° Connector 9.5 Metres
43682-K285-10.0 10.0m Cable with 90° Connector 10.0 Metres
43682-K285-10.5 10.5m Cable with 90° Connector 10.5 Metres
43682-K285-11.0 11.0m Cable with 90° Connector 11.0 Metres
43682-K285-11.5 11.5m Cable with 90° Connector 11.5 Metres
43682-K285-12.0 12.0m Cable with 90° Connector 12.0 Metres
43682-K285-12.5 12.5m Cable with 90° Connector 12.5 Metres
43682-K285-15.0 15.0m Cable with 90° Connector 15.0 Metres
43682-K285-17.5 17.5m Cable with 90° Connector 17.5 Metres
43682-K285-20.0 20.0m Cable with 90° Connector 20.0 Metres
43682-K285-22.5 22.5m Cable with 90° Connector 22.5 Metres
43682-K285-25.0 25.0m Cable with 90° Connector 25.0 Metres
43682-K285-27.5 27.5m Cable with 90° Connector 27.5 Metres
43682-K285-30.0 30.0m Cable with 90° Connector 30.0 Metres
43682-K285-32.5 32.5m Cable with 90° Connector 32.5 Metres
43682-K285-35.0 35.0m Cable with 90° Connector 35.0 Metres
CATERPILLAR DETECTORS
气缸油加热柜
Heating Tank For Cylinder Oil
认可资料
泰兴市海诚船舶设备有限公司
TAIXING HAICHENG MARINE EQUIMENT CO.,LTD.
1/6
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
目录 INDEX
1. 气缸油加热柜简介………………………………………………………………………………………………………….. 3
2、气缸油加热柜外形图(HTJRG-0.37-00)………………………………………………………………………….7
3、气缸油加热柜电气原理图………………………………………………………………………………………………..8
4、气缸油加热柜备件清单…………………………………………………………………………………………………16
2/6
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
气缸油加热柜简介
Introduction for Pumping Station
气缸油加热柜主要适用于MAN B&W 主机的注油器系统,为注油器系统提供稳
定温度的汽缸油供汽缸润滑。
Heating Tank For Cylinder Oil is mainly used for oil injection pump system
for MAN B&W main engine. Cylinder Oil supplies steady temperature of
一、组成
Consisting
气缸油加热柜主要由油箱、过滤器、温控电加热器、温度表温度开关、液位
开关、球阀和电气控制箱等组成。
Heating Tank For Cylinder Oil consists of fuel tank,filters, ELEC. heater,
thermometer, temperature switch, lever switch and electric control boxes, etc.
二、电气控制箱控制开关和指示灯
1、 白色指示灯——电源指示灯
2、 红色指示灯——低液位报警指示灯
3、 绿色指示灯——电加热运行指示灯
三、主要技术参数
3/6
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
1、 容 积:37L
Volume: 37L
2、 工作温度:40~50℃
3、 工作压力:3.0~4.0bar
4、 电加热功率:750W
5、 电制:440V/60Hz/3P或400V/50Hz/3P
Voltage:440V/60Hz/3P or 400V/50Hz/3P
四、安装、调试(主机停车时)
1、按照外形图HCJRG-0.37-00 连接各管路,检查各阀件的开启状态。
2、按照电气原理图接线,确保接线的正确。
3、打开加热柜电气控制箱上的电源开关。
4、加热柜进入正常状态。
4/6
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
五、维护
Maintenance
1、汽缸油加热柜配有两只滤器,互为备用。当加热柜工作一段时间后,处
于工作状态的滤器滤芯内沉淀了一定的杂质。这时应通过三通球阀切换至另
一台滤器,使其工作。
Two strainers were equipped on the Heating Tank For Cylinder Oil being
alternate each other. After period of working time, there will be some deposit of
impurity inside the strainer which is at the active status. While this happens,
another strainer should be put in use by the shift of the three way valve
2、滤芯清洗步骤:
1)将滤器盖板上的四只内六角螺栓卸下,打开滤器盖板。
Dismantle the four socket head hexagon bolts on the cover of the strainer,
2)取出滤网压板后,将滤芯取出。
Take out the press plate and then take out the filter;
3)将取出的滤芯放入柴油,用软毛刷清洗,清洗完成后用压缩空气吹干。清
洗杂质时,应检查滤芯有无破损。如滤芯破损,需及时更换。
Dip the filter into the diesel and clean it with soft brush, then dry it with
compressed air. Check if there is any damage of the filter element while
4)将清洁的滤芯放入滤器壳体内。确认滤器放置到位后,将滤芯压板置于
5/6
泰兴市海诚船舶设备有限公司
Taixing Haicheng Marine Equipment Co.,Ltd
滤芯的顶部,盖上滤器盖板,均匀拧紧螺栓。
Put the clean filter element back into the strainer shell and make sure it is fitted
in position, after this, put the press plate on the top of the filter element, close
5)清洗或更换滤芯的同时检查密封件完好情况。
Check if the sealing gasket is still in good condition while cleaning or replacing
六、注意事项
Note
1、加热柜具有自动加热功能,出厂时温度已设定45℃加热,不得任意调整。
Heating tank can auto heating. The temperature has been set by 45℃ before
2、低液位时不得启动电加热器。
Do not turn on the ELEC. heater while the low liquid level.
6/6
泰兴市海诚船舶设备有限公司
TAIXING HAICHENG SHIPPING EQUIPMENT CO.,LTD.
