Wärtsilä Switzerland Ltd Service

Sulzer 2-stroke Engines

PRELIMINARY
Adjustement Instruction

Table of Contents:

1 Brief function description .................................................................................................. 2

2 Incremental Wheels .......................................................................................................... 2
3 Pick-ups............................................................................................................................ 2
3.1 TDC detection............................................................................................................ 3
3.2 Direction detection..................................................................................................... 3
3.2.1 S1+ (AHEAD) ..................................................................................................... 3
3.2.2 S1 (ASTERN) ..................................................................................................... 3
4 Alignement........................................................................................................................ 4
4.1 Preparation................................................................................................................ 4
4.2 Initial alingement of the incremental wheels .............................................................. 4
4.3 Alignement of the pick-up bracket ............................................................................. 5
4.3.1 Vertical alignement of the pick-ups..................................................................... 6
4.3.2 Horizontal alignement of the pick-ups ................................................................ 6
4.3.3 Lateral alignement of the pick-ups...................................................................... 6
5 Calibration of the pick-ups ................................................................................................ 7
5.1 TDC Calibration ......................................................................................................... 7
5.2 S1+ (AHEAD) / S+ (ASTERN) Signal Calibration ...................................................... 7
5.2.1 S1+ (AHEAD) ..................................................................................................... 7
5.2.2 S1 (ASTERN) ..................................................................................................... 7
5.3 Final Calibration of the TDC Signal ........................................................................... 8
6 Troubleshooting................................................................................................................ 8
7 Protection ......................................................................................................................... 9
8 Remarks ........................................................................................................................... 9

Date : 15/06/2007 SHUD, 40159 Page : 1 / 9

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1 Brief function description

The RPLS CAS 3600 System consists of two (2) incremental wheels, mounted on the
propeller shaft, and two angle feedback pick-ups. The dual execution is due to redundancy
requirements. The pick-ups are equipped with 3 infrared photoelectric sensors. When the
TDC mark on the wheel passes the pick-up (sensor head 1) for the first time after power up
of the system, a reference point is set (0° Crank Angle = TDC Cyl. 1). Rotation detection is
made by sensor heads 2 + 3.

2 Incremental Wheels

TDC Slot

Incr. Slots

Longitudal
Bracket

Lateral
Brackets

3 Pick-ups
Sensor Nr. Position (view from shaft) Detects:
1 (TDC) 1st TDC Cyl. 1
2 (S) 2nd ASTERN (CCW - Rotation)
3 (S+) 3rd AHEAD (CW - Rotation)

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RPLS CAS 3600 Pick-up Infrared sensor heads (S1+ / S1 / TDC)

3.1 TDC detection
The Retrofit pulse lubrication uses the so called crank angle (CA) as a reference to determine
the position of the respective piston to calculate the time of cylinder lube oil injection. By
definition, TDC Cyl. 1 equals 0° CA. The respective TDC for the other cylinders is thereafter
calculated using the firing order. During assembly the TDC slot has to be aligned with the
TDC Cyl. 1 mark on the main engine’s flywheel. This allows the control system to set 0° CA
as soon as it receives an input signal from the TDC sensor head.

Note:
Due to the nature of the system, everytime the power suppy to the control systems is
switched of, the reference to TDC Cyl.1 (°CA) is lost. It will automatically be set when the
system power is switched on and the TDC slot has passed the pick-up for the first time
thereafter.

3.2 Direction detection

3.2.1 S1+ (AHEAD)
The infrared sensor head S1+ is slightly offset towards the upper edge of the pick-up
compared to S1. This allows the S1+ sensor to detect a slot earlier than S1 (which is lower)
when the propeller shaft is rotated clockwise (AHEAD).

Therefore the control system will count in positive (+) steps (0.5°CA) after first passage of
the TDC slot.

3.2.2 S1 (ASTERN)
When the S1 sensor detects a slot before the S1+ sensor, the propeller shaft is rotated
counter-clockwise (ASTERN).

Therefore the control system will count in negative (-) steps (0.5°CA) after first passage of
the TDC slot.

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4 Alignement
4.1 Preparation
Choose a location as close as possible to the flywheel and with some space in the
surrounding where the pick-up holder can be positioned.
Clean the shaft in the area where the wheel is supposed to be mounted.
Fit the pick-up holder as described below

Fitting of pick-up holder:

Choose a location where the holder can
be placed without interfereing with other
objects.
Check where you can weld-on the side
supports (tank top, hull)
Shorten the holder that its height will
match the distance between the tank top
and the middle of the shaft.
Make sure to position the holder as close
to the shaft / increment wheel as possible.
This allows to keep the pick-up bracket
short and reduces the vibrations on the
pick-ups.
Fix the holder by tack welding and control
the alignement again (height!)
Do the final welding and check the
alignement again after finishing of welding
works.

