MAN B&W > MAN Diesel & Turbo SCU / EGB Commissioning Page of 48 Ident No.: 0743782-0 General Guideline for Commissioning and Testing of SCU - Exh. Gas By-pass valve This document is valid for existing engine types on order as of the date of this docu- ment: Engine types: [AIIMC and MC-C engine types Scope and Field of Application This guide Is intended tor using during intial installation, commissionng, maintenance and service on EGB valves on MC and MC-C plants ‘or dolvory orin sorvcs. Operation Recommendation 0743782-0.0 July 2013 Info No: 391905 Structure No: 21-0002 Replaces: 5218460-4 Document history Data Designer Checked AC Revision change evsion poreoro PEK! _ LTDA 2 2 3 "enmatna tensorial gra ae Sense Meme clay omy te a uu tTOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 2 of 48 Contents Changes in this revision: 1. Introduction. 4 2. References ...... 4 3. Tost of Electrical System 4 8.1. Power supply and ground failure test 4 MOP OS Software set-uo (WIN XP embedded) 5 MOP SACS Software set-up 8 Programming the ID-key 7 Programming the ID-key with service terminal connected (optional 7 8.6. Network tost 8 3,7, MPC parameter upload 9 4. Sotup of EGB-vaive + local controller 10 41. Check valve position and Actuator position 10 4.2. Intialzation of Local Controller (Siemens Sipart) 10 4.3, Function test of Exhaust Gas By-Pass Valve (local control} 11 4.4. Check of fal-safe valve position 4 5, Setup of SCU System (engine stopped). ....- 12 5.1. Pro-Calibration of Fuel Indox transmittor 12 5.2, Calibration of Torque meter input (optional input) 13 5.3, Calibration of Scavenging Air Pressure sensor 14 5.4. Callration of engine RPM signal 15 85. Calbration of 1 RPM signal 16 5.6, Alarm test ~ Test of connection to Alarm Monitoring SysterniAMS) 18 8.1. Funetion haust Gas By-Pass Valve (Remote control) 6. Calibration/test of SCU System (engine running) 641. Test of TC speed slowdown 6.2, Test of High Scavenging air pressure slowdown 22 6.3. Calioration of fuel indox transmitter 23 6.4, Torque meter calir val load caleulation (optional nou) 26 65. Test of Scavenging Air Pressure regulation or 7% Commisioning of EGB...........+ 74. Commissioning of MC-C with ‘Part Load’ 72. Commissioning of MC-C with ‘Low Load’ EG 82 73, Commissioning of low ambient temperature / arctic conditions EGB 35 bate Designer AG Raiion change Fevision yow.ara0_ _ PEK! ° opi ©2013 Hales! & bc WANs 8 Tt SE, emany ‘77820. Gono Goon or Carminonhg aanal Operation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 3 of 48 8. Appendix 8.1. Dongle setup 36 8.2, LED colour codes, 36 8.3. Service terminal setup and connection 37 4, Dip switch settings and connections for MPC in normal operation 30 8.6. MPC overview a 86, How to Open Input channel 43 8,7, P-converter (Sip '82} commissioning 45 Data Designer AG Revision change evsion poreoro PEK o opin ©2013 MAN Deel Tre rach of MAN Dis Tat SE Germany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Introduction In order to ensure uniform quality of EGB commissioning from all licer is guide should be used when part co’ valve and controller. patibility in service, T The variable exhaust gat reduction th conditions, bypass (EGB) can be applied to engin: ugh better T/C matching at lower loads, or to enable operation at extreme ambient Page 4 0f 48 sees and improve spare ymmmissioning MDT supplied EGB for one of two reasons; SFOC ‘The EGB Is controlled from the SCU, according to a PScav Ref. table which is also part of the plants Unified Technical File. The EGB's fal sate position is open ang 2. References MAN 88W Production Specification: No, 0743196-1; Mounting and in tal 3. Test of Electrical System Before starting-up, tems in the production recommendation for mour nection of cables 0743606-1 must be checked, 3.1, Power supply and ground failure test Electrical plugs in all MPCs are disconnected tion of electrical equipment, ing of cableways anc con ‘Step [Action Expected result 1 | Gheck polarity and voltage on all power | Power supply is In the range 20->G0V and supply plugs polarity is correct. 2 [Plug in the power supplies, for MPG and | Ground failure check complete with MOP, observing the ground failure a minum allowable resistance of vice for each connection. Check that the} 100kOhm. ground falure device detects no gro. failure, 8 | Check that baci-up battery ang ID key is, mounted Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page of 48 3.2, MOP OS Software set-up (WIN XP embedded) MOP has @ USB keyboard connected and CD-ROM rive, ‘Step [Action Expected result 1__ [Power off the MOP MOP is powered off 2 [= Powor up the MOP and press F10 to| MOP is booting from the OD-ROM or enter Boot sea, USB flash drive = Insert the OS (Win XP} ghost CD or USB drive in the CD-ROM or USB drive = Boot the MOP on OD-rom or USB drive [= Ignore the licence warning ( any) by] Image of Win XP is being installed sel nue without marking | This can take several minutes drives" = Prass enter when weleame screen is shown = Solect LOCAL ~ PARTITION ~ FROM IMAGE = Browse to the CD_ROM or USB drive = Solect the ghost image located on the OD or USB dtive = Press OK to sek ce drive . ion as source part . the destination drive ‘= Solect the frst partition as destination partition (oress OK) Accept io overwrite old disk date % Remove OD or USB dre Windows XP will start up when restart Reset MOP Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany aun or Cormisoring aeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 6 of 48 3.3. MOP SACS Software set-up The MOP unit has Win XP embeded installed. MPC powered off and net A & B disconnected on MOP, MOP Ahas a bbe used. MOP distribution software (CD-ROM or USB drive) available, keyboard and an external Cl OM dfive attached (alternatively a USB key can ‘Step [Action Expected result 1 [Power on MOP , and insert the MOP dis- | Stoowat. bution CD or USB drive. Ii the MOP already is running a MOP ap- plication, the watchdog program must be stopped 1. Open the MOPLock program by pressing [Cirl] + [AR] + (Shift) + [Mk 2. Press the ‘Unlock’ futton to release the lock on common windows fe ndog program closed 2 [Press [Ctl] = [Esq] = select Windows Ex- [A MOP Tools folder shortout (eAProgram plorer 0 te Files\MANBW\Tools) is created on the five or USB key with the MOP distribu- | desktop, tion SW. Locate the fil install_mopA_XPE.bat’ ‘and double-click on the file to execute the instalation program, [For frst time installatons ‘drag’ the MOP_[ MOP application running on MOP A Tools folder to the start menu 4 _[Afier instalation - Reboot MOP. This ensures that all sereens will show the correct values. Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 7 of 48 3.4, Programming the ID-key Electrical plugs in all MPCs connected. Service terminal connected (optional ‘Step [Action Expected result 1 [Disconnect power to SCU-MPC TD-Key ready for progy Set DIP-switch S1 t0 "239" (OIPI-8= _| (Be aware of DIP-switch-numbering isin antt0t11} reverse order) Disconnect ID-Key (ID-Dongle} For more information See Appendix for Dongle’-setup 2 | Connect power to the MPC. The start-up program registers that the Id-key is not connected and the LED shows error code 4,2. For more information See Appendix for LED colour codes” Connect the ID-key. “The ld-key wil now be programmed ac- cording to the DIP- switch setting. After programming is fnished the LED will fash e 4,3 indicating that the DIP-switch can be set to neutral position (Allin OFF sition ch to “OFF position. Tne boot sequence wil proi will fash the code 21 7 DIP-Swi Sand the 3.5. Programming the ID-key with service terminal connected (optional) ‘The program first verifies i the ID-key is connected. In this case, it confirms that the ID-key is not nected and sends error code 42 through the LED. The service technician may now connect the ID-key for programming, The program switches to programming mode and reads the DIP-switch SS! value to determine the new ID number that the user wants to program the ID-key. This value must be a valid ID-key, ID number or the program will halt, Before programming, the program verifies if the ID-key is connected ang pi to program the new ID number. The MPC is then ready to continue booting and sends code 43 to the LED. This signals the technician to change the DIP-switch (81) back to its neutral po MPC is now ready to continue normal booting operation. jon. When the DIP-switch 1 is set to neutral (ff, Data Designer AG Revision change evsion o poreoro PEK oprah © 203M Dee Tare bach of MA iT SE Gomany ovesrez0, aun or Cormisoring aeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Starting Basic Systom. Testing RAM. RAM OK Initiaising BES oK Starting dongle verification = Reading Dongle ID. = Switching to programming mode. = Reading DIP-swi = Programming Dongle with DIP-switeh value, = Dongle not connected! Please connect = Dongle programmed successfully = Preparing to boot. = DP-swi S kernel ‘ot connected! Value = Reading DIP-switch... Value = 0 = Dongle verification done, = Continuing boot s 3.6, Network test Notwork plugs disconne. For test 4 state, network plugs conn dongle. Eleciric power on, Id-keys programmed (see above), 1d and service terminal Page 8 of 48 utral, Please set DIP-switch to neutral all MPC units in normal Action Expected result Sto} ‘Test both networks for ground fallure by measuring the resistance between each of the network wires and ground (engine ame). Le. between J85A->ground, J65B->ground, J66A->ground and J66B- ground, Observe that a ground det ing device will not detect ground fallure on the network, because the network connections are isolated from the MPC. Network ground failure check completed. Rosistance is infinite between J65A/8, and ground, and J66A/B and ground, (Check that a120 ohm resistor is mounted at the end of the network cables in SCU and that @ 120 chi resist unted ir ne network SUB-D9 plug in MOP A. Remove network »Ae plug (65) on MPO. land network »Ae plug on MOP. Measure resistance through network cable and resistor Measured resistance is 60 Ohm. Check of crossed network and network resistor cable completed, Data Designer AG Revision change evision poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany aun or Cormisoring aeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo heaod Page 9 of 48 ‘Aetion Expected result Measured resistance is 60 Ohm. Check of crossed network and network resistors cable completed Remove network “8” plug (66) on MPC and network “B" plug on MOP, Measure resistance through network cable and end resistor. ‘Above picture only green marks on SOU and MOP A ‘Reove pictures shaws ‘Correct set-up! 3.7. MPC parameter upload 1 On the MOP PC, press [CTRL] + [ESC select Windows Explorer or ‘My Computer’ and ‘open: C:\Program Files\ MANBW\MOP\Tools, Start the MPCArchive program (MpcArchive. x9) and select the “Update” tab. 2. Add the archive file by pressing the “Update System" bution and select the file to be used, The files can be located in a folder on the hard disk or on another media, 3. Select MPC to be updated and press the “Update Par” button. The MPC’s will reboot in configuration made thereby stopping the application, and the parameter files will be down- loaded, The status of the operation can be seen in the ‘Download Status’ colurnn, 4. After completion (Online Status ->Normal), select the MPC{s) in question and restart the MPO\s) by pressing “Start App.”. This will start the application using the new parameters. Finally reboot MOP in order to update the MOP display. Data Designer Checked AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo ke Be Page 10 of 28 4. Setup of EGB-valve + local controller 4.4. Check valve position and Actuator position Valve must be NO (Normally Oper). ple ~ in order make shipment easier rote: the valve can be delivered with the valve closed ‘Step [Action Expected result + | Close supply-valve for pneumatic airto | Preumatic pressure must be 0 EGB-system tuator and Controle (Actuator has spring-return) 2 | Dismount ‘tuator, check valve postion | Valve open’ {line on top of spindle}. Valve must be Temount of Actuator - Chack post | Actuator (and valve) in open position jon- indication on top of Actuator, it must] when no pneumatic pressure applied bbe according to Valve position 4,2. Initialization of Local Controller (Siemens Sipart) Setpoint signal from SCU must be connected as this signal 's Power Supply to Siemens Sipart ‘Step [Action Expected result Check that Pneumatic Pressure is sup- | Ar supply pled to Siemens Sipart (supplied from ‘Siemens Sipart = 7 bar Engine Control Air System 2 | Check electrical power supply to Sipart | Display shows number + "no ni (irom Set-point-signal connected