附件/备件/工具清单
LIST OF ACCESSORIES/SPARE/TOOL
序号 物品名称 规格 单位 数量 备注
NO. DESCRIPTION TYPE UNIT QT’Y NOTE
滤芯
1 Ф70×Ф50×L188 Set 1
FILTER ELEMENT
外压盖O型圈
2 O TYPE CIRCLE OF Ф90×Ф84×Ф3 Pcs 1
OUTER GLAND
滤器垫片
3 Ф78×Ф58×2 Pcs 1
Filter gasket
地址:江苏省泰兴市张桥镇工业集聚区同创路 299 号
Add:58,Shilidian Street,Yaowang town, Taixing City, Jiangsu, China
E-mail:txhc2011@163.com Tel:0523-89705288 Fax:0523-89705299
排气阀总成翻转台
使用说明书
Operation Instruction
for Turntable Machine of Exhaust Valve Assembly
上 海 齐 耀 系 统 工 程 有 限 公 司
QIYAO POWER SYSTEMS Co., LTD
1 概述
1.1 产品信息
TM 系列排气阀总成翻转台是为方便维修时拆装排气阀总成而设计的设备,适用于各型船用二冲程低速柴
油机排气阀总成拆装时的翻转操作。该设备结构简单可靠,操作快捷方便,体积小巧。
本说明书适用于 TM 系列排气阀总成翻转台设备的使用及维护保养,文中的图表仅用于本文的说明,保留
对设备和技术资料进行更新和改进的权力。
1.2 制造商信息
设计制造:上海齐耀系统工程有限公司
电话:+86-21-65687121
传真:+86-21-65680330
1.3 安全事项
1.3.1 使用及维护保养人员应在使用或维护前仔细阅读和学习本手册,并遵守相关安全规定。
1.3.2 安全措施与注意事项
运输:
运输及装卸时应注意安全。
必须使用安全合格的吊装工具与设备,吊装螺钉确保无损坏及安装牢固。
吊装时不允许有人员站在设备下。
使用:
每次使用前检查各部件的连接应牢固,而且运转正常。
操作中应使用必要的劳动防护用品。
其它注意事项:
不要用水清洁设备。
设备闲置时定期在光滑的加工面涂防锈油保护。
1.3.3 安全说明及标识
安全说明包含在说明书各章节中,操作者应严格遵守,以免造成对人员、财物、环境等的损害。
安全标识包含如下几类:
危险!
可能造成严重人身伤害
乃至死亡的伤害。
警告!
可能造成财物或环境
损害。
注意!
要求正确使用设备,
否则可能有轻微伤害或
损失。
2 产品介绍
2.1 设备特点:
本设备整体外形紧凑,重量轻,通用性好,整体焊接为主,刚性好,结构简单,可自锁,安全可靠。
2.2 结构简介
翻转台设备大致由以下几个部分构成:台架部件,传动部件,工件连接板,止动销和保护罩,如图 1
所示。
2.2.2 传动部件结构,如图 2 所示
传动部件包含一套蜗轮蜗杆机构,轴承机构,手轮等,它们整体固定在台架部件的上方支架内,实现
转动手轮翻转排气阀总成的目的。
2.2.4 止动销是在翻转排气阀总成前、后固定在工件连接板的槽内,防止传动装置转动,确保安全。
2.2.5 保护罩是用来保护蜗轮蜗杆传动机构的外罩。
2.3 适用范围:
本设备适用于二冲程船用低速柴油机排气阀总成维修时的拆装。
3 设备的安装
3.1 安装地点的选择
应考虑选取经济有效的合适地点安装此设备。
该处应避免有强烈震动。
该处应方便吊装并有足够的操作空间。
参考认可的安装图纸要求,安装在
船内合适的地方。
图3 设备的安装
3.2 设备的安装
参考图 3,为了防止设备受到震动的影响,把备件箱中的橡胶减震块放置在客户安装基座和设备机座中间,
用 M20 螺栓螺母标准件紧固。
4 翻转操作前的准备
4.1 设备的检查:操作前应转动手轮,检查设备各部分正常,传动零部件应松紧合适,动作平稳。
4.2 把止动销旋入工件连接板的槽内,以防传动装置受力转动,确保安全。
5 翻转操作
5.2 吊起排气阀总成,此时排气阀及排气阀座朝下,排气阀壳出气口部位对准翻转台的安装连接板,并拧
紧安装用的连接螺栓(参考图 5)。
5.3 注意此时止动销必须在工件连接板的销槽内,以防止排气阀总成意外转动,确保安全。
5.4 拆除排气阀壳上方的液压部件及气缸壳体,并吊离。剩下排气阀和阀座及阀壳等零部件。
5.5 将止动销从连接板的销槽内退出,缓慢、均匀转动翻转台手轮,使得排气阀盘及阀座翻转至上方。
5.6 将止动销再次旋入工件连接板的销槽内,以防止排气阀总成意外转动。
5.7 拆除卡环等锁住排气阀的零件,此时排气阀和阀座可使用吊具吊出,完成拆卸(参考图 6)
。
5.8 在翻转台上装配排气阀总成的操作按以上反向顺序进行。
警告!
翻转操作中注意安全!
切勿操作手轮转动太急!
图4 排气阀总成结构示意图
图5 翻转前示意图 图6 翻转后示意图
6 翻转台的维护保养
6.1 每半年空转检查设备正常、灵活、可靠。
6.2 每年二次向传动部件蜗轮蜗杆内添加润滑脂,检查并保持蜗轮蜗杆在良好润滑状态。
6.3 每次使用后都必须清洁设备并在连接板上涂一层防锈油膜,用防水塑料布扎紧罩住设备以防灰尘和潮
湿,确保设备安全及状态良好。
7 备件工具(实际详见随机提供的清单)
7.1 减振垫块:设备安装件
The TM series of turntable machine is designed to overturn the exhaust valve assembly by hand. It is
applicable to some types of marine engine exhaust valve assembly. The device has the advantages of simple and
credible structure, convenient operation, small volume.
This manual is intended primarily for the operator of the valve and valve seat grinding machine of the type
DM. The charts and drawings are used in this manual and may be changed in the future.
Telephone:+86-21-65687121 Fax:+86-21-65680330
Transportation:
Use the safe tools. Make sure the lifting eyebolts are undamaged and adequately fastened.
Operation:
Make sure the correct type of the equipment. Check all fixed parts to be correct and run normally.
Other warnings:
2EQUIPMENT DESCRIPTION
2.1 Features:
The overall appearance of the equipment is compact, light weight, good versatility, overall welding, good
rigidity, simple structure, safe and reliable self-locking.
The machine is composed of several parts as follows: framework assembly, transmission assembly,
connecting plate, a stop pin and a protective cover, see figure 1.
