You are on page 1of 25

MAN B&W Diesel

PMI On-line System


Set-up & commissioning

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Table of contents
Introduction................................................................................................................. 1
System description ..................................................................................................... 1
Installing the system on the engine ............................................................................ 2
Hardware installation .............................................................................................. 2
Positioning the trunk (Portable version only) ....................................................... 2
Mounting the sensors and charge amplifers........................................................ 2
Connecting the measuring chains (Portable version) .......................................... 2
Connecting a trigger system (Portable version)................................................... 2
Connecting a pscav signal/sensor (Portable version) ............................................ 3
Connecting Power supply (Portable version)....................................................... 3
Linking two trunks together.................................................................................. 4
Changing between Master & Master/Slave configuration........................................ 4
Additional hardware settings ................................................................................... 6
Input type selection ............................................................................................. 6
Signal Conditioner gain setting............................................................................ 6
ADAM 4520 switch setting................................................................................... 6
Advanced PMI System Set-up.................................................................................... 7
Gaining access to the Service mode....................................................................... 7
Creating a new engine set-up ................................................................................. 9
Basic System Set-up............................................................................................. 12
Performing Connection test................................................................................... 15
Establishing connection (Portable version)........................................................ 15
The Connection Test dialog............................................................................... 15
Additional functionality .............................................................................................. 21
Troubleshooting........................................................................................................ 22
Test Communication reports No connection to PMI unit ................................. 22
Incomplete pressure curves .............................................................................. 22
Connection test dialog reports values in V instead of mA.................................. 22
Connection test dialog reports 0 mA or 0 V on all channels .............................. 23
Pscav is incorrect................................................................................................. 23

Version tracking
Date
Modifier
2003-11-05 JYA
2004-08-18 JYA
2004-08-22 JYA
2005-02-09

JYA

2005-08-26

JYA

Doc. No. 3090644-4

Description
1.st edition
Basic System Set-up added
Additional HW settings & Troubleshooting
added
Doc.No., more HW settings & Trouble shooting,
Portable Pscav & tTrigger conn. changed
ACU connections corrected
Most sockets described
Engine Set-up dialogs updated to v.2.3

Version
1.0 (prel.)
1.1 (prel.)
2.0 (prel.)
3.0
3.1

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Introduction
The aim of this document is to describe the set-up of the PMI On-line System in
general and the set-up of the portable version in particular.
This document together with the standard documentation set for the PMI On-line
System, should hold the information needed to install, set-up and trouble-shoot the
system.
Contrary to the standard PMI On-line System, the set-up of the portable version is
changed very often, forcing the user to get familiar with parts of the system not
intended for day-to-day use.
This document describes the installation of the system on the engine, checking the
installation by means of the software, and setting up the system to measure on a new
engine.

System description
The Portable PMI On-line System is based on the components of the commercially
available PMI On-line System.
To fully utilize the potential of each component, and to ensure the portability, the
system has been limited to a maximum of 6 cylinders, with the possibility of
connecting two systems to cover up to 12 cylinders.
One Portable PMI On-line System consists of:
1. One trunk holding the main data collection unit, signal conditioners and
RS422/232 converter. In addition, software & manuals are stored in this trunk.
2. One box holding a set of 6 measuring chains (sensors & charge amplifiers)
3. One Box holding cables for connecting power, trigger signals, measuring
chains and pscav signal, as well as the Calibration measuring chain
(Transducer, Calibration box and cable) and an extra RS422/232 converter
with cables.

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Installing the system on the engine


Hardware installation
Positioning the trunk (Portable version only)
When choosing a suitable position for the trunk (1) it is important to take into account
the length of the cables for the measuring chains and the calibration box.
The trunk should be positioned so that all cables from the measuring chains can be
routed safely from the charge amplifiers to the trunk, i.e. under the gallery.
From the trunk, it must be possible to reach all cylinders with the calibration box
cable.

Mounting the sensors and charge amplifers


Mount the extension pieces between the indicator cocks and the cylinder covers.
Make sure that the sensor holes are pointing downwards, as this is the best
protected position for the sensors.
Mount the charge amplifiers within 1 metre of the extension pieces, with the
connectors pointing downwards. The charge amplifiers should be firmly mounted on
the cylinder covers, and with easy access to the connectors.
In the portable version of the system, brackets are supplied for mounting the
amplifiers on a suitable steel pipe.
Mount the sensors in the extension pieces and connect the sensor cables to the
charge amplifiers. Make sure that the cables are safely routed and that there is no
stress on sensor and connector

Connecting the measuring chains (Portable version)


Connect the cables between the charge amplifiers and the trunk.
The cables are connected to the top six 10 pole sockets on the side of the trunk.
Counting from the top of the trunk, the first socket is internally connected to input
channel no. 1, the second to input channel no. 2 and so on.
The order in which the measuring chains are connected is not important, but it is
important to note the relationship between cylinder no. and input channel. If the
engine set-up has already been prepared for the engine, it is important that the
cylinder no. vs. input channel matches the engine set-up.

