MAN Diesel

MAN Diesel & Turbo • Denmark

MPC Earth-Finder user manual:

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Content:

1. Preface.

2. MPC Earth-finder overview.

3. Measurements obtained with MPC Earth-finder:

4. Fault-finding low insulation on the MPC´s:

5. Low insulation located on a MPC

6. Standard MPC. Where can “MPC Earth-finder” locate of errors.

7. MPC 10. Where can “MPC Earth-finder” locate of errors.

8. PMI DAU. Where can “MPC Earth-finder” locate of errors.

9. Advantage / Disadvantage of the MPC Earth-finder method.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Preface:
The “MPC Earth-finder” originates from the philosophy of faultfinding on ECS low
insulation to the ship hull, without 24vdc power on the ECS. And that pinpointing low
insulation properties on the MPC´s to ship hull, is more fast and easy, by systematic
galvanic insulate MPC´s in the ECS one at the time. Leaving no doubt if any errors are
present on one of the nodes.

“MPC-Earth-finder” should be used in cases where the “Bender isometer” located in the
PSU “A”, indicates an insulation below 100kΩ.

MPC Earth-finder” is the tool which fast and accurate can find damaged sensors or wiring
on the MPC`s.

Combining the “Bender isometer” and the “MPC Earth-finder” in the search of low
insulation in the ECS gives a fast and reliable result as there will be no doubt where the
low insulation are located.

The “MPC Earth-finder” can be used for faultfinding on both running or stopped engines.

This tool can be used to pinpoint 2 types of issues on the MPC´s, which can influence the
ECS in a negative way:

1. Low insulation between the 24vdc / 0vdc power supply and to the ship hull, on ECS
powered sensors; actuators or wiring.

2. Missing galvanic insulation properties between the ECS and external systems, on
ECS powered signals.

The “MPC Earth-finder” can be used during commissioning / installation works and by any
people working on the ECS, to find and rectify low insulation properties on the MPC´s.

This tool can be used in the following situations:

Before first power-up of the ECS on the licenses.

(helps avoiding burned off components + rectify errors in the system prior to first
engine start)
Before first power-up of the ECS after engine installation at the shipyards.
(helps avoiding burned off components + rectify errors in the system prior to first
engine start)
Onboard sailing vessels in service by the crew them self.
(with or without engine running, both options can be chosen)

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

The basic idea of this method is to systematic galvanic isolate as many components in the
ECS as possible one at the time, in order to carry out a systematic fault-finding locally on
these first.

When these components are checked / tested, power has to be restored to these units.

“MPC Earth-finder” has to be connected to the MPC power supply plug J1, for easy fault-
finding on all sensors connected to the MPC in question.

This tool is made for easy faultfinding on low insulation issues on the MPC wiring and
sensors.

It is a very simple tool, which is used together with a fluke-meter, set to measure
resistance.

The basic idea of the “MPC Earth-finder” combined with a “fluke-meter” is to measure
resistance all the way from MPC power-plug J1:A or B or C through the whole circuit in the
MPC and then out to each sensor connected to the MPC and then checked against the
ship hull.

The method by disconnecting one MPC at the time from the rest of the ECS is very good
as it leaves the rest of the ECS powered on and the MPC which faultfinding is carried out
on is galvanic insulated from the rest of the ECS.

By having power on the rest of the nodes, makes it also possible to find missing galvanic
insulation on signals between two MPC´s .

The tool has been used to find the following:

Stationery earth-faults
Periodic earth-faults
Missing galvanic insulation properties between 2 MPC´s.
Missing galvanic insulation between our ECS and external systems.

When carrying out faultfinding on our ECS hardware / cables / MPC´s and so on, it is
important to remember that all the system is linked together by the power supply lines.
This makes it possible for earth-faults on one MPC to influence the rest of the system and
also makes it more difficult to pinpoint the location of the low insulation.

The MPC Earth-finder is the tool which makes it easy to pinpoint the location of an earth
fault present on a MPC.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

NOTE:

MPC´s will be taken out of operation during faultfinding, as the power is unplugged.