The transmission part includes a set of worm and worm gear,bearing mechanism, hand wheel ect. They are
overall fixed on the bench component, achieving to overturn the exhaust valve assembly.
1.worm gear 2. Worm 3. Hand wheel 4. Bearing for worm 5. Bearing for worm wheel
Figure 2
2.2.3 The connecting plate is a connecting piece for exhaust valve assembly by several bolts.
2.2.4 Stop pin is fixed connecting plate in the gap to prevent the driving device to rotate, to ensure the safety
while turned over the exhaust valve assembly.
2.2.5 The protection cover is used to cover the worm and worm gear.
2.3 Application:
This equipment is suitable for exhaust valve assembly of two stroke marine diesel engine while repairing is
needed.
3 INSTALLATION
Carefully consider where to locate the machine in the most effective and economical use.
drawing by us
Figure 3
3.2 Installation
Mount the grinding machine on the damping pads supplied in the spare box to prevent the vibrations by
standard parts of M20 (figure 3).
4.1 Turn the hand wheel before operating, check the equipment to be correct, the transmission parts should run
properly and smoothly.
4.2 The stop pin is screwed into the groove of the connection plate, in order to prevent the rotation by force, to
ensure the safety.
5 OPERATION OF TURNOVER
5.1 According to the diesel engine manufacturer’s instruction, dismantle the exhaust valve assembly from diesel
engine (see Figure 4),check the exhaust valve assembly. This equipment is necessary if the exhaust valve
assembly is needed repairing.
5.2 Lift the exhaust valve assembly, at the moment the exhaust valve and valve seat is downwards, exhaust valve
housing outlet is aligning with the connecting plate of the turntable, connecting and tighten the bolts (see Figure
5).
5.3 To be sure that the stop pin must be in the groove of the connection plate, to prevent exhaust valve
assembly to rotate accidentally, to ensure the safety.
5.4 Removing the hydraulic components and the cylinder shell above the exhaust valve, and hanging from the
assembly. There are the rest of the exhaust valve, seat and the valve shell parts.
5.5 Exit the stop pin from the pin groove on the connecting plate, turn the hand wheel slowly and smoothly, so
that the exhaust valve disc and valve seat turn to the top.
5.6 Screw the stopping pin into the connection plate again, to prevent exhaust valve assembly unintended rotation.
5.7 Remove such as the snap ring that locking the exhaust valve parts, then the exhaust valve and valve seat can
be hung out completely (see Figure 6).
5.8 the steps to install the exhaust valve assembly by the turntable is according to the above in reverse order.
Warning!
Ensure the safety during
operation!
Do not run the wheel too
quickly!
Figure 4 Exhaust valve assembly structure diagram
Check the following regularly in order to ensure a good condition and a safe operation:
6.1 Run idle to check the equipment normal, flexible and reliable every six months.
6.2 Add grease to the transmission parts such as worm , check and maintain the worm in good lubrication
condition two times a year.
6.3 Clean and coated with a layer of rust preventing oil after each operation on the connection plate, coat the
equipment to prevent dust and damp with a waterproof plastic cloth, ensure the safety of equipment and in good
condition.
7 APPENDIX TOOLS
There are following appendixes in the spare box along with the machine.
7.2 Hexagon wrench keys:S=5,10. 1 piece for each diameter,used for installing or removing the bolts.
乐春
LC-AVM-01
轴向振动监测仪使用说明书
(2017 版)
上海乐春重工机电设备有限公司
SHANGHAI LECHUN HEAVY MACHINERY & ELECTRONIC EQUIPMENT CO.,LTD
1. 序论 ......................................................................................................................... 3
2. 技术参数 .................................................................................................................. 4
3. 功能说明 .................................................................................................................. 4
4. 拆包(箱) ................................................................................................................ 5
5. 安装 ......................................................................................................................... 6