to terrni- nal6 +7 3 | Carry out commissioning of Siemens Si-_| Controller intialized, (feedback-magnet part adjusted, alarm is set-up} valve is work- ing. 4 that valve is closed at 0%6 0% not go to point 3) Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo ke Be Page 11 of 28 4.3, Function test of Exhaust Gas By-Pass Valve (local control) ‘Step [Action Expected result ‘Switch Sipart to manual “The SIPART goes in fo Manual control Press Hand (bottom mark with a hand) | The SIPART 1 to SCU as it than nds) is not in Automat 2 [In Manual-mode — the valve position can | Chack that the anges val valve position for ts bath on SIPART dis lows the set-poi play and on the vale, 9 = Valve Closed, 100% = Valve Open Trvale Is working inverse (0%=Open and | Go back to check In Manual Mode (point 100%=Closed} 142) a" or IPART back to Automatic, Tne SIPART goes to automatic-mode {alarm to SCU should disappear) 4,4, Check of fail-safe valve posi ‘Step [Action Expected result 1 [Disconnect p: toSemens | The Sipart will vent the actuator and Sipart springs in Actuator will force the vale (either at terminal 6 or J70 in SCU) n Sipart will give alatrn-signal to SCU. 5 2 [Reco int viect Power to Spart Sipart should move back from SOU Ang alarm signal to SCU is resets Data Designer AG Revision change evision poreoro PEK oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & Be Page 12 08 5. Setup of SCU System (engine stopped) 5.1. Pre-Calibration of Fuel Index transmitter ‘Stop [Precondition and |Action Expected result Checked initial state by /date Engine stopped. Fusl | Read tha mA signal on | Write down value, rack in 0 channel 31 ignated (1. pected value: 4.5 mA 2 [iffeedbackis not4.5 [Loose the 3 lockbolts | Fuel Index calibrated at turn transmitter IMeedback is 4.5, u (0% | in SCU, mA 3 ‘Adjust Param ‘uel Index calibrated at => Exit Para 0% lin SOUL => VO Torminals => 6h.81,8001, fuel in- => Sealing => S ing input (0 Insert value (1) in Scal- ing input(o) Sek te edit Parameters [Turn fuelrack to ex [Read the mA signal on | Write down value, des- pected maximum % | channel 31 ignated (2) Expected I eedback is not 19.5 mA First agjust transmis sion between transmit- ter and Index shaft If this is not enough adjust span with on potentiometer behind lock-screw marked on transmitter. Data Designer ac Fevision change Revision 2oreor0 Pek oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & Be Page 18 of 28 © _ | Service terminal con- | Adjust Parameters Jel Index calibrated at nected to SCUr MOP | => Eoit Parameters | maximum 9% in SCU maintenance /10/ | => V0 Terminals 31 Ch.81,8001, fuel in al calibration with dex=> running engine. Sealing input Insert value (2) in Sc ing input (1) Select Activate edited Parameters 7 |ifspan sadjusted | Greckindex=Zero |indeoxO=45 mA feedback not is 4.6 mA | Index max = 19.5 mv ~redo point 1 5.2. Calibration of Torque meter input (optional input) Step |Precondition and | Action Expected result Checked initial state by /date Engine stopped Read the mA signal on | Write down value, d channel 37 ignated 2 | Service terminal con- | Adjust Parameters forsion calibrated at 0% nected to SCUr MOP | => Euit Parameters | in SCU. maintenance /10/ | => VO Terminals => pected value mA 37. n.97,8825, Measured torque=> Scaling Scaling input (0) Insert value (3) in Scaling input (0) Service termi ‘Adjust Paramet forsion meter calbbrated nected toSCUcr | => Evit Parameters | at 100% lin SGU, Mop. > VO Terminals n.37,8825, Measured | Final calbration with torque-> Sealing => | running engine Scaling input} Insert value 20mA in Scaling input) Date Designer AC Revision change Fevision 2owsor70__ EK! ° oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & Be Page 14 of 48 5.3, Calibration of Scavenging Air Pressure sensor Normal sensor 4-20 mA /0-4 ‘Step [Precondition and J Action’ Expected result Checked initial state by/ date Engine stopped, Read the mA for Obar | Write down value, des- sor ignated (4) 2 [Service terminal con- [Adjust Parameters | O bar input checked / nected toSCUor | => Esit Parameters J adjusted MOP, => VO Terminals => 6n.82,8003, PecavSe- Scaling => Sealing input (0) Insert value (4) in Scaling input(0} Select Activate edited Parameters Engine stopoed, Read the mA for min, | Write down the value baron sensor xx) | (xx) he max pres | Write down the valuetyy) tho sensoriyy) [Service terminal con- Parameters | Min, bar input checked nected toSCUor | => Edit Parameters. | adjusted MOP, VO Terminal 32,8008, Pscav- Scaling => input (0) Insert value (xx) in Scaling input Sek ate edited Parameters vice ti ‘Adjust Parameters | Max. nected toSCUor | => Edit Parameters | /agjusted Mop. => V0 Termin Scaling output (1) Insert value (yy in Scaling output(!) Sek te edited Parameter Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 18 of 8 5.4, Calibration of engine RPM signal Step [Precondition and [Action Expected result Checked initial state by /dato Engine stopped. | Ask engine bullser/ | Write down value, des- yard for the range | ignated! 6 for minimum and (6 far maximur 2 | Service terminal con- | Aqust Parameters | Minmum engine speed nected to SOU or | => Evit Parameters input adj MOP. > WO Terminals => ©h.30,8000, Engine Minimum mA input | Speed=> Scaling Scaling input ©) Insert value 4A) in Sealing input} Select Activate edited Parameters @ | Sewice terminal con- | Adust Parameters | Miminum speed ad- nected to SOU or | => Euit Parameters |justea MOP. = V0 Terminals => ©h.30,8000, Engine | Value is negative or 0. Minimum speed ad- | Soeed=> Scaling => justment Scaling output (0) FPP value is negative Insert value (5) in CPP velue is 0 ing outputio} sek Parameters 2 [Service ter ‘Adjust Parameters | Maximum engine speed nected to SCU cr | => Fait Parameters | input adjustec MOP. => VO Terminals => n.30,8000, , Engine maximum mA input | Speed => Scaling => Scaling input Insert value 20(mA) in Scaling input() Sel edited Parameters ate Oesigner Ravson change Revlon poeor__ PEK ° oprah © 203M Dee Tare bach of MA iT SE Gomany ovesrez0, aun or Cormisoring aeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & Be Page 16 of 28 ‘Step [Precondition and J Action Expected result Checked ial state by / date 5 [Service terminal con- [Adjust Parameters | Maximum speed ad- nected to SCU or justed MoP Maximum speed ad- Scaling justment Scaling output (1 Insert value (6) in & ing output(t) Parameters 5.5, Calibration of T/C RPM signal ‘Step [Precondition and _ J Action Expected result Checked initial state by/ date Engine stopped, ‘Ask engine Write down value, des- yard TC maker for tre | ignated (7) for minimum range and (8) for maximum 2 ‘Adjust Parameters | Minimum WO speed in- nected to SCU o Ecit Parameters | put adjusted Mop, => V0 Termin Gh, 9, TC Minimum mAinput | speed=> Scaling => Scaling Input () Insert value 4(mA) in 3 [Service terminal con- Minimum TO speed nected to SOU or adjusted Mop, Value should be 0 [RPM Minimum speed ad- justment Scaling output (0) Insert value {7} in Scal- ing output Select Activate edited Parameters Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Ken Dal Page 17 of 8 Step Precondition and [Action Expected result Checked ial state by / date 4 [Service terminal con- [Adust Parameters | Maximum TIC speed nected to SCUcr | => Exit Parameters | input adjust MOP. Maximum ma input Scaling input ( Insert value 20 (mA) in Scaling input} Sel edte Parameters © | Service terminal con- [Adjust Parameters | Maximum V/0 speed nected to SCUcr => Exit Parameters | adjusted [RPM] MOP. > VO Ter minals => 6n.35,8019, 10 Maximum speed ad- | speed-> Scaling => justment Scaling output (1) Insert value (8) n Scal- ing output() Sel Paramotors Notel Scaling can advantageously be veriied with engine running. bate Oesigner AG Raiion change fevsion yow.ara0_ _ PEK! ° opi © 21 MA i ae, oc ofA el bE emany ‘77820. Gono Goon or Carminonhg aOperation Recommendation 0743782-0.0 5) MAN Diesel & Turbo ke Be Page 18 of 28 5.6, Alarm test - Test of connection to Alarm Monitoring System(AMS) ‘Stop [Precondition and | Action Expected result Checked initial state by/ date Engine stopoed. (Check that no alarms is active on MOP- 2 [Testot "SOU Com- [On MOP-screan go to ‘at AMS acti- mon Alerrn"™ Auxiliaries and go to Scavenge Ar somman Alarm Switch to Chief Mode (password: BADOIT) Press Bypass Mode Button and ewitch to Manuel - This will iit- ate alarm. (Switch back to Au- tomatic for resetting alarm) ‘Test SOU Power Fal Power down SOU. — This will nate alarm for Power Failure ‘Check that AMS acti- ‘SOU ~ Power Failure" 5.7. Function test of Exhaust Gas By-Pass Valve (Remote control) Preconditions and initial | Action Result state Engine stopped (On MOP-screen go to Aux laries and go to Scavenge Air Switch to Chief Mode (pass- word: BADOIT) ‘Switch to Manuel By-pass | Press Bypass Mode Button Mode. and switch to Manuel ‘Open By-Pass valve t0 50% Change “Variable Bypass ‘Sot_| Very that feedback on the Point" to 50% by pressing but- | screen ("Actuel” tons "up" or "down" and then | 80% and the valve is press “Apply” ‘open on the valve ‘Open By-Pass valve to 100% | Change “Variable Bypass Verity that feedback on the Point" to 100% by pressing _| screen ("Actual") changes to buttons “uo” or "downer press “Apply” 100% and the valve is fully open (100%) on the valve Data Designer Fevision change Revision poreoro PEK oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & ) Page 19 of 28 Preconditions andinitial | Action Result state ‘Close By-Pass valve 10.0% — | Change “Variable Bypass Set | Verify that feedback on the Point" to 0% by pressing but- | screen (‘Actual’) changes tons "up" or “down and then | 10 096 and the valve is fully press “Apply” closed (0%) on the valve ‘Switch back to normal (On the Scavenge Air Screen | Connection to valve con- Close “Variable Bypass Set | firmed Point" by prossing the X. Function of valve confrmed Press Bypass Mode Button and switch to Auto 6. Calibration/test of SCU System (engine running) Test of slowdowns (Engine running) 6.1. Test of T/C speed slowdown Defintions: = TC max Speed = TC speed at 110%MOR * 1.02 To max "1.02 = TC slowdown limit ‘The maximum speed of the turbocharger indicated on the maker plate, should in no case be exceeded. Data Designer Checkac AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Kenoa\ Page 20 of 28 ‘Stop [Precondition and _ Action Expected result Checked initial state by/ date Engine stopoed, Engine running with | Write down T/C speed low load ° Low load 10-18% load 2 ‘Add 50 APM to curren TC speed! Value (9) + 50 RPM = Valve (10 Service terminal con- [Adust Parameters > | Slowdown limit for 1/0 nected to SCU, Ezit Parameters speed adjusted for test Variable turbo charg- ing =>, Overst handling => Slowdown limit for VC speed=> Insert value (10) 1/6 slowdown limit ust above actual TIC speed. z Bagin to increase load | TO max speed activated rpm on engine, wait for | and VT should auto TO max speed limit to. | adjust, in an effort to be reached. reduce TC speed before peed slowdown Bagin to increase load? rpm on engine, wait for TC speed slowdown limit to be reached [Service terminal con- [Insert the original value wn test for WG nected to SCU, for Slowdown limit for} rom confirmed TC speed, 6.1.1. Important SCU over speed slowdown function does not replace the over speed function, provided by a direct, -tacho ar ine safety system. connection between A cirect connection between TC-tacho and Engine safety system is required by classification societies. Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 21 of 28 6.1.2, Information The Supervision Hysteresis value parameter effects how the EGB behaves when TC-speed reaches, “TC Mex Saeed This will cause the EGB-valve to open 100 %. This will (normaly) cause the the TC-speed to drop due to less exaust gas through the TC-turbine. When the TC-soeed has dropped below the hysteresis valve (default 1000 rpm) - then the EGB- valve will return to normal set point. If engine load is kept at the same level - the TC again and this could lead to “hunting! peed will properly build up to TC Max Speed It the autom i8-valve does not counter TC-speed high (or the valve doesn't Down Limit for TC Spec, a Slowdown is activated. d below the hysteresis. opening of the word) and the TC-speed reaches “Slo The Slowdown cannot & Ml scu 2 I System [EE 10 Temas Lead Estvation = [EE Scavenger Running Modes 1) [BF Scavengo Ai Contr I Eshausigae Bypass 1 Bl Or/OHrBypase = [I Contolable Vaiable Bypass [Bl Vz. VaiveAros2Arale Conversion cB Ve. Velve Enercise Furetion [ll Va. Vave Ovespeed Handing TCMat Speed 115200 RM Pe sesdown Linton 10 Speed tenn RM Super Hysteresis vahie joona APM [lB overspeed supervision Enabled Yee Ill TCOvespeed be reset before TC-speed has drop. Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo anal Page 22 of 28 6.2. Test of High Scavenging air pressure slowdown ‘Stop [Precondition and | Action Expected result Checked initial state by/ date Engine stopped, Engine running with | Write down scavenging low loas Low load 10-18% load 2 [Service terminal con- [Adjust Parameters => | Slowdown limit for nected to SCU, Euit Parameters => Scavenge air Controller , Pscav Slowdown mt Insert value (11) + 0.2 Pecav adjusted for Bagin to increase load? rpm on engine, walt for to be reached Slowdown activated minal con- [Insert the original value nected to SCU, for Slowdown limit f ‘Slowdown test for Pecav, confirmed Here below example of test-values, Actual reference-curve and Slowdown limits engine spec Scavenging Air Pressure [bar] Test of Control . =o © © 0 wD ond ate Ao evaon charge pevsin wom FX Ube o Cor ua wo tt my STO. Grelcactret Cormmera rsanal Page 23 of 28 Operation Recommendation 0743782-0.0 MAN Diesel & Turbo 6.3. Calibration of fuel index transmitter ECS for MO stand-alone plar tains a function that assists with fuel index calloration. It's found on the MOP in Maintenance/Celibration, ‘Step [Precondition and J Action Expected result Checked initial state by/ date 1 Inthe calibration guide |= Engine speed signal press start and press | connected and OK. done as each point is |= Fusl index transmitter procedure canbe | checked, see figure adjusted correctly started " Fuel quality Index offset adjusted cor rectly 2 [Preconditions are | Press “start” to pro- _| tris possible to continue “OK with the calibre- | to the next step of the tion procecure and | calibration process. low the instructions engine load and press done, see figure 2 3 [Step one of the ‘Accept mA value from | itis possible to continue calibration process is_| fuel index transmitter. ext st comp calibration pro _[Steo two ofthe Load up engine, when [tis posable to calioration process is_| engine is loaded up to complete 100% (between 80 and 100%, adjust the test value to the current engine load and press done, © [Steotves ofthe [Accept the mAvalue _ | Iris possible to continue calibration process is | from fuel index trans- | to the next step of the complete. mitter, see figure 3___| calibration process. © _| Stoo four of the Now to _ | Callbration of the fusr lioration process is | save and apply the | index transmitter is now completed new fuel index trans- | completed. mitter scaling, see figure 4, Please note: ArcEdit must de closed, in or- der for the ECS to be able to apply and save. Data Designer vision change evsion poreoro PEK o opin ©2013 MAN Deel Tre rach of MAN Dis Tat SE Germany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo had Page 24 of 28 Figure 1: Maintenance/calioration — preconditions, Figure 2: Start calibration procedure. Data Designer Checked AC Revision change evision poreoro PEK _LTDA o Cont © 203 MaDe Tro brach MAN es Tt SE Gemany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo had Page 25 of 28 Figure 3: Accept fuel index scaling at high load, od Figure 4: New scaling accepted and saved, Data Designer Checked AC Revision change evsion poreoro PEK _LTDA o Cont © 203 MaDe Tro brach MAN es Tt SE Gemany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & Be Page 26 of 28 6.4, Torque meter calibration for internal load calculation (optional input) ‘Stop [Precondition and | Action Expected result Checked initial state by/ date Engine running stable [Read the mA signal on wn the value at nel 37. (Aland 25-50% load the value of Plug 37 connected ‘orque meter(KNm) (8) 2 [Service terminal con- | Calculate following: nected to SCI X=B/(A-8) (a = 4A) Insert X in Adjust Parameters => Eait Paramotors Load caleulati Torque Meas. (kerma) Read the internal 3 [Engine running & forque meter callrated. at several different | calculation. Loads. Gan be 0 Confirm that it similar formed during other | to PMI or torque meter rest load Please note updating time on internal load calculation is slow! [Engine stopped Confirm that torque ‘pected approximately meter signal shows 4 | 4 mA when engine not mA running, Data Designer AG Revision change evision poreoro PEK oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 27 of 28 6.5, Test of Scavenging Air Pressure regulation ‘Stop [Precondition and | Action Expected result Checked initial state by/ date Engine running Engine running proxi- | Write down Scavenging mally oad | Air Pressure designated (Exn.By-Pass Vale | (5) Running Mode 1 should be a mal condition other- wise change Running Mode on Auxiliaries => Scavenge Air ~ screen) 2 [Service terminal con- | Adjust Parameters nected to SCU, Pscav ef, Curve ad- justed for test! avenge Air Running Modes => Running Mode 1=> Pscav Ret sca ref. Curve Ao- tual 2° sme value at load *Pscav ret, Curve Actual (3) Pscav. Curve is adjust- ed ust above actual Pscay (Curve is flat (horizontal) 50. Bagin to Increase load | Pscav stays at prox rpm on engine. mally same value Observe that Exh, By- Pass Valve begins to ‘open and Scavenging Ai Pressure stays at proximally same value. ne original Test of Scavenging Air nected to SCU, values for Pscav Ret. | Pressure regulation Curve confirmed Here below example of test-valu: Actual reference-curve and Slowdown limitis engine specifi Data Designer AG Revision change evsion o poreoro PEK oprah © 203M Dee Tare bach of MA iT SE Gomany ovesrez0, aun or Cormisoring aeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 28 of 8 Scavenging Air Pressure [bar] Test of Control 400 30 eo eee aston Down imi for Pew 3 Actual Pscav.-no EBP-alve —e ActualPseav.