ME Engine Operation - Basic
ME Engine Operation - Basic
Table of Contents
Page 25
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
Abbreviation List
In case of a major alarm, it is recommended that a proper history log of the alarms is prepared.
The event log can be used for viewing the history of events and to support the operator in
troubleshooting. Events stay in the log even after they have been acknowledged and re no longer
active.
Note: Always ensure that any USB memory stick inserted into the MOP is scanned and cleaned
from any malware.
HCU Events and HPS Events can be accessed through Maintenance -> Troubleshooting.
These screens are an aid to the engineer and are used to monitor the actual movements of the
HCU/HPS related signal. Both are used to show the actual movements of FIVA valve, plunger
positions exhaust valve movements and swash plate positions as trend graphs.
It is recommended to take manual HCU and HPS Event Logs from time to time where no problems
or malfunctions are present. By comparing these logs with logs from emergency situations, it is
possible to make proper conclusions regarding the cause of the problems.
HCU / HPS Event logs can be exported manually and saved on a USD memory stick.
2.1. General
The Engine Control System (ECS) consists of a set of controllers. Briefly described, the functions
of the controllers are:
MOP
EICU : The Engine Interface Control Units handle the interface to external systems
ECU : The Engine Control Units perform the engine control functions:
engine speed, running modes and start sequence
ACU : The Auxiliary Control Units control the pumps of the hydraulic system and the auxiliary
blowers
CCU : The Cylinder Control Units control the ELFI/ELVA and FIVA valves, starting air valves
and the M/E cylinder lubricators
SCU : The Scavenge air Control Unit controls both the EGB (Exhaust Gas By-pass
The normal function of the ECS controllers can be checked through the System View I/O tab, in the
Maintenance section of the MOP. On this tab, a potential MPC malfunction can be detected by the
Not Accessible indication.
Note: It is recommended that before you proceed with the MPC replacement, you should carry out
a reboot of the MPC. You can reboot the MPC by disconnecting and connecting back the power
cable.
Warning!! Static electricity may harm the MPC. When changing battery or doing other
maintenance on MPC, it is important to level the electric potential between hand and frame.
In case of new MPC board, the MPC board will automatically download software and setting from
MOP panel. Once the program completes the ID-key verification and continues the boot sequence.
Start-up process will take about 15 minutes
When the LED shows GREEN, the MPC board is running normally.
After the replacement of the MPC, the normal function is confirmed by the following:
Note: After the replacement of the MPC and before we start the main engine, one Slow Turn and
one Air Run must be ordered. Otherwise, the engine will NOT start.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
One spare MPC and one spare MPC-10 are included in the main engine standard spare parts. In case
of MPC failure, the defected MPC must be replaced at first chance, otherwise the ECS redundancy
is compromised and the operation of the main engine might be seriously affected.
The following table summarizes the actions that must be taken, in case that the spare MPC or MPC-
10 has already been used and there is not any additional spare available on board.
ECS Type of
Case Remarks / Action
Controller MPC
System is redundant, engine operation is maintained.
A SCU MPC
Engine load must be kept below 80%.
If EICU A fails, EICU B will take over the control, without any
EICU A MPC
interruption
B
If EICU B fails, EICU A will take over the control, without any
EICU B MPC
interruption
EICU
C MPC Engine control must be transferred to the LOP
A&B
If ECU A fails, ECU B will take over the control, without any
ECU A MPC
interruption
D
If ECU B fails, ECU A will take over the control, without any
ECU B MPC
interruption
Engine cannot operate.
It is recommended to use existing MPC as spare.
ECU 1st option: SCU (Keep engine load below 80%)
E MPC
A&B 2nd option : EICU
3rd option : ECU
4th option: ACU 3
System is redundant, engine operation is maintained.
ACU 1 MPC Auxiliary blower #1 is out of control.
Engine-driven pump #1 is locked in AH/AS position
System is redundant, engine operation is maintained.
F
ACU 2 MPC Auxiliary blower #2 is out of control.
Engine-driven pump #2 is locked in AH/AS position
System is redundant, engine operation is maintained.
ACU 3 MPC
Engine-driven pump #3 is locked in AH/AS position
Cylinder Cut-Off is recommended.
