GMS 250 7 3 en 4FW

Monitoring
ATTENTION !
PRIOR TO UNPACK the product READ this INSTRUCTION HANDBOOK !
OBEY ALL INSTRUCTIONS STRICTLY as stated in the manual !
Added drawings
Assembly
G0 01612- G2 07835- G2 07486Parts list
--.
INSTRUCTION HANDBOOK
N. : 5002::EN Hull No: CMA CGM 4125..4128
Type
GMS 250/7/3 ARRANGEMENT 1
GEISLINGER MONITORING - GMS MARK4
GENERAL
Geislinger Monitoring System Mark4 Instruction Manual Part I

This manual is divided into two parts. Part I contains general information which is for all GMS the same. Part II contains information which is specific for your installation.
Geislinger GmbH Hallwanger Landesstrasse 3 A-5300 Hallwang/Salzburg AUSTRIA Phone FAX Email Internet +43 662 66999-0 +43 662 66999-40 info@geislinger.com www.geislinger.com
Geislinger GmbH - 5002EN/Rev.1.2
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GENERAL
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GENERAL
TABLE OF CONTENTS
1. GENERAL
1.1. Description 1.2. Components 1.2.1. Digital Sensors 1.2.2. Junction box 1.2.3. System Unit
5
5 5 6 6 6
2. INSTALLATION
2.1. Sensors 2.2. Junction box 2.3. Cabling 2.4. System Unit 2.5. Alarm outputs / connection to remote control systems 2.5.1. Relay outputs 2.5.2. Analog output 2.5.3. Testing the outputs
7
7 9 10 10 11 11 11 12
3. OPERATION
3.1. Description of display and buttons 3.1.1. Display description 3.1.2. Buttons 3.1.3. Light Emitting Diodes 3.2. Menu Handling 3.3. Standard monitoring functions 3.3.1. Free end total 3.3.2. Free end filtered 3.3.3. Damper twist 3.4. Alarm indication 3.5. Torsional vibration measurements 3.5.1. Requirements 3.5.2. Steps for recording measurements with a PC
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13 13 14 15 15 17 17 17 17 17 19 19 20
4. TROUBLESHOOTING
4.1. Nothing to see on the display 4.2. System lamp is shining 4.3. No values are shown though the engine is running 4.4. Wrong speed is indicated
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23 23 23 23
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GENERAL
4.5. Alarms occur 4.6. How to check the power supply of GMS 4.7. How to check the Junction box 4.8. How to check the sensors 4.9. How to test the alarm outputs 4.10. How to find out type and works-no. of GMS installed 4.11. Reset of the GMS
23 24 24 24 25 25 25
5. TECHNICAL DATA
5.1. Dimensions and weights 5.2. Assembly opening for System Unit 5.3. Type sign 5.4. Serial communication line RS232
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26 26 27 27
6. MISCELLANEOUS
6.1. What are torsional vibrations 6.2. Some torsional vibration terms 6.3. Description of Signal processing 6.4. General range of applications for the GMS 6.4.1. Monitoring of free end 6.4.2. Damper monitoring 6.4.3. Coupling monitoring
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28 28 28 31 31 31 32
7. MANUFACTURER DECLARATION 8. APPENDIX

8.1. Blank form for sweep information and data
33 34
34
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GENERAL
1. GENERAL
1.1. Description
The Geislinger Monitoring GMS Mark4 (4th generation) is an instrument designed to continuously monitor the torsional vibration amplitudes. The system gives an alarm signal when safety limits are reached or exceeded. Additional the GMS indicates engine speed and operating hours. Measurements of torsional vibration amplitudes and output of analyzed results to a PC can also be done.
1.2. Components
The GMS consists of three main components: Digital Sensors Outer and Inner Junction box System Unit
Fig.1 General Arrangement of Components
System Unit Outer Sensor 2 orange cable
elastic teel spring ades
outer part
Junction box
black cable Inner Sensor 1 inner part
Section view of a Geislinger damper
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GENERAL
1.2.1. Digital Sensors

The signal detection is usually done with digital sensors of inductive type which are mounted in a fixed position and measure against rotating wheels with grooves or teeth. If no such wheels are available, the use of angle encoders is also possible.
1.2.2. Junction box

At the Junction box the cables from the sensors are united to a single cable which leads to the System Unit. The signals from the sensors are converted and transmitted to the System Unit.
1.2.3. System Unit