Drill holes in the top plate of the holder that the pick-up brackets can be mounted

4.2 Initial alingement of the incremental wheels

Fit the two incremental wheels (2) with the tensioning belt (3/4/5) onto the propeller
shaft (6) and tighten the tensioning belt slightly.
Distance between the wheels shall be between 120mm…360mm.
Insert the 4 positioning pins (8), this will simplify the installation.
Turn the engine to TDC Cyl.1
Pre-position the TDC mark of the two wheels near the pick-ups.
Tighten the tensioning belt with 15 Nm.
Use a dial gauge and check the alignement

Check: Deviation allowed: [mm] Correct as follows:

Axial true run: 1.0 Loosen tensioning bolts (4) and tap the wheel
laterally until true run is within limits
Radial true run: 0.5 Loosen M6 bolts (9) and slightly tap with
plastic hammer until true run is within deviation
limits

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After you have veryfied the correct alignement, tighten the tension belt again with
15Nm

1. Pick-up
2. Incr. Wheel
3./4./5. Tensioning
Belt
6. Shaft
7. Holder
8. Positioning pin(s)
9. M6 bolts

Center line of
Holder

4.3 Alignement of the pick-up bracket

Mark one of the wheel holders with a centre line as shown above. Since the wheel
holders are mounted flat to the shaft, this line will necessary point to the shaft’s centre.
Mount the bracket as shown below and roughly align it.

Check that the increment wheel is centered in the slot

of the pick-up.

Mounting of the bracket (view from below) S1 sensor (A) / TDC sensor (B)

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Install now the two (2) pick-ups on the bracket. Make sure the designations “ENGINE”
and “PROPELLER” point towards the appropriate direction.

4.3.1 Vertical alignement of the pick-ups

Take a ruler and align it with the sensor heads of the S1 sensor and the TDC sensor
(as shown above). This line has now to be aligned with the center line of the holder.
Fix the holder now preliminary in this position.

4.3.2 Horizontal alignement of the pick-ups

Verify that the increment slot covers the S1+ and S1 sensor heads. Use the two white
lines for judgement.
Check that there is sufficient top clearance by turning the wheel one full revolution.

Top Clearance

Incremental Wheel

Increment Slot

TDC Slot

4.3.3 Lateral alignement of the pick-ups

Shift the pick-up sideways until the increment wheel runs centred in the slot of the
pick-up.
Check the side clearance by turning the wheel one full revolution.

The pick-up is now mechanically adjusted. Fix the bolts with Loctite to prevent loosening.

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5 Calibration of the pick-ups

Fig.1) TDC - LED Fig.2) S1+ (AHEAD) Fig.3) S1+ & S1 Fig.4) S1 (ASTERN)

5.1 TDC Calibration

Turn the engine in AHEAD direction to the TDC Cyl. 1 mark on the flywheel.
Power up the RPLS control system. Make sure you receive power on the pick-up
connection box (Fig.1-4)
Slightly slacken the tensioning belt of the FWD increment wheel.
Slowly move the increment wheel by carefully knocking on a holder (9) using a plastic
hammer.
When the red TDC LED comes on, as in Fig.1, the respective wheel is set to TDC.
Repeat the procedure with the AFT wheel.

5.2 S1+ (AHEAD) / S+ (ASTERN) Signal Calibration

5.2.1 S1+ (AHEAD)

Turn the engine Ahead until one of the green S1+ LEDs comes on, as in Fig. 2 (try to
find the point where it just switches).
Move the second wheel carefully until the other S1+ LED just comes on. The more
careful you do this the more accurate the calibration gets.
5.2.2 S1 (ASTERN)
Turn the engine Astern until one of the yellow S1 LEDs comes on, as in Fig. 4 (try to
find the point where it just switches).
Move the second wheel carefully until the other S1 LED just comes on. The more
careful you do this the more accurate the calibration gets.

Repeat steps 5.2.1 / 5.2.2 until the signals of the two incremental wheels arrive at the pick-up
connection box as simultaneously as possible. This is essential for a trouble free operation of
the lubrication system.
Turn the engine once again to TDC Cyl.1 and verify that both red TDC LEDs are on. Then
tighten the tension belts of the two (2) incremental wheels with 15 Nm.

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5.3 Final Calibration of the TDC Signal

Power up the Retrofit pulse lubrication system then rotate the shaft and make sure
that the TDC slot of both incremental wheels have passed the pick-ups at least one
time.
Set the engine to TDC Cyl.1 and check the Crank angle 1/2 feedback on the flexView
ADJUST page. Increase or decrease the offset (positive (+) or negative (-) values are
possible) until both actual angles are zero (0).

Offset Adjustement

Actual Angles

6 Troubleshooting
Should the sensors deliver strange signals or abnormal alarms are being displayed in the
flexView proceed as follows:
Check the wiring again. Is power supply for CA1 connected to FCM1 (E40 T51/52)
and CA2 connected to FCM2 (E40 T71/72)?
Check the signal cables for correct connection.

If there are no wiring faults try the following:

Switch of all power supplies in the E40 box and wait for 30 seconds.
Close the flexView program
Power up the E40 box again
Turn the engine over TDC Cyl.1 (TDC Slot!)
Switch flexView on

If the failure remains check the alignement again. Make sure the pick-up points to the center
of the propeller shaft. Change the pick-up if you suspect a failure of the part.

Protection cover

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7 Protection
Install a cover or a similar protection over the wheels and the pick-ups to protect them from
mechanical damage from foreign objects. See above picture for reference.

8 Remarks
This guideline is for reference only and meant as a help to the Commissioning Engineer of
any Retrofit Pulse Lubrication Project using the RPLS CAS 3600 Sensor. Please consult the
official Lemag Installation, Operation and Maintenance Instruction which is available from
WCH for more specific informations.

Wärtsilä Switzerland Ltd SHUD, 40159