- wath kBP ave ood P41 Run the engine at 85% load and agjust manually the bypass u bas obtained at Note the Bypass position at the MOP and also note mec positions should be us P-scay = (P-scav,100% - 0.8 orract P-max, This can possible take some adjustments, ‘anical indication at the bypass. These s reference for next engine, 7. Commisioning of EGB Note! Commissioning of EGB depends on EGB optimization Commissioning of ME-C with ‘Part Load! or ‘Lew Load EGB and Commissioning of ME-8 and MC-C with ‘Part Load’ EGB refer to part 71 Commissioning of ME-B and MC-C with ‘Low Load” EGB refer to part 2.2 Data AG Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areanal Page 29 of 28 Operation Recommendation 0743782-0.0 MAN Diesel & Turbo 7,1. Commissioning of MC-C with ‘Part Load’ tthe EGB is pre-callbrated according to the below, further instructions on this Itis assume: subject can be found in Siemens Sipart commissioning guide (ref, 0743767-2.0) or part 9.7 of this, document. Physical Position Valve Flow Area MOP Indication Fully open (physical or 100% 00% Fully closed fohysical end 0% 0% stop) Reset the Pscav reference curve by entering ‘0.00’ forall ‘Pscav Ref. Curve. Actually in the 'Pscaw Ret. Curve’ parameters. These are placed in the SCU > Scavenge Air Running Modes -> Running Mode 1 /2 - Pscay Ref, Curve. ‘Action Expected result ‘Set EGB in manual mode on the MOP ‘Set EG position 10 0% tart and run in engine During running in monitor Pcomp/Pscav and Pmax at 25%, 50% and 7596 engine load (with closed EGB) ‘Above 75% load, open the EGB to 100% Tris test is conducted to verily EGB orifice {and verity a drop in scavenge air prossure. amoter. ‘The pressure drop must be between 0.30bar and 0.48bar. Cases wher rease in scavenge air pressure cannot tained, must be rectified by changing the orifice in the EGB line, Maintain EGB in manual 100% open Note! That tis the ISO corrected scav- position and proceed with shop test as lenge air pressure which must fui normal, calbrate fuel index and adjust the design value. Poomp/Pscav and Pmax as normal s i Cases where this scavenge air pressure cannot be obtained, must be handled as traditional matching cases where turbo charger maker representatve must be EGB-vahe operation is kept in manual mode forthe duration of the shop test. Perform TC matching as normal ISO rected, +0.1/-0.1 bar, (Check that the measured scavenge ai pressure + 0.2 bar at 100% engine load, ner than the desired scavenge air pressure on the MOP before setting EGB In automatic control Data Designer AG Revision change evsion poreoro PEK o opin ©2013 MAN Deel Tre rach of MAN Dis Tat SE Germany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 30 of 28 Expected result cary out Scavenge Air Running Modes -> Running Mode 1 /2- P Action Expected result ‘Set EG in manual mode on the MOP {ot EGB position 10 0% ‘Start and run in engine During running in monitor Poomp/P Prax at 25% and 60% engine load {with closed EGR) ‘At 7596 engine load open the EGB t0 100% Tris tests 6 and verity in scavenge air pressure, and nducted to verly EGR. ure drop must be between 0.0 bar and 0.46 bar. Cases where this, ‘scavenge air pressure cannot ‘At 75% engine load adjust Pooma/Pscav and Pmax with fully open EGE, Maintan EGB in manual 100% open Note! That itis the ISO corrected scav- position and wth lenge air prossure which must ful normal, calbrate fuel index and adjust he Pcomp/Pscav and Pmax as normal. sign value. Cases where this s wvenge ai pressure 3t be obtained, must be handled as tional matching ¢: ;B-valve operation is kept in manual mode for the duration of the shop test 1s where turbo lative must be Perform TC matching as normal (ISO cor cd, +0.4/4041 bath Data Designer poreoro PEK AG Revision change evision oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 Data 2oreor0 MAN Diesel & Turbo & Be pressure on the MOP before setting EGB in automatic control Page 33 of 28 Action Expected result (Check that the measure pressure + 0.2 bar at 100: is higher than the desired scavenge air iis recommended to carry out the Surge test as instructed by TC maker guidelines, at the highest EGB is fully closed. ible load point where Reduce engine ‘and finalize com missioning at this load point with open EGR, Raduce engine 50%, Close EGB and finalize commissioning at 50% and 25% load. During quay- & sea trial: “The EGB is set to automatic control on the MOP and EGB function is naw sione can advantageously be tested aft nas well, bul note thal no other running in tasks or performance measurements can cartied out simultaneously, “The EGB postion is now controled as le vale cing to the scav- enge air pressure target values shown on MOP. These two values most correspond throughout the EGB active load Designer AG Revision change Pek Revision oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & ) Page 34 of 28 7.24, Important: Please note: That the scavenge air pressure obtained during the fully closed position at 75% (point 4), is not necessarily the scavenge air pressure the engine will experience after going to automatic, control at 75%, In ‘Automatic Control’ the EGB position is determined by a specific control strategy ‘according to the type of optimisation method (low or part load optimisation). Furthermore, actual valve positions will be dependent on ambient conditions Please notice that after setting EGB in Automatic control, effecis of ambient changes in scavenge air pressure can be different than normal, That also means thal when comparing member engines with different ambient conditions and normal ISO corrections, it's important to compare the ob- servations with the EGB in manual mode. It is recommended to carry out a test at guarantee load at which the bypass is partly open. This should be performed in manual mode and a reference bypass position must be noted for test on. next engine, The reference bypass position is decided based on predicted scavenging air pressure in the guarantee point The scavenge air at guarantee point can be calculated based on the predicted decrease in P-scav from 100% to guarantee point found in, for instance, tech data. Example: 11 85% load is guarantee load and performance must be compared to next member engine at ISO corrected values the following procedure is to be used: ‘The predicted decrease in P-scav. from 100% to 86% load running with bypass is 0.93 bar, Run the engine at 8596 load and adjust manually the bypass untl P-scav. = (P-scav.100% - 0.33 boar is obtained at correct P-max, This can possible take some adjustments, Note! The Byoass posttion at the MOP and also note mechanical indication at the bypass. ‘These positions should be used as reference for next engine. Data Designer Checkac AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo ke Be Page 35 of 28 7.3. Commissioning of low ambient temperature / arctic conditions EGB 7.3.1. Test bed running with low ambient temperature-/artic conditions Exhaust Gas By-pass valve The arctic bypass is adjusted according to ne P-scav ret, curve in the SCU. Engine load ‘Set-point: ME-C and ME-C