The System Unit contains a LCD-display, three alarm lamps, four push buttons and a printed circuit board equipped with a microprocessor which calculates primarily the phase velocity of rotating elements. By means of measurements taken on one or two torsionally vibrating elements, for instance on a coupling or damper, the values of the static and dynamic twist between the elements and the vibratory angle of the elements are calculated. The calculated torsional vibration values and other parameters are shown on the LCD-display as a graph or as FFT analyzed values. The power supply for the GMS and the alarm outputs (relay and analog outputs) for a Ship Control System are at the rear of the System Unit. A serial communication port RS232 for measurements and programming is also included in the System Unit.
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INSTALLATION
2. INSTALLATION
For detailed information see also the appropriate assembly drawing and cable plan which are included in this Instruction manual.
2.1. Sensors
The sensors are equipped only with short cables to avoid disturbances of the signal. Therefore the Junction box has to be placed close to the sensors (max. distance = 1.7m). Ensure that the welding flanges are installed correctly in the damper-housing. For permissible tolerances of deviation see assembly drawing (sheet1). Use undamaged sensors only (visual check of the sensor head). Installation of the sensor: Lead the sensor through the inlet thread into the sensor holder. Ensure that the sensor is equipped with a counter nut. Use the Outer sensor 2 (orange cable) for the outer part, the Inner sensor 1 (black cable) for the inner part (see: Fig.1 General Arrangement of Components) Screw the sensor into the thread of the angle bracket. Check whether the sensor is positioned correctly in axial direction. The whole front face of the sensor must be placed over the groove (axial vibrations of crankshaft).
Fig. 2 Sensor position
min7mm
Sensor position
permissible area
min7mm
Adjust the correct sensor gap (see Fig.3). Secure the sensor with the counter nut. Fasten the sensor cable with cable ties using the provided holes in the angle bracket.
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INSTALLATION
Fig. 3 Sensor adjustment
Thread M12 x 1 Tip: Screw in sensor to surface, and turn 2 revolutions back
sensor head
air gap 2 0.2 mm
Mounting of the cable gland (see Fig. 3): It must seal the sensor cable oil tight and secure the protective tube from being pulled out. Insert the body(A) of the cable gland firmly into the inlet thread of the sensor holder. Put a washer(C) + sealing ring(B) + washer(C) over the sensor cable and push them over the whole cable length to the body(A) of the cable gland at the sensor side. ATTENTION: Use only sealings from this delivery with an inner diameter fitting to the outer diameter of the sensor cable. Put gland bolt(D) of the cable gland over the sensor cable towards the sensor side. Screw and tighten the gland bolt(D) into the body(A). Pull the protective tube over the sensor cable. Pull protective tube into the tension-relief(E) and tighten the screws. This stops the protective tube from being pulled out.
Fig. 4 Assembly of cable gland
protective tube
sensor cable
A B C D E
body of cable gland sealing ring washer gland bolt screws of tension relief
Function check of sensors: Ensure that the Junction box is connected with the GMS System Unit and the system is switched on. The red light diode inside the Junction box must be ON. Turn the crankshaft
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INSTALLATION
slowly and watch the green light diode inside the junction box. An other possibility is to measure the voltage inside the Junction box. Sensor position State of green LED State of green LED new pcb 'td 142' old pcb 'td 119'
(since 2005) (before 2005)
Measured voltage between GROUND and SIGNAL
Over ground
OFF
ON
(LED shines)
approx. 12 VDC ( 15%)
Over a groove
ON
(LED shines)
OFF
no voltage
When you measure with an oscilloscope or scopemeter while the engine is running you must receive a signal with the following shape:
Fig. 5 Sensor signal
Volt time
The above mentioned points apply for both sensors.
2.2. Junction box

The Junction box can be mounted directly to the engine or damperhousing by welding the supplied mounting plate to the engine or damper housing and screwing the Junction box on the plate. Check the dip switches for sensor type (PNP/NPN) used. Standard type of sensors for dampers on 2-stroke engines is PNP.
Fig.6 Dip switch for sensor type
type PNP (standard type)

ON ON
type NPN
sensor 1
sensor 2
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INSTALLATION
Pay attention to correct allocation of the sensors related to damper inner part and damper outer part:
Fig. 7 sensor allocation
Sensor 2 Outer sensor (orange cable)

connect to
green light diodes
Damper OUTER part SYSTEM UNIT Sensor 1 Inner sensor (black cable)
connect to
Damper INNER part

If the Junction box is connected to the GMS System Unit and the system is switched on the red light diode inside the Junction box must be ON. If the damper is rotating very slow and the green light diodes are flashing indicate that the sensors are working well. For further details see cable plan.
2.3. Cabling
All cables are supplied by the customer. This includes also the cable between System Unit and Junction box. The cables used must be approved by the classification society. Between System Unit and Junction box Geislinger recommends a cable with a common copper screen, 6 conductors in pairs, each conductor minimum 0.5 mm cross-section.
2.4. System Unit

The System Unit is normally placed in the engine control panel inside the engine control room. For dimensions of installation openings and fixing holes see 5.2, Assembly opening for System Unit. All cable connections are located ate the rear. Cable connection to plugs is done with cage clamp connectors which ensure permanent connection. No special tools are required (only a screwdriver and a pair of wire strippers are necessary). The strip length of screen and sheath is 90mm. Pull back the copper screen approx. 20mm over the sheath.
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INSTALLATION
Fig.8 System Unit rear
2.5. Alarm outputs / connection to remote control systems

2.5.1. Relay outputs
The GMS has 4 relay outputs which can be connected to a remote Ship Control System. In the standard version the relays are connected as follows. relay 1 ... WARNING output for all programmed applications relay 2 ... ALARM output for all programmed applications relay 3 ... free relay 4 ... SYSTEM failure of GMS In normal condition the relay contacts are closed. They are open in alarm condition or when the system is switched off (no power supplied). If you want to have a common alarm at your Ship Control System you can connect the single relays in serie (make a bridge). This can be done at the plug at the rear of the System Unit. For further details see cable plan. If you want to have programmed special output of alarms please contact GEISLINGER.
2.5.2. Analog output

The GMS has 1 analog output (4...20 mAmpere) for a remote indication of measured values. In the standard version the values of monitoring fuction (application) no. 1 (Free end total) are indicated by the analog output.
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INSTALLATION
The maximum value of the analog indication is the same as the maximum indication value of the bar graph of the corresponding monitoring function. Example: The maximum value for indication of Free end total in the bar graph is 15 mrad. Therefore 20 mAmp. at the analog output are corresponding to 15 mrad vibratory angle. Note that the permissible vibratory for analog output angle may be varying over the speed corresponds to 4 mAmp range. Therefore the analog output should only be used for indication purposes and not for alarm detection.
minimum reading
Fig.9 Description of a Monitoring Function
maximum reading for analog output corresponds to 20 mAmp
2.5.3. Testing the outputs