G CCU MPC-10 In top emergency case, MPC can be used as spare, instead of
MPC-10
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
i. Pull out electric power supply connector (J1) of MPC / MPC-10, of the ID key that must be
replaced.
ii. Set DIP switch S1 of the MPC, by referring to the below table
iii. Remove existing ID key and connect electric power supply connector (J1)
iv. Check the LED color flashing sequence until you notice the following:
RED: 4 times, GREEN: 2 times
v. Fit the new ID key
vi. Check the LED color flashing sequence until you notice the following:
RED: 4 times, GREEN: 3 times
vii. Turn OFF all DIP switches S1
viii. Check the LED color flashing sequence until you notice the following:
RED: 4 times, GREEN: 4 times
ix. After you confirm the color flashing sequence above, turn ON the first DIP switch S1 for 2
seconds and then turn OFF.
x. Wait for about 1-2 minutes, until LED becomes green permanently.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
3. Tacho System
Most common reason of tacho set failure alarm is failure of MSA (Masterslave) signal from the
pick-up sensor of the flywheel. In this case, our first actions are the following:
i. Disconnect the MSA signal cable of the pick-up sensor from the Tacho System Amplifier
(TSA) A
ii. Connect the separately isolated MSA signal cable of the angle encoder sensor A to the Tacho
System Amplifier (TSA) A
iii. If the alarms resets, it is probably attributed to defective pick-up sensor. Replace the pick-up
sensor and carry out function test for verification.
iv. If the alarm does not reset, next possible reason might be defective angle encoder sensor
and/or MPC. Replace the defective sensor and carry out function test and fine adjustment.
Check System View I/O tab and replace MPC, if needed.
Note: Tacho system is redundant and does not give Shut Down Alarm. In case of one angle
encoder sensor failure, M/E continues to run with one sensor in operation.
Tacho alignment error occurs when the readings of Tacho A & Tacho B are different
The function test is performed by selecting Maintenance / Function Test, from the MOP.
Function test requires the crew assistance, the MOP must be in CHIEF access level and the engine
must be stopped.
The tacho test allows for the verification of the angles of the tacho pick-ups and angle encoder fine
adjustment.
i. Make sure that an assistant is standing by the flywheel in order to operate the turning gear and
verify the crankshaft position
ii. Press start and follow the instructions on the screen.
iii. before
iv. -booted
v. Turn engine at the indicated angles and verify that the test value is the same as the reference
value. Please find the following table of reference values for your information.
Setting of Fine Adjustment Parameters is necessary when the angle encoder sensor is replaced.
i. With engine running, press Start button. As indicated on the screen, the engine must be
running at a minimum required speed.
ii. From PMI, select ,
in order to perform PMI-0 diagram and calculate the trigger offset.
iii. From PMI, select
in order to view the calculated trigger offset.
iv. Meanwhile, the ECS is measuring the Delta Tacho-B value. During ECS, the value is verified
to be within limits.
v. Enter the Trig offset ahead value, as occurred from the PMI-0 diagram and save.
vi. Setting of Fine Adjustment parameter is completed.
Note: It is recommended that function test results are saved (Print screen & paste in paint
document) and sent by email, together with alarm event log and HCU/HPS event logs.
The sensor reset is performed from the MOP, in order to address to the specific alarm and check if
the signal is frozen
If the alarm remains, the engine must be checked for mechanical damage. If there is no mechanical
damage of the engine components, function test must be performed on the faulty HCU.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
The function test is performed by selecting Maintenance / Function Test, from the MOP. Function
test requires the crew assistance, the MOP must be in CHIEF access level and the engine must be
stopped.
i. Preparation: To begin the function test, press the START button and follow the indicated
steps.
ii. Test of FIVA valve / Calibration of fuel plunger: When the function test starts, the CCU
MPC is automatically rebooted to test mode. For testing, the FIVA will make one fuel
injection and will activate the respective exhaust valve once.
During the test, one crew member must be stationed on the engine top at the cylinder unit in
question, in order to verify that the fuel booster and/or exhaust valve are functioning properly.
Note: When rebooting an MPC in test mode, multiple alarms irrelevant to the test may occur.
Note: Function test of amplifiers is only applicable to Curtis-Wright FIVA valves, where the HCU
is equipped with external amplifiers.
iii. Cycle test of exhaust valve and / or fuel injection : When START button is pressed, a set of
buttons will appear on the toolbar, which enables the C/E to start a repeated cyclic test of the
exhaust valve. (The exhaust valve will start opening & closing until the STOP button is
pressed). Also, a single injection for the fuel booster is possible.
iv. CCU MPC is automatically rebooted and set to normal operating mode.