Connecting a trigger system (Portable version)


To perform measurements the system needs trigger input either from an encoder, a
trigger ring or a zebra band. A minimum of 360 pulses/rev is recommended for a
satisfactory sampling of the pressure curves. The pulse train should not have more
than 1024 pulses as this would overload the CPU.
The cable is connected to the 10 pole socket next to the circular MIL connector on
the side of the trunk.
The most common sources of trigger signals on MC, MC-C, ME & ME-C engines are
the Intermediate Box and the Tacho Signal Amplifier (TSA). Refer to Figure 1 for
connections.

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Tacho Signal Amplifier &


ME encoder

Intermediate Box &


standard encoder

0V

BU

24V

BK

0V

BU

BU

TRIG

BK

0V

BK

BK

BK

BU

BK

BU

BU

TDC

24V

Intm. Box
J2

Q1A

0V

MMA

0V

0V
TSA J5-J8

Figure 1: Connection of trigger systems to the trunks

The trunk supplies 24V for the trigger system through pair no. 3 of the cable. The
TDC signal (which must be coincident with TDC for cyl. no.1) is connected through
pair no. 1 and the trigger pulse train is connected through pair no. 2.

Connecting a pscav signal/sensor (Portable version)


A scavenge air pressure signal should be connected to the trunk to ensure correct
online values. If the pscav signal is not connected, the system will estimate a value.
The cable is connected to the 5 pole socket next to the circular MIL connector on the
side of the trunk.
The trunk can supply 24V for a sensor, and accepts both current and voltage signals,
depending on set-up. The standard set-up is current signal.
The signal is connected to core no. 3 & 4, while power is available from core no. 1
(24V) & 2 (0V).
For an ME type engine, a pscav signal can be obtained from ACU2, J71.B & J71.C.
When connecting, please make sure to insulate core no. 1 & 2 individually to avoid
short-circuiting the sensor power supply!
Remember to check polarity of this input during connection test.

Connecting Power supply (Portable version)


The trunk requires a minimum of 2A (slow blow) for operation. 4A is recommended.
The cable is connected to the 4 pole socket on the top of the trunk.
Before connecting the power supply cable, open the trunk and make sure that the
main power switch is turned off.
After connecting the power, the system is ready for power-up.

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Note: After power-up, power will be supplied to both trigger system and pscav
sensor. If these cables are not connected or the power supply is not used, make sure
that the cores are electrically insulated and not short-circuited.
Turn on the system by switching on the automatic fuse (F1) inside the trunk. The LED
on the trunk will flash orange shortly and after a few seconds turn green.

Linking two trunks together


When measuring on engines with 7 to 12 cylinders, two trunks are coupled together.
The installation of the second trunk is similar to first trunk with a few exceptions:

The second trunk will need no trigger input, as this is passed on from the first
trunk via the link cable
The second trunk will need no pscav input, as this value is made available for
the unit via the network between the two units
Communication can only be established to the trunk set up as Master. Any
attempts to use the communication connectors on the Slave trunk will fail.

The two trunks are linked together using the ready-made Link cable with 10 pole
heavy duty connectors in each end. The cable is connected to the 10 pole socket
next to the communication connectors on the top of the trunk.

Changing between Master & Master/Slave configuration


Before the system becomes operational with two trunks coupled together, the set-up
of the units must be changed.
This requires that the metal boxes containing the CPU boards on the units be
temporarily removed to give access to the Address DIP switch.

Figure 2: DIP switches found under the metal boxes on the PMI units

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

The Address switch functionality is described in Table 1.