5.2.1 电缆 .............................................................................................................. 7
6. 系统设置 .................................................................................................................. 8
7. 故障 ....................................................................................................................... 10
8. 附录 ....................................................................................................................... 15
4. Unpacking ............................................................................................................... 22
5. Mounting ................................................................................................................. 24
8. Appendix ................................................................................................................. 34
1.2 产品支持
如果您需要安装或者服务,请与我们联系:
上海乐春重工机电设备有限公司
上海市浦东新区浦三路 4399 号 8 栋
电话:0086-21-51961688
传真:0086-21-51961601
为了能最有效帮助您,请准备以下信息:
1) 船名、厂名
2) 可疑部件(故障)名称
3) 部件识别号(序列号)
2. 技术参数
运行温度范围: - 10 ℃ ~ + 70 ℃
防护等级: IP55
测量范围: 最大值:10.00 mm 峰-峰值(±5.00 mm)
线性度:5.00 mm 峰-峰值(±2.50 mm)
电源: 电源电压:24 V±20 %
最大电流消耗:300 mA
传感器: 型号:LC - AVM - P01 电缆长度:7 m
安装距离:8.5 mm
报警 / 监测电流输出:
输出:4 - 20 mA 最大载荷:250 欧姆
0 mm 峰-峰值=> 4 mA
5 mm 峰-峰值=> 20 mA
Iout [mA] = 1.6×(位移mm峰-峰值)+ 4
减速输出: 点接触电位(NO)
最大载荷:50 V 100 mA
设置点调整范围:0.00 至 10.00 mm
减速延迟时间: 0 - 300 秒 每次 20 秒
精确度: 传感器输入至显示,曲轴位置输出报警 / 监测电流输出:±5 %
减速延迟时间:±15 %
3. 功能说明
传感器传送电流信号至控制单元(电流信号的强度直接与传感器和曲轴之间的距离成
比例),控制单元将来自于传感器的电流信号转换成每 mm 曲轴位移为 1 v 的电压。峰-
峰值位移量显示在具有 0.01 分辨率的四位显示屏上。并通过一个电压一电流转换器,将
一个 4 - 20 mA 电流信号发送至“报警/监测电流输出”端口。
4. 拆包(箱)
交货付款要检验以确保 AVM 系统没有损坏,包装内容如下:
1) 轴向振动监测仪安装、设置说明(文件)
2) 轴向振动监测单元
检查电路板上的识别码与 AVM 系统标准单上是否一致,如果不对应,请与我们联系。
5. 安装
5.1 机械部分安装
传感器安装请参照附录 —— 机械安装说明图纸。为了保证峰 - 峰值的正确读出,
传感器与被测件之间的正确距离是非常重要的。LC - AVM - 01 传感器的正确安装间隙为
8.5 mm。
安装钢管,将便于电缆通过钢管连接到发动机外部侧壁上,轴向振动监测控制单元
装在电缆所能连接的范围内。
更多的细节请参阅所附图纸。
5.2 电子部分安装
LC - AVM - 01 振动监控仪控制单元的主板上安装有 K1 至 K6 的接线柱。每只接线柱
上标明引脚号。例如:在 K4 上的引脚 3 可特指为 K4.3。主板的接线如下图所示。接地标
志表明 K1.2、K3.2 和 K4.2 通过主板直接接地。
5.2.1 电缆
传感器电缆可以根据要求进行剪切,还可以用相同电缆和接线盒进行延伸。
报警 / 监测电流输出使用屏蔽线与发动机控制系统连接,电缆的屏蔽部分与接头的
连接按下图:
减速输出使用屏蔽线与发动机控制系统连接,电缆内的屏蔽可不接,减速和报警 / 监
测电流输出可以使用一根多芯屏蔽电缆来替代两根电缆。我们建议使用横截面为 0.75
mm2的电缆。
5.2.2 安装和登记
为了有效的提供帮助,我们提供登记表。详细填写相关信息并寄回给我们,当需要替
换故障部件时,我们可根据登记信息提供有效服务。
线路图包含有接线说明,减速延迟时间设置,减速设置点调整和显示等信息。并且也
提供了传感器的安装间隙。在安装传感器和连接电路板之后,将准备设置轴向振动监测仪。
设置过程有两步:
根据你所使用的发动机型号,参考“发动机安全运行的轴向振动范围”。按住设置点
按纽通过旋转调节电位器(P4)来调整设置,直到屏上显示出要求的设置点。
1) 调节减速延迟波段开关以确定延迟时间,建议初始设置为 100 S(“5”)。
7.1 故障检测过程
当出现可疑故障时,通过下列步骤,将执行一个完整的系统检测以确定故障。
7.1.1 检查传感器电源
连接电源至 K1
显示屏会显示 18.88(错误码)
检查 K2 上的电压,此时读数为 14.0 ~ 16.0 V
否则,电路板有故障,需要替换(参见 7.2.2 替换电路板)。
连接欧姆表至 K4
调节减速延迟时间至“0”位
部分连接 K2 至检测接线端 K5:K2.1 - K5.1,K2.2 - K5.2
通过设置点按钮检查实际设置点,如设置点明显大于 5 mm,则调节 P4,减小设置点。
当初始显示高于调整后的设置点,减速继电器将被激活:Rsd = 0 Ω,
连接 K2.3 至 K5.3 并观察欧姆表上的读数。
当 显 示 读 数 小 于 调 整 后 的 设 置 点 时 , 减 速 继 电 器 将 断 开 , Rsd = ∞ 或 Rsd =
Rsupervisionif,一监控电阻安装于 K6.1 和K6.3 之间。
如果减速继电器有故障,则电路板需要替换(参见 7.2.2 替换电路板)。
注意:记住恢复设置的减速延迟时间和设置点至原始数值。
连接电源和安培表至传感器(如图)。
通过来回移动一块在传感器前的金属来检查,如果Ip没有任何变化,则传感器或者电
缆可能有故障,需更换(参见 7.2.1 替换传感器)。
7.2 替换部件
如果故障检测显示系统故障,我们可以提供新的电路板和传感器。
7.2.1 替换传感器
当传感器出现故障,可以向我们订购一个新传感器。
新电路板和传感器的安装请参照第 6 章系统设置。
注意:请记住替换旧的校准纸。
7.2.2 替换电路板
当电路板出现故障,请订购一块替换电路板,订货时注明传感器和电路板上的识别号。
替换电路将进行相应的校准。
取下 6 颗固定螺母,拆下旧电路板,然后安装上新电路板。
连线和设置请参照 5.2 节电子部分安装和第 6 章系统设置。
注意:记得替换包含旧序列号的 LC - AVM - 01 整机校准表。
8. 附录
Instruction Manual of Axial Vibration Monitor LC - AVM - 01 / LC - AVM - 01 振动监控仪使用手册 15
附件在此页之后:
z 机械部分安装说明
z 登记表(请寄回给我们)
z AVM 整机校准表
机械安装说明
Instruction Manual of Axial Vibration Monitor LC - AVM - 01 / LC - AVM - 01 振动监控仪使用手册 16
传感器与显示峰-峰值运动的控制单元相连并将信号发送至发动机控制系统。
传感器安装在减振器壳体上,既可安装在减震器上部,也可安装在下部。
登记表
振动监控仪
产品信息
型号(LC - AVM - 01)
完整的识别号
电路板识别号
传感器识别号
型号和标识号都可以在控制单元的电路板中找到。
船 / 工厂信息
船 / 工厂名称
劳埃德号 船号
船厂
发动机型号 发动机号
发动机制造商
安装日期 安装由: 船厂 / 承包商 / 首席工程师(请
注明)
备注:
振动监控仪校准表
LC - AVM - 01 电路板序列号:
LC - AVM - 01 传感器序列号:
由于其它传感器的读数可能会不正确,请勿使用未经我们重新校准的传感器。
发动机安全运行的轴向振动限制
发动机型号 检修 报警 减速
电路板测试及校准由:
签字:
1. Introduction
2. Technical parameters
4. Unpacking
Delivery must be inspected to ensure that the AVM system package is complete
and undamaged. The contents of the package are as follows:
1) Axial Vibration Monitor Mounting and set-up instruction (This Document).