The System Unit contains a service code protected menu which allows testing the alarm outputs.
The ALARMTEST menu is located in the main menu. The number of the service code = 1010. Enter the first digit by pressing the UP or DOWN button. Confirm your selection with the SELECT button. The cursor jumps automatically to the next digit. After entering of all four digits the service menu appears. If a wrong code was entered, the cursor jumps back to the first digit.
Fig. 10 Servicecode
Activating the test function opens the relay for 20 seconds. Then the relay is close for another 20 seconds. After this the relay returns to the conditon it was before the test started.
Fig. 11 Alarm testing
Attention: If an alarm output is connected to an automatic slow down of the engine, testing the output will activate the slow down.
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OPERATION
3. OPERATION
The System Unit is starting up automatically when electrical power is supplied. The System Unit does not have a Power ON/OFF switch. During startup all LEDs are shining once and all relay outputs are activated once. When the engine is running, the readings are taken from the sensors and processed simultaneously. The computed values of the monitoring functions are shown both as numbers and graphically in a bar graph on the display.
3.1. Description of display and buttons

The System Unit has 4 push-buttons and 3 LEDs.
Fig.12 Front of System Unit
LEDs
push buttons
LCD display area
cover of serial communication line
3.1.1. Display description

Fig.13 Display Description
application no. monitoring function no. 1 area for alarms
monitoring function no. 2 area for messages monitoring function no. 3
engine speed
operating hours; values in decimal format: 3.50 = 3 hours 30 minutes
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OPERATION
Detailed description of a monitoring function:

application no. (number of monitoring function) name of monitoring function
Fig.14 Description of a Monitoring Function
minimum value for bar indication
bar graph
maximum value for bar indication WARNING HIGH limit ALARM limit
actual value (unit is milliradian)
WARNING LOW limit (if defined)
3.1.2. Buttons
Fig.15 Buttons
UP / DOWN During normal operation this button changes the contrast of the LCDdisplay. Pressing the button in menu mode moves the cursor one entry up or down. If in menu mode not all applications fit onto the screen at once. (eg. menu Alarmcurves, Signalcurve or Fourier), the buttons switch between the applications. SELECT Pressing the SELECT button during normal operation calls the Menu of the GMS. In Menu mode this button is to confirm a selected function. CANCEL In Menu mode this button is to leave the current menu and to move one menu level higher. If you are already in the Main menu, the Menu disappears.
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OPERATION
3.1.3. Light Emitting Diodes

At normal operation all LEDs are off. If an error, warning or alarm occurs, the corresponding LED goes on. The LED is shining, as long as the error, warning or alarm remains active.
3.2. Menu Handling

Pressing the SELECT button during normal operation calls the main menu of the GMS. It contains the following menu entrys: INFOS This menu contains general information. SYSTEM APPLICAT. ALARMCURVE general information (system type, setup version,..) information about the programmed monitoring functions (applications). The programmed alarm curves are shown in graphical mode.
Fig. 16 Programmed alarmcurves
SERIAL
current serial communication line settings.
CONTRAST In this menu the contrast (brightness) of the LCD-display can also be adjusted. FOURIER Shows the amplitude of the different orders for each application after a FFT (Fast Fourier Transformation) analysis.
Fig. 17 fourier graphic
Pressing SELECT in the FOURIER menu shows the numbers of the analyzed values. By pressing SELECT again, the menu switches back to graphic mode.
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OPERATION
SIGNALCURVE Shows the torsional vibration signal for each programmed application for one revolution.
Fig. 18 waveform graphic
MEASURE This menu defines what kind of data are transmitted via the serial communication line RS232 to a Personal computer. These settings are necessary for recording measurements with a PC only. See 3.5.2, Steps for recording measurements with a PC for further details. SERIAL Sets the parameters for the serial communication line RS232 (baud rate, protocol, communication format). These settings are necessary for recording measurements with a PC and downloading a new setup. See 3.5.2, Steps for recording measurements with a PC for further details. SERVICE ALARMTEST for details. Contains special functions, only for service engineers. Allows testing the outputs of the GMS, see chapter 2.5.3, Testing the outputs
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OPERATION
3.3. Standard monitoring functions

3.3.1. Free end total
This monitoring function shows the synthesis of the vibratory angle at the free end of the crankshaft. This indicates how balanced the engine is running. Reduced power or breakdown of a cylinder or misfiring of a cylinder increases the vibratory angle at the free end of the crankshaft. For this monitoring function the sensor signal directly from the crankshaft resp. damper inner part is used (damper inner part is bolted to the crankshaft).
3.3.2. Free end filtered

This application calculates the vibratory angle of a single order or a range of orders out of the synthesis of the vibratory angle at the free end of the crankshaft. In many propulsion systems only a specific order, or a range of orders is responsible for critical shaft, crankshaft or intermediate shaft stresses caused by torsional vibrations. Monitoring the amplitude of this order is a proper method for detection of dangerous operating conditions. For this monitoring function the same sensor signal as in monitoring function Free end total is used.
3.3.3. Damper twist

Shows the vibratory twist angle between damper inner part and damper outer part. This application controls the damper load. A broken oil supply or heavy wear of the damper springs leads to an increased vibratory twist. This will activate an alarm on the GMS. A blocked damper with no vibratory twist causes also an alarm, because other parts of the propulsion system (eg. crankshaft, intermediate shaft) are overloaded if the damper does not work. Monitoring of the damper is also very useful to determine the exact condition of the damper before an engine overhaul or drydocking. If the evaluation of the measurements show that the damper/coupling is working properly, it can be justified against the classification society, that no overhaul is necessary. Should an overhaul be necessary it can be planned and the spare parts can be ordered in time.
3.4. Alarm indication