In case that the faultfinding is carried out on CCU´s during engine running, the load
should be reduced to “slow” and the troubleshooting is not allowed to exceed 5
min, as the cylinder lubrication is not active on the unit in question.

In order to avoid any damage to cylinder liners, and to have unlimited time for
trouble-shooting MAN Diesel & Turbo recommend to install and use the “emergency
lubrication cable” connected to ECU-A or B, in case where trouble-shooting on a
CCU is carried out during engine running:

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

MPC Earth-finder overview.

1. Connection to MPC J1.

2. Connection the Fluke meter.
3. Selector switch:

“A” = 0Vdc to ship hull

“B” = 24Vdc from PSU “A” to ship hull
“C” = 24Vdc from PSU “B” to ship hull

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Measurements obtained with MPC Earth-finder:

Measurements on a “healthy” MPC without any low insulation properties:

“A” = 0Vdc to ship hull (resistance should be above 10MΩ)

“B” = 24Vdc from PSU “A” to ship hull (resistance should be above 10MΩ)

“C” = 24Vdc from PSU “B” to ship hull (resistance should be above 10MΩ)

In general a healthy MPC with all sensors connected will be in a range of 10MΩ to
20MΩ.

Measurements on a MPC with low insulation properties:

If values below 1MΩ are measured on the MPC, earth-failures or missing galvanic
insulation would most likely be influencing the system.
It can also be the MPC itself which has faults.
(these faults most be found and rectified)

Values below 500KΩ will cause problems, and can indicate static or periodic earth-
faults.
(these faults must be found and rectified as they indicate poor insulation properties)

Values which are measured to be periodic, or to some extend fluctuating from 100KΩ
to above 15MΩ and down again, can indicate missing galvanic insulation to the ship
hull or to other external systems.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Fault-finding low insulation on the MPC´s:

The first thing to do when carrying out faultfinding is to galvanic isolate MPC`s one at the
time from the rest of the ECS and then locally carry out faultfinding on this MPC before
proceeding to the next MPC.

Proceed in the following way:

The measurements in following explanation, are what you will measure on a “healthy”
MPC and the connect sensors, without any low insulation properties:

Please follow this procedure when using the MPC Earth-finder:

1. Disconnect the power plug J1 to the MPC. NOTE: unit is taken out of function.
2. Connect the “ MPC Earth-finder to the MPC J1.
3. Connect the “MPC Earth-finder to the Fluke meter.
4. MPC Earth-finder Selector switch put on position “A”
5. Switch on the fluke meter and set it on Ω
The fluke meter will now “charge” its measuring voltage into the MPC PCB and all
the connected sensors.
The measurement you will see during “charging” on a “healthy” MPC is a resistance
from 150kΩ rising slowly up to above 18MΩ.
In case you are impatient during “charging” measuring voltage unto the MPC, you
can by switching to “B” and “C” a couple of times and then back to “A”, eliminate
some waiting time.
6. After ended “charging” you will now by use of the selector switch, measure and note
down the insulation levels at:
“A” (0vdc to ship hull) =
“B” (24vdc PSU “A” to ship hull) =
“C” (24vdc PSU “B” to ship hull) =
Please have patience during the measurements, wait 30sec. before changing to
next measurement.
The measurements should end up being stable and above 10MΩ
7. Now all sensors, valves or wiring connected to the MPC in question, has been
checked.
In case no abnormal measurements are found please proceed to the next
MPC.
8. Switch off Fluke Meter
9. Disconnect MPC Earth-finder from the MPC J1.
10. Re-connect power plug J1 to the MPC, and check that it reboot correctly.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Low insulation located on a MPC

If low insulation is present on a MPC, simply start disconnecting one sensor plug at the
time on the MPC in question, and in the same time monitor the Fluke meter.

When the insulation level slowly start rise and stabilize above 10MΩ on the fluke-meter,
this indicates that you have found the sensor or wires which has the fault.

You have now found the sensor which has the earth-fault. Then the cabling all the way
from the plug to the sensor has to be checked.

Most times the low insulation is found at the following places.

Damaged wiring in the sensor plug.