2) Axial Vibration Monitor Control Unit
Open the box cover and check whether the circuit board identification number is
consistent with the identification number on the AVM calibration sheet. If not, please
contact us.
The Slow Down Output is also connected to the engine control system by a
shielding cable, and the shield is to be terminated in the cable gland.
The Slow Down and the Alarm/Monitoring Current Output can be replaced by a
multi-core shielded cable instead of two cables.
We recommends cables with a cross section of 0.75 mm². Please refer to the plant
specification for information on plant specific requirements.
The circuit diagram contains terminal assignment, slow down delay time setting,
slow down set-point adjustment and readout, etc. And the probe mounting gap is
indicated for quick reference. After mounting the probe and connecting the circuit board,
the Axial Vibration Monitor is ready for set-up.
The set-up procedure has two steps:
Dismount the old circuit board by taking out six screws holding the metal plate.
8. Appendix
The following appendix are to be found on the next page:
z Mechanical mounting instruction
z Registration form (Please send to us)
z AVM Calibration Sheet
Registration Form
Product information
Type(LC - AVM - 01)
Complete Identification No.
Circuit board Identification No.
Probe Identification No.
The type and identification number can be found on the circuit board of the control unit.
Remarks:
Please do not use the probe without our recalibration as other probes may cause
incorrect readouts.
Sig.
Supplier: AAM
Component designation: Viscous Vibration Damper
Dimensions: Ø2700 X 380
AAM Document number: DOC002866
AAM part number: SPN047366
Engine: QMD-MAN 6G45ME-C9.5
Application: Main Propulsion Engine
Shipyard: SHANHAIGUAN
1
AAM
131 Parkinson Lane
Halifax
West Yorkshire
HX1 3RD
United Kingdom
Tel: +44 1422 395106
Fax: +44 1422 357234
Email: David.Whitaker@aam.com
2
DOC002866
TABLE OF CONTENTS
1 ABOUT THIS MANUAL ............................................................................................................................. 5
2 SAFETY REGULATIONS ............................................................................................................................. 6
2.1 INTENDED USE ........................................................................................................................................... 6
2.2 SYMBOLS AND WARNING SIGNS ..................................................................................................................... 6
2.3 STRUCTURE OF SAFETY MESSAGES.................................................................................................................. 6
2.4 PERSONAL PROTECTION ............................................................................................................................... 6
2.5 REQUIREMENTS OF THE OPERATING PERSONNEL ............................................................................................... 6
2.6 ENVIRONMENTAL PROTECTION...................................................................................................................... 6
3 PRODUCT DESCRIPTION .......................................................................................................................... 7
3.1 DESCRIPTION OF THE DAMPER ...................................................................................................................... 7
3.2 APPLICATION ............................................................................................................................................. 7
3.3 FUNCTIONAL DESCRIPTION ........................................................................................................................... 7
4 TECHNICAL DATA ..................................................................................................................................... 8
4.1 PRODUCT IDENTIFICATION............................................................................................................................ 8
4.2 TECHNICAL SPECIFICATIONS .......................................................................................................................... 8
4.3 TECHNICAL DRAWING .................................................................................................................................. 9
5 TRANSPORT AND STORAGE ................................................................................................................... 10
5.1 TRANSPORT ............................................................................................................................................ 10
5.2 CHECK FOR TRANSPORT DAMAGE................................................................................................................. 10
5.3 STORAGE ................................................................................................................................................ 10
5.4 UNPACKING ............................................................................................................................................ 10
6 INSTALLATION ....................................................................................................................................... 11
6.1 GENERAL ................................................................................................................................................ 11
6.2 HORIZONTAL LIFTING ................................................................................................................................ 11
6.3 HORIZONTAL TO VERTICAL LIFTING ............................................................................................................... 12
6.4 VERTICAL LIFTING ..................................................................................................................................... 13
6.5 ASSEMBLY TO ENGINE ............................................................................................................................... 13
7 OPERATION ........................................................................................................................................... 14
7.1 COMMISSIONING ..................................................................................................................................... 14
7.2 WARNING .............................................................................................................................................. 14
7.3 DAMPER COOLING ................................................................................................................................... 14
8 CONDITION MONITORING ..................................................................................................................... 15
8.1 DAMPER SERVICE LIFE ............................................................................................................................... 15
8.2 SAMPLING SILICONE FLUID FOR CONDITION MONITORING ................................................................................. 15
8.3 SILICONE SAMPLING PROCESS ..................................................................................................................... 15
8.4 RETURN SAMPLE TO AAM FOR ANALYSIS ...................................................................................................... 16
8.5 FURTHER SAMPLE INTERVAL ....................................................................................................................... 16
9 MAINTENANCE ...................................................................................................................................... 16
10 REPAIRS ................................................................................................................................................. 16
11 SPARE PARTS ......................................................................................................................................... 16
12 ATTACHMENTS ...................................................................................................................................... 17
12.1 DECLARATION OF INCORPORATION .............................................................................................................. 17
12.2 MATERIAL DECLARATION FOR IMO SHIP RECYCLING ........................................................................................ 18
3
DOC002866
12.3 REACH SAFETY DATA FOR SILICONE FLUID ..................................................................................................... 20
12.4 TRACTOL SAFETY DATA FOR GREY PRIMER ................................................................................................... 28
12.5 ENSIS-DW 2455 safety data for corrosion protection ......................................................................... 37
4
DOC002866
1 About this Manual
These operating instructions contain important information on the use of the product. Carry
out these instructions carefully and precisely. This helps to avoid hazards, downtime and
repair costs whilst also increasing the reliability and service life of the product.
The operating manual contains information which is intended to support the user in his or her
work, and information that needs to be observed in order to ensure safe operation. This
information is intended to complement the experience and capabilities of the members of
staff who are responsible for:
The operating manual must be available to the members of staff at all times. The members of
staff delegated with the task of operating the component must adequately familiarise
themselves with the structure of the operating instructions, so that they can find the
information they need without an extended search.
A prerequisite for the protection of the members of staff from dangers, for the prevention of
faults and for the operation of the component in a fault-free and safe manner is the
knowledge of the content of the technical documentation of the component.