When the engine is running, the readings are taken from the sensors and processed simultaneously. After the CPU has calculated the vibratory angle or vibratory twist, the results are evaluated against limit curves. Limit curves are defined as continuous lines with a maximum of 20 supporting points. Each point is defined by its coordinates. The unit of the x-coordinate is rpm (or the static twist in case of coupling monitoring), the unit of the the y-coordinate unit is milliradian. Depending on the engine speed the system reads the appropriate limits from the memory and compares these values with the computed values for exceedings of limits. To avoid short term alarms the required number of successively alarms can be defined before an alarm is really activated. The limiting values are also shown within the bar graph.
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OPERATION
Fig.19 Alarm Definition
vibratory angle or vibratory twist [mrad] 10 9 8 7 6 5 4 3 2 1
ALARM curve WARNING HIGH curve
actual limit for ALARM actual limit for WARNING
actual calculated value
normal operating graph
WARNING LOW curve
30
40
50
60
70
80
90
100
110
120
speed [rpm]
not monitored speed range
permissible operating range
The WARNING LOW curve is normally only defined for monitoring of damper- or coupling-twist. If a value is over a warning or alarm limit the following happens: You can see a message at the right side of the display at which monitoring function the warning respectively alarm occured.
Fig. 20 alarms on display
For monitoring function (application) no. 1 WARNING limit is exceeded.
For monitoring function (application) no. 3 both WARNING limit and ALARM LIMIT are exceeded.
The corresponding LED is shining. If this warning/alarm is combined to a relay, the corresponding relay output is opened. For standard values see chapter 2.5 ,Alarm outputs / connection to remote control systems. The GMS can for special applications be programmed in a way that warnings or alarms from certain monitoring functions are not connected to the relay output. Exceedings of the WARNING levels can occur sometimes due to abnormal engine handling, but should not be the normal condition. Exceeding of ALARM levels must be strictly avoided.
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OPERATION
3.5. Torsional vibration measurements

Torsional vibration measurements are normally done within a sweep of the engine. A sweep is a steady raise of the engine from slow speed up to full speed. With the values measured and recorded during the sweep, GEISLINGER is able to redo the torsional vibration calculation and to determine the condition of the damper. For recording of the values there are two possible ways: Connecting the GMS to a Personal Computer and record the values to a data file. Writing down the values. A blank form for a sweep is enclosed to this manual (see appendix). Write down as many values as possible, at least every minute.
Geislinger strongly recommends to record the data with a PC. This method ensures datarecording at every speed and allows recording the FFT values which allows enhanced analysis of the data.
Standard values for speed increase 2-stroke engine 4-stroke engine 3 rpm / minute 30 rpm / minute
speed
No steps
time
3.5.1. Requirements
Please try to ensure the following requirements: Vessel should have load (preferred) or at least ballast condition (propeller must be fully under water) Sail straight ahead during the sweep area with deep water under the keel Sail some time with low speed before starting with the sweep (to ensure that the propeller is not driven by the vessel speed) The actual vessel speed must correspond with the nominal speed according to the engine rpm. It is very important to have the power at nominal speed. If you cannot go up to nominal speed please note the power at the highest possible speed. Supply us with the following information: Vessel, engine and damper data Engine power load conditon going straight ahead or rudder laid weather condition (heavy sea, ...) additional information (not all cylinders firing, shaft generator running...) .......... (what you believe it is worth mentioning)
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OPERATION
3.5.2. Steps for recording measurements with a PC