Note: It is recommended that function test is carried out for a non-faulty cylinder as well, in order
to compare the function test signal results with the faulty one.
Reporting:
The function test results should be saved (Print screen & paste in paint document) and sent by
email, together with alarm event log and HCU/HPS event logs.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
Diagnostics
If there was not any fuel injection or valve opening sound during the function test, but the
output signals were within normal range, the cause of the alarm is limited between the MPC-
10 and the proportional valve of the HCU. In this case, the faulty MPC-10 must be swapped
with a working one, in order to clarify whether the problem is the MPC-10 or the valve.
If the fuel injection and valve opening sounds were normal during the function test, but the
output signals were not within normal range, the cause of the alarm is limited between the
MPC-10 and the position sensors. In this case, the faulty MPC-10 must be swapped with a
working one, in order to clarify whether the problem is the MPC-10 or the sensor.
Note: In case of sensor failure, it is highly recommended that the complete FIVA valve is replaced.
Each position sensor is calibrated for the specific FIVA valve which is mounted on. If the defective
sensor is replaced with a non-calibrated one, the cylinder will not run without fine tuning.
However, in emergency cases, the non-calibrated sensor can temporarily be used.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
In case of emergency, when there is not enough time to perform the troubleshooting instructions
mentioned above, the cylinder cut-off procedure must be carried out.
When there is a HCU failure, we follow the procedure that corresponds to case C, as indicated in
the table below.
Troubleshooting Guide for MAN B&W
GOLDEN UNION SHIPPING CO. S.A.
Electronically Controlled Main Engine
Depending on whether the engine load will be over or under 50%, the exhaust valve shall kept
open or closed, respectively.
Note:
non-cancellable alarm, the relevant signal cable must be disconnected from the CCU. There will be
a signal missing alarm, but no slow down alarm.
The cause of the failure can be detected by HPS function test. The HPS function test allows for the
test and calibration of the hydraulic pumps. Each tab corresponds to a specific pump.
Function test requires the crew assistance, the MOP must be in CHIEF access level and the engine
must be stopped.
i. Make sure that a start-up pump is set to local control on the starter cabinet and running so that
hydraulic pressure can be maintained.
ii.
iii. After the relevant ACU MPC is automatically set in test mode, full ahead signal is ordered to
the proportional valve of the HPS.
iv. The position of the swash plate position is visually inspected by the crew and the feedback
signal (Channel 34) on the MOP is assessed.
v. Full astern signal is ordered to the proportional valve of the HPS.
vi. The position of the swash plate position is visually inspected by the crew and the feedback
signal (Channel 34) on the MOP is assessed.
vii. Calibration is saved and ACU MPC is automatically set back in normal mode.
Diagnostics :
If swash plates do not follow the signal order, the proportional valve has failed and must be
replaced.
If swash position is normal, but feedback signal is not within normal mA limits, then the
feedback sensor has failed and must be replaced
Reporting: The function test results should be saved (Print screen & paste in paint document) and
sent by email, together with alarm event log and HCU/HPS event logs.
In case start-up pump hydraulic oil pressure is low, leakage check must be carried out as follows:
If the oil pressure remains low, the start-up pump local safety valve must be checked for
leakage.
If the oil pressure rises to normal values of 170-200bar, the leakage point must be detected.
Continue by opening valves 420, one by one, while start-up pumps are running
Check and verify that the following drain valves are CLOSED, as normal:
Valve 315 on distribution block
Valve 421 on each HCU
In case of feedback failure, we perform the following actions to identify the cause of the failure:
i. Measure the voltage of channel 52 socket at the respective MPC-10 of the CCU.
If there is low voltage of the socket, cylinder lubrication is not affected.
ii. Check the lubricator solenoid valve.
If the valve is not flashing, there is no cylinder lubrication and the solenoid valve must be
replaced.
iii. Check the lubricator feedback sensor.
If the sensor has failed, there is no cylinder lubrication and the sensor must be replaced.
iv. We select Maintenance / System View I/O Test from the MOP and we check if the respective
CCU is accessible or not. However, in this case, possible MPC-10 failure is highly unlikely
6.3. No supply
In case of no supply alarm, we perform the following actions to identify the cause of the failure:
In case of CCU failure (and the CCU cannot be changed immediately), activation of the ME
lubricator can be achieved as follows:
Appendix
System A
System B
Standard is:
angle encoders with one
reference sensor on the turning
wheel (A-system)
Semi-circular
marking ring
pos. 2