The operating manual must always be available (in the control room, for example).
All persons who are responsible for the transport, assembly, initial commissioning,
operating, maintaining or repair of the component must be acquainted with the
operating manual. We recommend that the user has the operators confirm to him in
writing that they are acquainted with the operating manual.
All requirements and instructions in this operating manual must be complied with.
The documentation of purchased items is a constituent part of this operating manual. All
safety information in this operating manual and all other information must be observed.
All relevant national regulations, regulations concerning accident prevention and
environmental protection as well as the confirmed technical regulations for safe and
proper working must be complied with.
If the product is transferred to a new owner, these instructions and all associated documents
are to be passed on to the new owner.
5
DOC002866
2 Safety Regulations
2.1 Intended use
The vibration damper must only be used for the suppression of torsional vibration on a diesel
engine crankshaft.
The text in the cell to the right of the WARNING symbol contains important
information that must be followed to avoid injury to the user.
WARNING!
The text in the cell to the right of the CAUTION symbol contains important
information that must be followed to avoid damage to the damper.
CAUTION!
Safety shoes
Safety helmet
Protective gloves for handling and fitting work
The vibration damper should only be lifted, move and handled by personnel
who:
Have been trained in safe working practices and any international,
national and local requirements and regulations that apply for
prevention of accidents.
WARNING!
Have the required license to work with cranes.
Are familiar with these transport and lifting instructions.
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3 Product description
3.1 Description of the damper
The vibration damper is viscous torsional vibration damper.
3.2 Application
The damper is designed for use on the QMD-MAN 6G45ME-C9.5 Main propulsion engine and
is not interchangeable with other engines or applications.
The torsional damper consists of an inertia ring (seismic mass) surrounded by a thin film of
highly viscous silicone fluid, enclosed in a casing attached to the engine crankshaft. The inertia
ring is free to rotate within the casing and is supported on bearings. Relative movement
between the inertia ring and the damper casing caused by crankshaft torsional vibration
shears the silicone fluid which produces a reaction torque. The shearing of the fluid absorbs
energy from the torsional vibration and generates heat which is dissipated through the
external surfaces of the damper.
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4 Technical data
4.1 Product identification
Each vibration damper has an individual six digit serial number stamped on the case adjacent
to the silicone fluid sampling plug.
Weight: 11635 kg
Cover
Case
Radial bearing
Inertia ring
Axial bearing
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4.3 Technical drawing
9
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5 Transport and storage
5.1 Transport
AAM vibration dampers are transported in specially strengthened wooden packing cases and
protected from rust by a sealed polythene film.
The damper should only be transported in a horizontal orientation. The packing case should
not be tilted.
5.3 Storage
If storage is necessary, the damper should remain in the packing case and be stored in a dry,
well-ventilated area.
5.4 Unpacking
Remove the packing film and rust-inhibiting paper from the damper (if provided)
Take the damper out of the wooden packing case using eyebolts in the lifting holes provided
(see section 6.2)
Ensure that the packaging materials are disposed of properly in an environmentally friendly
manner. Contact AAM for details of or data sheets for the packaging materials used.
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6 Installation
6.1 General
The vibration damper should only be lifted and handled by personnel who:
Have been trained in safe working practices and any international,
national and local requirements and regulations that apply for
prevention of accidents.
Have the required license to work with cranes.
WARNING!
Are familiar with these transport and lifting instructions.
WARNING!
WARNING!
4 eyebolt holes are provided in the damper flange for lifting the damper while it is in a
horizontal orientation, such as removal from the packing case. The eyebolt holes are tapped
M48.
Before assembling the eyebolts into the eyebolt holes, the relevant tapped lifting holes must
be checked to ensure that they are suitable for use.
A tapped hole must not be used for lifting the damper if any of the following
is true:
The thread is damaged in any way.
The thread is corroded.
WARNING!
There are signs that the tapped thread has been reworked.
Lifting of the damper when it is in a horizontal orientation should only be carried out using
suitable lifting equipment (slings, chains, ropes) that distributes the weight of the damper as
evenly as possible between the eyebolts.
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6.3 Horizontal to vertical lifting
A soft sling, (rope, leather, etc.) passed through the central bore of the damper can be used to
change orientation of the damper from horizontal to vertical.
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6.4 Vertical lifting
Sling guide
SPN047542
QTY: 04 NOS.
Flat belt slings or wire ropes should be used when lifting the damper in a vertical orientation,
such as when assembling the damper to the engine crankshaft.
Before assembly to the engine, all mounting surfaces should visually inspected to ensure that
they are clean and free from damage.
For details of the method for assembling the damper to the engine, consult the
documentation provided by the engine manufacturer.
The vibration damper should only be assembled to an engine which has been
shut down and isolated so that it cannot be started during the damper
assembly operation.
WARNING!
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7 Operation
7.1 Commissioning
Each AAM damper is individually designed and manufactured to the specific torsional
requirements of the engine installation.
7.2 Warning
The vibration damper contains precision machined internal moving parts with very small
clearance gaps. Do not allow any object to impact the external casing or serious internal
damage may occur.
Damage to the damper casing can cause failure of the damper and the engine
crankshaft.
CAUTION!
IMPACT
CAUTION NOT
ALLOWED
INTERNAL
ALLOWED
DAMAGE
The damper is fitted inside the engine crankcase cover and is designed to be used with oil
spray cooling onto the external surface of the damper to increase the heat dissipation
capacity. The flow rate of oil required for effective cooling has been calculated by AAM (see
section 4.2). The design and installation of the necessary piping etc. is the responsibility of the
engine builder. Any restriction in cooling oil flow could lead to the damper overheating with
consequent significant reduction in the damper service life.
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8 Condition monitoring
8.1 Damper service life
The service life of viscous dampers fitted to 2-stroke engines can vary depending upon the
application. It can be influenced by engine application and loading as well as non-torsional
factors associated with the engine’s environment such as vibrations induced from adjacent
machinery, engine mountings, shafting systems and hull vibrations.
However, experience has proven that 50,000 - 75,000 operating hours is possible before
damper service is required.