Water in the sensor plug.
Damaged internal wiring inside the MPC cabinet.
Connection between wires and cable screen´s.
Damaged sensors / valves.

If there still should be some issues related to the MPC in question after disconnecting all
plugs, please try to exchange it with another unit, in order to check if the MPC has
problems, which this method cannot find. This is a very easy way to see if you move the
problem from one unit to another.

When one MPC is checked and found in good working order, the power should be
restored to this unit.

Continue with the next MPC as described in above (point 1 to 10), until all MPC´s has
been checked and the insulation properties on the MPC´s are found to be above 10MΩ.

Please always be very systematic and rule-out areas of the ECS one by one, when
carrying out low insulation trouble shooting. This will help you to find the errors.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

“MPC Earth-finder” connected to a “healthy MPC”, resistance level 12MΩ.

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Standard MPC. Where can “MPC Earth-finder” locate of errors:

J3 to J9 = Yes

J20 to J27 = Yes in case the consumers are powered by the MPC.

J30 to J37 = Yes in case the consumers are powered by the MPC.

J40 to J43 = Yes in case the consumers are powered by the MPC.

J44 to J47 = Yes in case the consumers are powered by the MPC.

J48 to J53 = Yes in case the consumers are powered by the MPC.

J60 to J61 = Yes in case the consumers are powered by the MPC.

J70 to J71 = Yes in case the consumers are powered by the MPC.

J2 = No (potential free)

J80 to J85 = NO (potential free)

J65 to J66 = NO (galvanic insulated)

J68 = NO

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

MPC 10. Where can “MPC Earth-finder” locate of errors:

J48 = Yes in case the consumer is powered by the MPC.

J53 = Yes in case the consumer is powered by the MPC.

J71 = Yes in case the consumer is powered by the MPC.

J33 = Yes in case the consumer is powered by the MPC.

J35 = Yes in case the consumer is powered by the MPC.

J21 = Yes in case the consumer is powered by the MPC.

J30 = Yes in case the consumer is powered by the MPC.

J31 = Yes in case the consumer is powered by the MPC.

J34 = Yes in case the consumer is powered by the MPC.

J32 = Yes in case the consumer is powered by the MPC.

J50 = Yes in case the consumer is powered by the MPC.

J51 = Yes in case the consumer is powered by the MPC.

J52 = Yes in case the consumer is powered by the MPC.

J9 = YES

J70 = Yes in case the consumer is powered by the MPC.

J103 = NO

J40 to J43 = NO

J44 to J47 = NO
J65 to J66 = NO

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

PMI DAU. Where can “MPC Earth-finder” locate of errors:

J2 to J13 = YES

J300 to J302 = Yes in case the consumers are powered by the MPC.

J340 to J343 = Yes in case the consumers are powered by the MPC.

J330 to J337 = Yes in case the consumers are powered by the MPC.

J360 = Yes in case the consumer is powered by the MPC.

J310 to J323 = NO (galvanic insulated)

J65 to J66 = NO

KBH / LEO 2011

 MAN Diesel
MAN Diesel & Turbo • Denmark

Advantage / Disadvantage of the MPC Earth-finder method.

The advantages of this method:

Low cost method / tool

Finds all earth-faults on MPC´s which are related to the wiring /sensors/actuators
where our own 24vdc is used as supply.
Nodes are galvanic insulated between each others during fault-finding, making
more systematic trouble shooting possible.
No power on the system during faultfinding.
Reduces the risk of burned off components.
Improves the accuracy of the measurements carried out and direct and fast pinpoint
the low insulation if present on a MPC.
The resistance value can be noted down for future reference.
Can be use on the ECS prior to first power up on the licensees.
Can be used on vessels in service, by the crew them self.
Can be used during engine running.
Can be used on standard MPC, MPC 10 and PMI DAU units.

The disadvantage of this method:

Method is not tested to find errors related to half conductors on the MPC itself.
MPC Earth-finder can only find low insulation properties on sensors and cabling,
which is connected to the MPC power supply. This is however also approximately
95% of all the MPC connections which are used.

KBH / LEO 2011