For recording data during a torsional vibration measurement the following steps are necessary: 1) Connect the System Unit with a serial interface cable to a serial communication port COM1 or COM2 at the PC. At the System Unit the serial port is located behind the cover in the bottom right corner at the front of the System Unit. Ensure that you use an interface cable as specified in chapter 5.4, Serial communication line RS232. 2) Adjust the parameters at the GMS. The following parameters are necessary 2a) Communication parameters in SERIAL menu BAUDRATE 19200 PROTOCOL ASCII SETTINGS N81 Press the SELECT button to adjust a value in the serial menu. In the following submenu move the cursor with the UP or DOWN button to the value you want to select. Press SELECT to store the value. To leave the submenu press the CANCEL button. Note: You MUST ADJUST the same communication parameters at the terminal program of your PC. 2b) Choose the kind of the transmitted data in MEASURE menu. To enable an entry in the Measure menu move the cursor with the UP or DOWN button to the entry. Press SELECT to enable it. The entry is now marked with a * (star) on the right side. All marked entries are sent via the RS232 to the PC. To disable an enabled entry press SELECT again. Leave the menu with the CANCEL button. Mark all entrys as shown in the figure. After setting of these parameters the GMS is already sending data to the PC. 3) Start the terminal program at the PC and prepare to record the data to a file. We assume that you use a PC with one of the following operating systems installed: MS-Windows 95/98, Millenium Edition, Windows NT4.0, Windows2000, Windows XP In all of these operating systems a terminal program called HyperTerminal is included. 3a) Start the Hyperterminal. The normal menu tree of Windows is: Start Programs Accessories Communications HyperTerminal Tip: If you cannot find it there, search for the file hypertrm.exe at the windows directory of your PC. Start the program with a double click. 3b) If you are not prompted for a new connection, go to menu File Enter a name for the connection. New Connection
Fig.22 measure menu Fig.21 serial menu
3c) You are prompted for the communication port you want to use. Connect using: select COM1 or COM2 (depending on where the interface cable is connected) 3d) Enter the Port settings Bits per second: Data bits: 19200 8
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OPERATION
Parity: None Stop bits: 1 Flow Control: Xon/Xoff Attention: The settings for the serial communication line RS232 must be the same at the GMS and at the PC. Otherwise no data or unreadable data will be shown at the PC. If your PC is to slow for processing these data, select a lower baudrate (9600). You can check your settings by menu File Properties
Fig.23 Hyperterminal properties
Tip: To configure the serial interface the data flow must be interrupted (see description of buttons below). 3e) Start receiving of data You can interrupt and continue the data flow at the HyperTerminal with the following buttons. enables the data flow (or use menu Call Connect)
interrupts the data flow (or use menu Call Disconnect) Note: Interrupting and continuing the data flow is not the same as recording (capture) the data to a file! Now the transmitted values should be displayed in a readable format on the screen of the PC. If nothing is displayed after a waiting time of max. 1 minute (this delay can be caused by the XON/XOFF flow control) check the connections and the setup of the communication on both sides. Note: The values shown on the screen are not stored to a file till now. They are just shown to the screen.
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OPERATION
Fig.24 Hyperterminal readings
4) If data transmission is working properly, prepare for the sweep and enable file storage of transmitted data. Select the Menu Transfer Capture Text... and specify a file in which the data are stored (fileextention should be .TXT )
Fig.25 Hyperterminal file capture
5) Carry out the sweep. Write down the engine power at the end of the measurement (at the highest possible speed) 6) After completion of measurement stop recording of data by selecting menu Transfer Capture Text... Stop. Check the recorded file by opening it with a text-editor (eg. Notepad or Wordpad). The contents of the file must look like shown in the screen of the HyperTerminal 7) Disable the sending of data at the GMS (menu SERIAL PROTOCOL DISABLE). 8) Send the recorded file with E-mail to Geislinger. Please compress the file(s) by the use of a file compression utility like WinZip. 9) It is very important for GEISLINGER to receive all the additional information as specified in chapter 3.5.1, Requirements together with the measured data. Use the enclosed form Additional information to a sweep (see 8, Appendix).
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TROUBLESHOOTING
4. TROUBLESHOOTING
4.1. Nothing to see on the display
No power is supplied to the GMS. Follow the instructions in chapter 4.6, How to check the power supply of GMS. Contrast control of the LCD-display is out of visible range.
-
Press five times the CANCEL button (just to be sure that you are in main menu) Try to adjust the contrast by pressing the UP or DOWN button (press at least 5 seconds in each direction).
4.2. System lamp is shining

The GMS has an internal error. Please contact GEISLINGER. Inform us about the works-no. of the GMS (see chapter 5.3, Type sign for location of type sign).
4.3. No values are shown though the engine is running

Follow the instructions in chapter 4.7, How to check the Junction box. Follow the instructions in chapter 4.8, How to check the sensors.
4.4. Wrong speed is indicated

Speed is sometimes wrong or zero It is possible that the sensor does not recognize all signals due to bad electrical connections or a wrong adjusted sensor. Speed detection is done by sensor 1 installed at the inner part of the damper/coupling.
-
Speed is always wrong This may be an indication for a wrong programmed GMS. This means that the number of impulses which is programmed in the GMS is not the same as the number of grooves/teeth machined on the damper or coupling. Check the number in the GMS. Enter the main menu, select INFOS, select SYSTEM. You can read the programmed number of impulses in the following lines: Impulses Channel 1: (= damper/coupling inner part) Impulses Channel 2: (= damper/coupling outer part) Check the number of grooves at the damper. Therefore open the cover of the sensorholder and count the number of grooves by use of the turning gear for one revolution. If the number of grooves on the damper does not correspond with the number of impulses programmed in the GMS please contact GEISLINGER.
4.5. Alarms occur

If alarms occur already during commissioning or sea trials, please check the allocation of the sensor cables inside the Junction box relating to the damper inner part and damper outer part (see chapter 2.2, Junction box and cable plan which is enclosed to this manual for detailed instructions).
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TROUBLESHOOTING
It is possible that the sensor does not recognize all signals due to bad electrical connections or a wrong adjusted sensor.
-
Try to operate the engine in a range where no further alarms occur. See Part II of this manual, which is specific for your system for special actions in your case. Contact GEISLINGER. Please inform us about the following items:
-
Type and works-no. of GMS and GEISLINGER damper or coupling. Speed range where the alarm occurs. Monitoring function at which the alarm occurs. If somehow possible make a sweep and record the data (see chapter 3.5, Torsional vibration measurements).
4.6. How to check the power supply of GMS

Check the power supply connection on the rear of the System Unit. The power supply cable must be connected to the power supply plug (2-pin plug) and the plug must be plugged in properly on the rear of the System Unit. Observe polarity of voltage (for details see cable plan). The System Unit is equipped with a self-healing fuse. To reset the fuse the electrical power must be disconnected (remove plug) for at least 2 minutes.
4.7. How to check the Junction box

System Unit side: The cable must be connected to the Junction box plug (6-pin plug) and the plug must be plugged in properly on the rear of the System Unit. Junction box side: The cable must be connected properly to the clamps inside the Junction box. The red light diode inside the Junction box must be ON if the system is switched on. Check supply voltage of Junction box. Voltage must be 15 VDC ( 15%) (see cable plan). Follow the instructions in chapter 2.2, Junction box. Please look also at the cable plan which is enclosed to this manual for detailed instructions.
4.8. How to check the sensors