engines <= 50%6 at 5086 load + 0.15 bar 50%-100% Scted ISO PScav at the load pont + 0.15 ba 110% pected ISO PScav at 110% load Action Expected result This is imoorta inthe op test the bypass must sed on the MOP, tion of the shop tin order to avoid any Hence installa ‘to manual and action from the bypass that readings used for judging tt ‘Atic-bypass valve is closed for the dure- 1 of the vale is not nec- Io interfere essary on the shoo test Wc of P-scav curve is requred | Note! Itis impossible to four estimate on considerable ( >0.2 bar) from confirm adjust- ments in the SCU (range, 5 etc), if installa omitted Data Designer poreoro PEK oprah © 203M Dee Tare bach of MA iT SE Gomany Revision AG Revision changeOperation Recommendation 0743782-0.0 MAN Diesel & Turbo ke Be Page 36 of 28 8. Appendix 8:1. Dongle setup Id-key: Note! Bo aware that the binary settings in relation to number on OIP-switcn $1, aro in reverse order (see below), and 1=On, 0=OFF U: Number on DIP-switch [1 2 @ 4 5 6 7 A Binary setting 1 i 1 1 0 1 1 Tag Node SOU) 8,2, LED colour codes The MPC L tions aro D show indications by either emitting constant light or by flashing. The LED indice tified by the colour that the MPC LED ernits. indication consists of two pulse trains separated in time by + Flashing pulses are second pauses. All inst a yellow background. The first pulse train will change between a yellow Ind a red foreground, and the second will use gre backgro, nas foreground. ait, a e ~_—» 1 second pause pause To identity the LED colour code note the number of red and green pulses. The frst digit is the number of red pulses and the second digit is the number of green pulses. In the illustration above, the colour code is (2, 3}. Data Designer AG Revision change evision poreoro PEK oprah © 203M Dee Tare bach of MA iT SE GomanyOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 37 of 28 8.2.1. Constant Colour [Shore name [Snort descrioton Red ERROR [Ether early infakzaton or fatal eror Orange [INT Tnialzstion, ne parameters avalable or non-normal node mode Green | NORMAL [Appiiction up ang running 8.2.2. Flashing Digits __ | Shortrame Short deserpto cn CTRL PRG. Onboard contol programming in progress ea) TAPPLOAD_SCAN | Application downloac in progress — soancing for sever (2,2) APPLOAD._DOWN- Application download in progress - downloading program LOAD APPLOAD_pp | APblballon downloas complied = ress yelow DIP sich sot to ON a BOOTLOAD_SCAN | Bootloader download n progress ~ scanning for sewer : BOOTLOAD, ; _ 6.2) CoWMonn | Bootloader downicad in progress downloading program (4) BONGLE_VERIFY | Checking node ID dongle a2) DONGLE ERROR [Dongle not mountea, programmed or defective aa DONGLE_DIP [Node I DIP ewitch not conectly reset — reset to 0x00 8.3. Service terminal setup and connection = Solect ‘Start’ and ‘Run’, write hypertrm.oxe in the dialogue box and select ‘OK’ Ts tx 7 ‘Type the name of a grooram, folder, document, or Internet resource, and Windows wil open it for you, = The Hyper Terminal program will stat up, and a 'New Connection’ dialogue box will appear. Write 6.9. Service Terminal and select ‘OK’ Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are> Operation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 38 of 28 1 Inthe next dialogue open the COM1 and sel ‘onnect using’ oxitield and select the port to be used, Le. Enter details for the phone number that you want to dik County/regon: [Derma (5) oH = Inthe next dialogue, set up the port settings as follows and select ‘OK’ = Bits per second: 9600. = Data bits: & = Parity: None. = Flow control Xon/Xotf, ts 1 1, Access to Service Terminal Connect a PC to the MPC. onterminal plug J67, 2. Type followed by pressing enter. Data AG Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo had Page 39 of 28 Dip switch settings and connections for MPC in normal operation View of MPG board with ID-key connected Battery mounted on MPC board LED (Led Emitting Diode) Service Terminal Connection (J87) ID-key Mounted on MPC (J206) DIP-switch St on MPC board DIP-switeh St DIP-switch $1: Neutral => Allin off postion a = Binary 1 0) OFF = Binary 0 Data Designer Checked AC Revision change evsion poreoro PEK _LTDA o Cont © 203 MaDe Tro brach MAN es Tt SE Gemany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 40 of 28 Mutt colour DIP-switch on side of MPC board, settings for connection test and normal service DIP-switch Nos. 1 & 8 must be in off poston 94 ON = Binary 1 of OFF = Binary 0 Reset button for MPC (The reset button on the side of the MPC board) Data Designer Checked AC Revision change evsion poreoro PEK _LTDA o Cont © 203 MaDe Tro brach MAN es Tt SE Gemany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo heaod age 48 5. MPC overview Fuse specication et aw ee ter 82, (4210) FI 12a ea a em ) la = By fine (hierar iia: 2a Melton (66 N65 * iin \Eoe # Nats Halal Bl ee, {uae [43140 33 [43026 (2320. ani tteor|ifenttenares|tensvralsventrcaltenetes| |, ys. ao yaa s7_us4_|J31_\o7 [oa a1 eT Be) wR me | A lat yo Pei) yr rrp roe ee es rie : Chock that each Fuse isthe spocitod type. bate __Desgrer Creches AC. Revlon change facsion wom FX Ube o ae 203 MaDe Tre bach HAN Die Tt SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo ke aval Page 42 of 28 8.5.1. Overview J-Fuse plugs on MPC J-plug number Function of fuse 1 ‘owersupply z Powerfailure Power Out 24V_ jecting terminals (Loop ete) ‘Analog In Fast Digital In(Galv. Isolated) Fast Digital In/out{@alv, Isolated) ‘Service term ‘Analog Qut(Galv. isolated) Digital Out fo) Dongle Key connec 210) Battery 8.5.2. MPC Parameter download (back up of software) MPC p: ameter Download (parameter backup}: (On the MOP PC, press [CTRL] + [ESC]. select Windows Explorer or ‘My Comouter’ and open: C:\Program Files\MANBW\MOP\Tools. Start the MPCArchive program (MpcArchive. “Archive” tab. exe) and select th 2. Browse/solect destination folder for archiving the fle. 3. Press "Get All" to start extraction of the parameter archive files. The status of the can be seen in the ‘Upload Status’ column 4. After completion (Online Status ->Normal), select the MPC{s) in question and restart the MPO\s) by pressing “Start App.” This will start the application using the new parameters. Finally reboot MOP in order to update the MOP display. 5. Close program MPCArchive when message Getting of Archive Finished. Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany cussOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & ) Page 43 of 28 8.5.3, /0 test Descried using to jumpers and mult meter. Analog input tester. Resistor should be 2K2. (ama) Binary input tester 8.6. How to Open Input channel “Open System view /O test” under maintenance menu ~ Click on the channel no. 8.6.1. Test of binary Input channels: 1. On the MOP change the mode of the SCU to “TEST MODE” 2. Remove plug J20 and J36 Open inout channel J20 on MOP or on Service terminal 4, Insert binary input tester in J20, observe that input changes. 5. Open input channel J36 on MOP or on Service terminal. 6. Insert binary input tester in J26, observe that input changes, 7 Test finished, installed removed plug again Data Designer Checkac AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 44 of 28 8.6.2. Test of analog input channels: (On the MOP change the mode of the SCU to “TEST MODE" 2, Remove plug J30-181-J82-J34-J36 and 37 3. Open input channel J30 on MOP or on Service terminal 4, Insert binary input tester in J80, observe that input changes from offal) to 12mA. 6. 6 z Open input channel J31 on MOP or on Service ter Insert binary input tester in J1, observe that input anges from Offa) to 12mA. on MOP ar on Serviee terminal Open input channel J3: 2. Insert binary input tester in J32, observe that input changes from Otfail) to *2mA, 9. Open input channel J34 on MOP or on Service terminal 0, Insert binary input tester in J&4, observe that inout changes from Offall to 12mA, 4, Open input channel J35 on MOP or on Service t 12, Insert binary input tester in J35, observe that input c! 48. Open input channel J37 on MOP or on Sen 14, Insert binary input tester in J37, observe thal input changes from Ofall to 12m, 5 OT led removed plug again. minal ng terminal from Offa) to 12mA, finished, ins 8.6.3. Test of binary output channel (cannot be tested in Test Mode): Channel 60 have to be tested actually. Slowdown will 3e during cunning of the engine, later test in this document} 2, Channel 61 can be tested by clearing all alarms in the alarm list (cut-out for examole, re- member to put the channels back in normal operation when fris| 8.6.4. Test of Analog output channel: (On the MOP change the mode of the SGU to "TEST MODE” Remove plug J70 on the MPC Insert an empty plug in J70 and measure between B and © mA (multimeter) ‘Open VO screen on channel 70 Insert different values in channel 70 on MOP, confirm the output values on the multimeter g again Test finished, installed removed plu When all VO test are finished change the MPC mode back to normal operation. Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng areOperation Recommendation 0743782-0.0 MAN Diesel & Turbo & ) Page 45 of 28 .IP-converter (Sipart PS2) commissioning 8.7.1. [P-converter (Sipart PS2) commissioning 1. Connect all cables according to Drawing no. §136097-0 ‘SetPoint cable connected to terminal 6, 7 (SCU ch.70) ‘Alarm cable connected to terminal $1, 32 (SCU ch.20} Feedback cable connected to terminal 61, 62 (on ly-module) (SGU ch.34), see figure below. Position-feedback-cable connected from NCS-sensor to EMC Filter module, see figure be- low. sistem Feedback cable connected to terminal Posttion-feedback-cable connected 2. On the SIPART. Switch the yellow Transmission Ratio Selector to "30 with a pen or screwdriver, Data Designer Checkac AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By PashOperation Recommendation 0743782-0.0 MAN Diesel & Turbo heaod 10, 1. 12, 13, Page 46 of 28 Press Hand (bottom mark with a hand) for minimum § seconds, The SIPART goes in to Configuration-mode for the parameters ‘Set Parameter 1 (Type of Actuator) to *-neSt" by the “+" and The SIPART is set to Part-turn-actuator with inverse action. (Actuato’ and Open = 100 9%, By pressing the hand ~ change te parameter 2, ‘This should already be 90°, as this chosen by the yellow Transmission Ratio Selector. Go to parameter 4 ~ initia'sing of Sipart. Press "+" for min. § seconds for starting Initiation. ‘The SIPART will un the Automatic Initiation Program with § steps, Ir the Initial process stop at "RUNT” - the direction of the actuator is inverse. Set paramoter 1 Check of actuator working direction. Ifthe Initial process stop at"RUN2", “down tolerance band violatea", Turn magnet on the top of the actuator unti the display shows zero - between d and U, Checking of travel and adjustment of “O"-position When magnet position is OK, display should be lke this If the Initial process stop at "RUN2". “up tolerance band violated” ‘Turn magnet on the top of the actuator untl the display shows a higher value fanaroximately 95), ‘Then restart initalising, Checking of travel and adjustment of stroke (maxcposition), ‘When the display shows “Finish’ - the Initial process is terminated successtuly, ‘Automatic Initiation Program terminated successtully By pressing the hand ~ change to parameter 47, ‘Set parameter 47 (Alarm Switch Functior) to “Fault + not automatic” (normal The SIPART is set-up to send a alarm when it has a fault or is not in Automatic-Mode. Press hand for more than 5 seconds for exit of Configuration Mode. IMPORTANT -BECAUSE THIS SAVES PARAMETER CHANGES, Sot-up and parameters saved. Display will show “software version 4,00" ~ and system is ready to use. By a short press on Hand you can toggle between “Auto” and "Manual In Manual-mode — the valve position can be changed by pressing "+" or *- ‘Test the valve with several set-points between O° - 20% Check that the valve actual postion follows. The function of SIPART and the vale is tested, NO (Normal Oper} For more information of the SIPART see “SIPART Operation - a concise overview" on the next pages. Data Designer Checkac AC Revision change evsion poreoro PEK _LTDA o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are Tsing of SOU Be. Ga By Pash8 MAN Diesel & Turbo Operation Recommendation 0743782-0.0 Page 47 of 28 a concise overview 8.7.2. SIPART Operation Ses Ve Shes sa] supe soma aie evision AG Revision change Designer Checked Data ry Pek 2oreor0 oprah © 203M Dee Tare bach of MA iT SE Gomanyanal Operation Recommendation 0743782-0.0 MAN Diesel & Turbo Page 48 of 28 = at > swe anny oe F 5 j Data Designer AG Revision change evsion poreoro PEK o oprah © 203M Dee Tare bach of MA iT SE Gomany 07487820, Genoa Gubalne fo Canmissonng are