Removal of a silicone fluid sample should initially be carried out at 18 000 – 20 000 hours of
engine operation or at the first major engine service, whichever occurs first. Examination of
the first silicone sample will enable AAM to advise the subsequent sampling intervals, and by
following this procedure and AAM’s recommendations, the necessity for overhauling or
replacing the damper can be anticipated.
Special sampling kits complete with instructions for removal of silicone fluid samples are
available from AAM or appointed service agents.
For further details of the process for taking a sample of silicone fluid, refer to the instruction
supplied with the AAM sampling kit.
15
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The AAM damper is filled with a precise volume of fluid, relative to the ‘free space’ within the
enclosed casing. This precise volume is strictly controlled during assembly and filling, to allow
for expansion during operation and the removal of a controlled number of 1 cc. fluid samples
for condition monitoring.
The damper design incorporates a reservoir to compensate for the fluid sample.
Replenishment of the small volume extracted at each sampling is not necessary.
Any excess loss of fluid during sampling may seriously affect the damper.
If this occurs, contact AAM for advice.
CAUTION!
9 Maintenance
The AAM damper does not require any regular maintenance (but see section 8 above).
However, it is recommended that at major engine services the flange mounting bolts
connecting the damper to the crankshaft are checked for tightness and that a visual inspection
is made of the damper, checking for signs of damage or leakage.
10 Repairs
There are no user serviceable parts inside the damper.
Removing the cover of the damper will render the damper inoperable.
CAUTION!
11 Spare parts
There are no spare parts for the AAM vibration damper.
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12 Attachments
12.1 Declaration of Incorporation
DECLARATION OF INCORPORATION
We, AAM Powertrain (UK) Ltd.
of 131 Parkinson Lane
Halifax
HX1 3RD
Phone: +44 (0)1422 357234
Fax: +44 (0)1422 354432
Declare under our sole responsibility that in accordance with EUROPEAN PARLIAMENT AND
COUNCIL DIRECTIVE 2006/42/EC on machinery, the Partly Completed Machinery identified as:
Conforms to the following Essential Health and Safety Requirements (EHSR) of the Directive in
Annex 1:
1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.4, 1.5.4.
ESHRs not listed above are not considered to apply to this Partly Completed Machinery or
must be fulfilled by the assembler.
The above referenced damper is incomplete machinery and must not be put into service
until the final machinery into which it is to be incorporated has been declared in conformity
with the provisions of the applicable directives.
The relevant technical documentation is compiled in accordance with Annex VII(B) of the
Directive.
On receipt of a reasoned request to our authorised representative (The Quality Manager,
AAM) by an appropriate national authority, all relevant technical documentation about the
partially completed machinery will be provided in writing.
Signed:
17
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12.2 Material declaration for IMO ship recycling
Material Declaration
Date of Declaration
Date 2018-11-13
Supplier Information
Company name AAM Powertrain (UK) Ltd.
Division name Vibration Control Systems
Address 131 Parkinson Lane, Halifax, HX1 3RD, U.K.
Telephone no. +44 1422 395110
Fax no. +44 1422 354432
E-mail address Yahyaa.Mulla@aam.com
Product Information
Product total mass
Product name Part or drawing number Product information
Mass Unit
Vibration damper SPN047366 11635 kg Viscous torsional vibration damper
18
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Intentionally
If yes,
added above If yes, detailed
Threshold material
Table Materials name threshold material
level level mass
information
yes/no Mass Unit
Cadmium and Cadmium No
100 mg/kg
Compounds
Hexavalent Chromium Compounds 1000 mg/kg No
Lead and Lead Compounds 1000 mg/kg No
Table B Mercury and Mercury Compounds 1000 mg/kg No
(Materials Polybrominated Biphenyl (PBBs) 1000 mg/kg No
listed in Polybrominated Dephenyl ethers No
appendix 2 1000 mg/kg
(PBDEs)
of the
no threshold No
Convention) Polychloronaphthalanes (Cl=>3)
level
no threshold No
Radioactive Substances
level
Certain Short chain Chlorinated No
1%
Paraffins
We hereby confirm that the products we deliver to HHM are declared to our best knowledge.
_______________________
Signature
19
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12.3 REACH safety data for silicone fluid
20
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21
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22
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23
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24
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25
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26
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27
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12.4 TRACTOL 816 safety data for grey primer
28
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29
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30
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31
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32
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33
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34
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35
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36
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12.5 ENSIS-DW 2455 safety data for corrosion protection
37
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38
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39
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40
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41
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42
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43
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44
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8 7 6 5 4 3 2 1
32
G
SIDE 1
G
20 X45 $
F F
8 X45 $ 8 X45 $
(950.026-950.116)
950 G7
WARNING
2680
1500
1500
2700
NOTE
AAM
88.5
E
C OF G E
100
100
R2
0
0
D D
R2
C C
B B
THIS DRAWING AND THE INTELLECTUAL PROPERTY RIGHTS AND OTHER INFORMATION CONTAINED OR DISCLOSED
HEREIN: (1) ARE THE EXCLUSIVE PROPERTY OF AAM AND NO LICENSES ARE GRANTED HEREUNDER, AND
2
(2) CONSTITUTE CONFIDENTIAL AND PROPRIETARY INFORMATION OF AAM WHICH MAY NOT BE USED,
DISCLOSED OR COPIED WITHOUT AAM'S EXPRESS WRITTEN AUTHORIZATION.