Check whether the sensor head is damaged physically. Check whether the sensor gap is adjusted correctly. Check whether the counter nut of the sensor has been tightened too strong. When this happens, the thread of the sensor can break between counter nut and angle bracket of the sensor holder. Check supply voltage of sensors. Voltage must be 15 VDC ( 15%) (see cable plan). Make a function check of the sensor (see chapter 2.1, Sensors). Please look also at the cable plan which is enclosed to this manual for detailed instructions.
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TROUBLESHOOTING
4.9. How to test the alarm outputs

Please read chapter 2.5.3, Testing the outputs.
4.10. How to find out type and works-no. of GMS installed

Type and works-no. of GMS are marked on the type sign located at the rear of the GMS. Information about the programmed setup is also available in the main menu (INFOS SYSTEM)
4.11. Reset of the GMS

A reset of the System Unit causes a new startup. The System Unit can be resetted by the following methods: Press all 4 buttons simultaneously for at least 10 seconds Interrupt the elctrical power for at least10 seconds (100%method) Attention: If an alarm output is connected to an automatic slow down of the engine, testing the output will activate the slow down.
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TECHNICAL DATA
5. TECHNICAL DATA
Permissible ambient temperature System Unit Junction box Inductive Sensors Power supply Voltage: Maximum current consumption: Fuse: Outputs 55 Celsius 70 Celsius 100 Celsius 24V DC 20% 1 Ampere self healing fuse inside 4 Relay outputs (max. 24 VDC, 1 Ampere) 1 Analog output (4 .. 20 mAmp.) 1 serial communication line RS232 Electrical and environmental testings according to IACS E-10 rules and type approval from DNV
Technical standards
5.1. Dimensions and weights

System Unit 192 x 147 mm, depth: approx. 135mm (including space for cables at rear) weight: 1.5 kg 130 x 130 mm (including space for cable glands) Height: 60 mm weight: 0.6 kg
Junction box
5.2. Assembly opening for System Unit

Fig.26 Assembly opening
8 x 45
182
134
135
Installation depth: 135mm
Dimensions of System Unit frame: 192 x 147 mm
M4
179
26/36
TECHNICAL DATA
5.3. Type sign

The type sign of the GMS is located at the rear of the System Unit. Information about the programmed setup is also available in the main menu (INFOS SYSTEM)
5.4. Serial communication line RS232

The GMS is equipped with a standard RS232 communication interface for measuring purposes. The interface is located in the bottom right corner at the front of the System Unit behind a cover. On System Unit side there is a standard RS232 9-pin male connector. Normally a Personal Computer has the same connector for a serial communication line. So for measurements and download of a new setup a serial cable with a 9-pin female connector on both ends is needed. These are standard cables, sometimes called AT Link cable. For pin-to-pin wiring see Fig 27. The interface parameters and baudrate can be set in the GMS menu. For standard values see chapter 3.5.2, Steps for recording measurements with a PC. We suggest to use cables not longer than 15 metres. For baudrates higher 19200 we recommend shorter cables (3m).
Fig 27 Serial communication cable
5 4 3 2 1
ground 9 8 7 6 transmit receive
5 4 3 2 1
9 8 7 6
27/36
MISCELLANEOUS
6. MISCELLANEOUS
6.1. What are torsional vibrations
Torsional vibrations are the result of the pulsing torque of a reciprocating combustion engine and the torsional elasticity of the shaftline. All system components like crankshaft, intermediate shaft, propeller shaft and optional couplings and gears have to transmit the static torque and the additional vibratory torque. The GMS (Geislinger Monitoring System) monitors the torsional vibrations.
6.2. Some torsional vibration terms

order synthesis FFT ... ... ... vibration frequency divided by speed summary of single orders Fast Fourier Transformation - frequency analyzed vibration
6.3. Description of Signal processing

The sensor which is mounted on a fixed position measures against a rotating toothed wheel, or an angle encoder mounted on the front end of a wheel or shaft, is supplying a digital signal. This signal switches from low output to high output when a tooth passes the sensorhead. The measured signal is the elapsed time (pulse duration) between a tooth and the next tooth (see Fig. 28). The measured pulse duration is proportional to the angular velocity. A microprocessor records the signal of the last ten revolutions. On demand this sample of ten revolutions is used for further signal processing.
Fig. 28 Signal processing
sensor
sensor signal
high low t1 t2 t3 t4 t5 t...
A plot of the time over the angle gives a graph as shown in Fig. 29. The mean time between two teeth (constant angular velocity or rpm) can be subtracted.
28/36
MISCELLANEOUS
Fig. 29 Plot of sensor signal
time
t1
t2
t3
t4
t5
t6
t7
t8
t9
mean time between two teeth

angle
To obtain the peaks of the signal, it is necessary to do oversampling (insert additional generic points). Another necessary step is to calculate from time differences to angle differences by use of the angular velocity.
Fig. 30 Signal oversampling
vibratory angle generic points
t5 t1 t2 t3 t4
t6
t7
t8
t9 angle
After these calculation steps (result is shown in Fig. 30) the signal passes through a bandpass-filter (Fig. 31). The purpose of the bandpass filter is to remove accelerations (caused by the engine speed control system) by removing low orders (below the first order in case of 2-stroke engines, below the 0.5th order in case of 4-stroke engines) and to smooth the signal by interpreting the additional inserted points as high frequent interferences (this is necessary to obtain the exact amplitude of the vibratory angle).
29/36
MISCELLANEOUS
Fig. 31 Results of signal filtering
Bandpass-filter
order
vibratory angle
max
amplitude = (max -min) / 2
angle min
The result of the filtered values is the vibratory angle of the synthesis of a specified range of orders (Fig. 31) depending on the filtersettings. The quality of the used filters allows filtering of just one order or half orders. The last step is to calculate the amplitude by the (maximum-minimum)/2 of the vibratory (twist) angle and check this value against safety limits. These limits are depending on the engine speed (rpm). For explanation of Alarm limits see chapter 3.4, Alarm indication .
30/36
MISCELLANEOUS
6.4. General range of applications for the GMS

6.4.1. Monitoring of free end
This function calculates from a sensor signal the synthesis of all orders of the absolute vibratory angle of a rotating part. Also a range of orders or a single order can be filtered out. For this monitoring function only one sensor (inductive sensor or angle encoder) is used. Applications: Misfiring detector The synthesis of the vibratory angle at the free end of the crankshaft indicates how balanced the engine is running. Misfiring of one or more cylinders of a combustion engine will cause an increase in loads due to torsional vibrations (increased amplitude of the synthesis of the vibratory angle) and may result in a damage of certain components. Shaft, crankshaft stress or intermediate shaft stress monitoring In many propulsion systems only a specific order is responsible for critical shaft, crankshaft or intermediate shaft stresses caused by torsional vibrations. Monitoring of the amplitude of this order is a proper method for detection of dangerous operating conditions.
Fig. 32 Free end monitoring
6.4.2. Damper monitoring

Monitoring of the synthesis of the vibratory twist angle between two rotating parts. The two rotating parts are combined elastically. For this monitoring function two sensors are necessary. From the signal of each sensor the synthesis of all orders of the absolute vibratory angle is calculated. The synthesis of the amplitude of the difference between these values is monitored.
Fig. 33 Damper monitoring
Applications: GEISLINGER damper monitoring Monitoring of the vibratory twist angle between damper inner part and damper outer part is necessary to control the damper load. A broken oil supply or heavy wear of the damper springs leads to an increased vibratory twist. This will activate an alarm on the GMS. A blocked damper with no vibratory twist causes also an alarm, because other parts of the propulsion system (eg. crankshaft, intermediate shaft) are overloaded. Monitoring of the damper is also very useful to determine the exact condition of the damper before an engine overhaul or drydocking. If the measurements show that the damper is working
31/36
MISCELLANEOUS
properly, it can be justified against the classification society, that no damper overhaul is necessary. In the rare case of a spare part need, they can be ordered in time.
6.4.3. Coupling monitoring

Monitoring of the synthesis of the vibratory twist angle between two rotating parts with a static offset (caused by torque) in relation to this static offset. Based on the measured static twist, computing of the transmitted torque and power is possible. The two rotating parts are combined elastically. For this monitoring function two sensors are necessary. Both rotating parts must have a reference mark (a longer gap or tooth), which is used to recognize the static offset. The torsional stiffness of the monitored part can be entered as a cubic polynom and is used to caclulate torque and transmitted power.
Fig. 34 Coupling monitoring
Applications: GEISLINGER coupling monitoring One sensor is mounted on the power input side, the other on the power output side of the coupling. The GEISLINGER coupling is equipped with elastically steel spring blades. Monitoring of the vibratory twist angle between coupling inner part and coupling outer part is necessary to control the coupling load. A broken oil supply or heavy wear of the coupling springs due to overload leads to an increased vibratory twist. This will activate an alarm on the GMS. A blocked coupling with no vibratory twist causes also an alarm, because other parts of the propulsion system are overloaded. Monitoring of the coupling is also very useful to determine the exact condition of the coupling before an engine overhaul or drydocking. If the measurements show that the coupling is working properly, it can be justified against the classification society, that no coupling overhaul is necessary. In the rare case of a spare part need, they can be ordered in time. Shaft monitoring Shaft monitoring is similar to coupling monitoring. The only difference is, that the stiffness of the springs is substituted by the stiffness of the shaft. The accuracy of the measured torque increases with the distance between the sensors (=length of shaft).
32/36
MANUFACTURER DECLARATION
7. MANUFACTURER DECLARATION
NOTICE The information in this manual is subject to change without notification. Additional pages may be inserted in future editions. The user is asked to excuse any omissions or errors in the present edition. No responsibility is assumed if accidents occur while the user is following the instructions in this manual. No resposibility is assumed for defects in the GMS firmware. The contents of this manual are protected by copyright. No part of this manual may be reproduced by any means, including translation into a different language or conversion to a different format or media, without the permission of the copyright holder. The same copyright protection applies to the GMS firmware. Document no. Revision-no. Date Language: First Edition: 5002 1.2 November 2006 English July 2002
This manual is also availabe in electronical form. Copyright 2002, 2005 by Geislinger GmbH, A-5300 Hallwang / Salzburg, AUSTRIA All rights reserved.
33/36
APPENDIX
8. APPENDIX
The following items are appended to this manual: Blank forms sweep information and data Part II (specific information for your GMS-system) Assembly drawing Cable plan Parts list List of service stations
8.1. Blank form for sweep information and data

See next page.
34/36
APPENDIX
Additional information to a sweep

Engine power table
Engine speed [rpm] Power [kW]
Damper data
Type (eg. D260/22/2) Works-no. Oil pressure (damper inlet) Oil temperature
Vessel / engine data

Vessel name Hull no. / yard Engine type Engine no. / builder Engine operating hours Notes about engine condition (all cylinders firing,..)
Additional info to sweep

Date / Name: Place of sweep: Vessel load condition Weather condition Sailing straight ahead (max. Yes/no rudder angle 5) area with deep water Comments: Yes no
35/36
APPENDIX
Form for a sweep with increasing speed

Speed
[rpm] 30 33 36 39 42 45 48 51 54 57 60 63 66 69 72 75 78 81 84 87 90 93 96 99 102 105 108 114 117 120
Monitoring function1
[mrad]
[mrad]
[mrad]
Fill out also the form with the additional info. Date/Name: Vessel name:
36/36
SPECIFIC INSTRUCTIONS
Geislinger Monitoring System Mark4 Instruction Manual Part II