SHIPYARD = SHANHAIGUAN
2
CAD TYPE CAD LOCATION CAD FILE
SPN047366_OT
EFFECTIVE INERTIA = 9014 kgm
PRO/E HALIFAX
A0 METRIC
HULLS = TBD DESIGNER DATE DRAWING
DRW SIZE
GENERAL TOLERANCES TO APPROVED DATE FOR QMD 6G45ME-C9.5
PERMISSIBLE DAMPER POWER = 38.2 kW TOTAL WEIGHT OF DAMPER = 11635 kg FOR ASSEMBLY SEE SPN047441 ISO 2768-mK - - IN SHANHAIGUAN SHIPYARD
SCALE SHT GROUP REVISION
ITEM STANDARDS - NUMBER AND NAME 1 -
- - 1:5
OF
1 VCS IS MASTER 02
8 7 6 5 4 3 2 1
Operation Manual / 1 Introduction
Table of contents
Introduction
1 Introduction............................................................................................................ 2
1.1 Purpose of the manual.................................................................................................. 2
1.2 Symbols, definitions...................................................................................................... 3
1.3 Storage of new turbochargers and spare parts ...................................................... 5
1.4 Contact information...................................................................................................... 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.1 Purpose of the manual
1 Introduction
This Operation Manual belongs to the turbocharger with the identical serial number (01), see
chapter 3 (Safety data sheet) and the rating plate on the turbocharger.
Page 2 / 7
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates an action step.
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Page 3 / 7
are described in chapter Safety and must be complied with.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Apply screw locking paste (e.g. Please note text for numbered
Loctite) work step
Apply high-temperature grease See document
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Page 5 / 7
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.
u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
¡ Checking the component
¡ Replacing the desiccant
¡ Repackaging the component.
NOTICE
Replacement components which are ready for operation
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is not damaged, the replacement turbocharger or replacement cartridge
group can be put into operation without previously having been checked by
an ABB Turbocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.4 Contact information
www.abb.com/turbocharging
Page 7 / 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 4 Product description / AlOO-L
5 Operation and service / 5.2 Service work
,.,.,.,
Jl ll ll
� Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging
.-1 Service Station. Damaged and worn out parts must be replaced with original ABB parts.
� ► Remove the filter silencer.
� ► Clean filter silencer and check for damage.
► Dismantle the wall insert.
► Check axial clearance A.
► Clean wall insert, diffuser and compressor casing and check for damage.
► Remove the gas inlet casing and dismantle the nozzle ring and cover ring.
► Clean the nozzle ring and cover ring and check for damage.
► Dismantle, inspect and balance the rotor.
► Replace the plain bearing
© Copyright 2017 ABB. AII rights reserved. HZTL4034_EN Revision K June 2017
Operation Manual / 2 Safety / A100-L, A200-L
Table of contents
Safety
1 Safety ...................................................................................................................... 2
1.1 Introduction .................................................................................................................... 2
1.2 CE conformity ................................................................................................................. 2
1.3 Definition of mandatory signs .................................................................................... 3
1.4 Definition of safety instructions ................................................................................ 3
1.5 Intended use .................................................................................................................. 4
1.6 Warning plates on the turbocharger.......................................................................... 5
1.7 Turbocharger rating plate........................................................................................... 6
1.8 Periodic check of the pressure vessels...................................................................... 7
1.9 Lifting of loads .............................................................................................................. 8
1.10 Prerequisites for operation and maintenance........................................................ 9
1.11 Hazards during operation and maintenance ......................................................... 10
1.12 Safe operation .............................................................................................................. 12
1.13 Safe maintenance ........................................................................................................ 13
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.1 Introduction
1 Safety
1.1 Introduction
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and
health protection requirements are met. This ensures safe operation of the turbocharger.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡ Are caused by the turbocharger itself or its accessories.
¡ Are caused by the operating equipment used or supplies and materials.
¡ Are a consequence of insufficient compliance with safety instructions.
¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
Page 2 / 16
All further safety instructions contained and specifically identified in every chapter of this
manual (Definition of safety instructions →3) must also be observed.
1.2 CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.3 Definition of mandatory signs
Page 3 / 16
Table 2: Personal protective equipment to be worn specific to the respective task
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.5 Intended use
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
Page 4 / 16
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.6 Warning plates on the turbocharger
If warning plates are not present in the intended locations or are not legible, they must be
replaced with new warning plates. The necessary information can be found in the Operation
Manual, Chapter 4 Product description.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
Page 5 / 16
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.7 Turbocharger rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
Page 6 / 16
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.8 Periodic check of the pressure vessels
Page 7 / 16
The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are
so-called "simple pressure vessels".
¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡ The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.9 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.
u The assembly devices must be completely screwed in and must not unscrew during use.
u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.10 Prerequisites for operation and maintenance
Page 9 / 16
Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB Turbo Systems.
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur-
bochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.11 Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission during operation is influenced by its installation and op-
erating conditions. A noise level exceeding 85 dB(A) is harmful.
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.11 Hazards during operation and maintenance
WARNING
Hot surfaces on the non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
WARNING
Physical hazards
Contact with rotating parts can cause severe injury. The turbocharger must
Page 11 / 16
never be used without the filter silencer or the air suction branch. With the
engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.
WARNING
Dangers during work on electrical installations
Electrical installations use voltages that can lead to severe injury to person-
nel or accidents resulting in fatalities.
At the same time, electrical or electronic components and parts can also be
damaged or destroyed.
u Only specially trained personnel should perform work on, or with, elec-
trical components.
u Observe national regulations.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.12 Safe operation
WARNING
Absence of grounding on electrical installations
Missing or incorrectly fitted grounding conductors can lead to severe injury
to personnel or accidents resulting in fatalities.
Electric shock or elevated electromagnetic disturbances can damage or des-
troy electrical and electronic components.
u Ground electrical installations properly with grounding conductors.
u Check the grounding connections on a regular basis and make sure they
are properly connected.
u Switch off the power supply before working on any electrical installations.
u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge
and hot components to cool down.
u Ensure the power supply is switched off when working on electrical installations.
u Do not carry out any tests with regard to insulation resistance or voltage on the electrical
components.
u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.13 Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Page 13 / 16
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Have oil binding agents ready and provide or keep oil pans at hand.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.13 Safe maintenance
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the electric cables for abrasion and damage before and after your cleaning work.
u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
u Observe the material safety data sheet for the cleaning and mothballing agents.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.13 Safe maintenance
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
WARNING
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Page 15 / 16
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / 2 Safety / A100-L, A200-L
1 Safety / 1.13 Safe maintenance
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
Page 16 / 16
WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017
Operation Manual / A1... / Safety data sheet
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