Specific Instructions for Geislinger damper
D 250/7/3
valid for H
Arrangement drawing Assembly drawing / Part list Cableplan Date: Geislinger ref.no.
4125..4128
G001612G207835G207486October 2007 4FW
This part of the Instruction manual is only a supplementation of the common part (Part I). The instructions and explanations of the monitoring functions on the next pages are specific for this installation.
Geislinger GmbH Hallwanger Landesstrasse 3 A-5300 Hallwang/Salzburg AUSTRIA Phone FAX Email Internet +43 662 66999-0 +43 662 66999-40 info@geislinger.com www.geislinger.com
Geislinger GmbH - 5002EN - PartII
1/4
1. FREE END TOTAL MONITORING

The monitoring of free end total shows the synthesis of the vibratory angle at the free end of the crankshaft measured at damper inner part. This indicates how balanced the engine is running. Misfiring or unbalanced running of the engine causes an increase of these measured values. The upper curve shown in the diagram named misfiring condition shows the vibratory angle over the engine speed under full load, if one cylinder is not working. The curve named unbalanced shows the readings, if the gas excitation of one cylinder is reduced to 80% of its normal value. MCR - Maximum Continuous Rating of the ship engines Repeated exceeding of the alarm limits can seriously damage the crankshaft.
Limits for "Free end total" 35 2.0
MCR
30
1.5 25
20
mrad
1.0 15
10
(3)
0.5 5
(2) (1)
0 30 40 50 60 70
rpm
Alarm limit Warning limit (1) Ideal operation (2) Unbalanced condition (3) Misfiring condition
80
90
100
0.0 110
deg
2/4
2. FREE END FILTERED MONITORING

This application calculates the synthesis of the vibratory angular amplitude of the 8th and 9th order at the free end of the crankshaft. As a damaged damper can be the reason for the alarm, change the engine speed to an operating range where no further alarms will occur and send a message to GEISLINGER. Exceeding the warning limit does not damage the shaft, but indicates an abnormal condition.
Limits for "Free end filtered" 4.5 0.25 4
3.5
0.20
3 0.15
deg
2.5
mrad
2 0.10 1.5
1 0.05 0.5
0 30 40 50 60 70
rpm Alarm limit Warning limit Ideal operation Misfiring condition
80
90
100
0.00 110
3/4
3. DAMPER TWIST MONITORING

This application monitors the vibratory angle between damper inner part and damper outer part. If the twist exceeds the alarm level, the damper is overloaded (check oil supply of the damper). In this case send a message to GEISLINGER and try to operate the ship in a way, that no further exceeding of the DAMPER TWIST and the FREE END FILTERED alarm level will occur (reduce engine speed). If the measured value for this monitoring function falls under the WARNING LOW level, the damper becomes blocked. This situation will lead to an increased shaft stress level and will also be monitored by the free end filtered monitoring function.
Limits for "Damper Twist" 15 0.8
0.6 10
mrad
0.4
5 0.2
0 30 40 50 60 70 80 90 100
rpm Alarm limit Warning limit Warning low limit Ideal operation Misfiring condition
0.0 110
deg
4/4
G e i s l i n g e r Co u p l i n g
Geislinger Damper
G e i s l i n g e r G e s i l co
G e i s l i n g e r Fl e x l i n k
G e i s l i n g e r M o n i to r i n g
G e i s l i n g e r Ca r b o to rq
Geislinger Vdamp
Geislinger GmbH A - 5 3 0 0 H a l l w a n g / S a l z b u rg, Au s t r i a H a l l w a n g e r L a n d e s s t ra s s e 3 Te l . + 4 3 / 6 6 2 / 6 6 9 9 9 - 0 Fa x + 4 3 / 6 6 2 / 6 6 9 9 9 - 4 0 i n fo @ g e i s l i n g e r. co m w w w. g e i s l i n g e r. co m

GMS 250 7 3 en 4FW

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Monitoring

OBEY ALL INSTRUCTIONS STRICTLY as stated in the manual !

G0 01612- G2 07835- G2 07486Parts list

GMS 250/7/3 ARRANGEMENT 1

GEISLINGER MONITORING - GMS MARK4

Geislinger Monitoring System Mark4 Instruction Manual Part I

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

This page left intentionally blank.

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

7. MANUFACTURER DECLARATION 8. APPENDIX

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

System Unit Outer Sensor 2 orange cable

elastic teel spring ades

black cable Inner Sensor 1 inner part

Section view of a Geislinger damper

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

1.2.1. Digital Sensors

1.2.2. Junction box

1.2.3. System Unit

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Fig. 3 Sensor adjustment

air gap 2 0.2 mm

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Measured voltage between GROUND and SIGNAL

approx. 12 VDC ( 15%)

The above mentioned points apply for both sensors.

2.2. Junction box

type PNP (standard type)

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Sensor 2 Outer sensor (orange cable)

green light diodes

Damper INNER part

2.4. System Unit

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Fig.8 System Unit rear

2.5. Alarm outputs / connection to remote control systems

2.5.2. Analog output

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

Fig.9 Description of a Monitoring Function

maximum reading for analog output corresponds to 20 mAmp

2.5.3. Testing the outputs

Fig. 11 Alarm testing

Geislinger GmbH - 5002EN/Rev.1.2

GEISLINGER MONITORING - GMS MARK4

3.1. Description of display and buttons

LCD display area

cover of serial communication line

3.1.1. Display description

application no. monitoring function no. 1 area for alarms