No.
1
2
3
4
5
6
7
8

ON
Only used when SW1.8 is OFF
Only used when SW1.8 is OFF
Baudrate setting refer to table 2
Baudrate setting refer to table 2
RS232 serial interface
Master/slave configuration
Unit is Slave in a master/slave system
Unit set-up controlled by SW1

OFF
Only used when SW1.8 is OFF
Only used when SW1.8 is OFF

RS422 serial interface


Single master configuration
Unit is Master in a master/slave system
1
Unit set-up controlled by Alpha14 software

Table 1: Address DIP switch functionality


SW1.3
OFF
ON
OFF
ON

SW1.4
OFF
OFF
ON
ON

Baudrate
9600 bps
19200 bps
38400 bps
<currently not supported>

Table 2: Baudrate setting

A stand-alone trunk must be set-up as Single Master while two trunks linked
together must be set-up as Master and Slave. The recommended switch settings
are shown below:
Single Master set-up
ON
OFF

x
x

x
x

Master set-up
ON
OFF

x
x

x
x

x
x

Slave set-up
ON
OFF

x
x

Table 3: Recommended address switch settings

When the DIP switches have been set according to the immediate situation, the
metal boxes are mounted again.
Before mounting the metal boxes again, please refer to Input type selection on page
6.
Note: When mounting the metal boxes on the units, take care not to damage the
threads.
After power-up the status LEDs on the PMI Units/trunks may blink green for a few
seconds as they are automatically reprogrammed according to the new DIP switch
settings.
If the status LED on a trunk continues to blink green or red, the switch setting may be
incorrect, and should be checked.

The Alpha14 software referred to in Table 1 is only used for MAN B&W development, and as such
not further described in this document

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Additional hardware settings


Input type selection
The measuring chains for the on-line sensors and the calibration transducer deliver
4-20 mA current signals to the input channels on the PMI units. Therefore the Input
type switch (Figure 2) no. 1-6 & 8 must be set ON.
The scavenge air pressure is connected to input channel 7 on the PMI Master unit,
and the Input type switch no. 7 must match the sensor/signal type connected.

Signal Conditioner gain setting


To match the signal range from the on-line measuring chains to the range of the input
channels on the PMI units, as well as activating the automatic drift compensation, the
DIP switches on the Signal Conditioners must be checked.
The recommended initial gain is 1.0
The recommended switch setting for all channels is shown below for the two existing
versions of Signal Conditioners.
ON
OFF

x
x

5267Q02
ON
OFF

x
x

5267Q03
Table 4: Recommended switch settings for Signal Conditioners

ADAM 4520 switch setting


When commissioning a new system, the delivered ADAM 4520 converter has the
default RS485, 9600 bps setup. This should be changed to RS422.
To do this, open the blue plastic shell by removing the 2 screw on the backside, and
set the SW2 DIP switch as shown in Table 5:
ON
OFF

x
x

Table 5: ADAM 4520 switch setting

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Advanced PMI System Set-up


After a standard installation of the PMI On-line software, the PMI set-up programme
allows the user to edit engine data and to perform reference measurements.
By starting the set-up-programme in service mode, the functionality is expanded to
allow connection test of the system, creating new engine set-ups and perform various
calculations.
This section describes how to start the PMI set-up programme in service mode and
how to use the extended functionality.
The main PMI program can be started the using the same parameter, after which e.g.
blow back pressure is calculated.
Starting either of the programmes in service mode and using the internal link
between the two programmes (from the PMI Set-up, choose Communication->Start
PMI, and from the PMI program, choose Tools->Setup) transfers the service mode
to the other program.

Gaining access to the Service mode


To start up the set-up programme in service mode, a password must be entered in
the command line that starts the programme.
First, create a new shortcut to the PMI Set-up on the desktop, by navigating through
the Start menu and right-clicking on the PMI System On-line Set-up:

Figure 3: Sending a shortcut to the desktop of the computer

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

To edit the command line, right-click on the new shortcut and select Properties:

Figure 4: The properties dialog of the shortcut

In the Target field, add a blank space followed by 2440:

Figure 5: The edited shortcut for the service mode

Select OK to close the dialog.

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Creating a new engine set-up


Start the PMI On-line set-up using the newly edited icon for the service mode.
Select New Engine from the File menu, and enter an appropriate name for the new
engine set-up:

Figure 6: New engine dialog

Make sure that Copy defaults is checked, as this makes it possible to select firing
order, bore, stroke etc. from a set of MAN B&W databases.
If predefined data is not available, these extra databases may be missing in the
installation, as they are not part of the standard scope of supply for the software. In
this case, contact MAN B&W for assistance.
After selecting according to the engine in question, select OK to go on to the Edit
Engine Data dialog.

Figure 7: Edit Engine Data dialog, 'General' tab

Doc. No. 3090644-4

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

If Copy defaults was checked, most of the engine properties will have been predefined based on MAN B&W data. Remember to set the p(i) adjustment value; it
must be set to the rated p(i) pressure times 0.01 in order for the system to suggest
correct index corrections.
Next, select the Crank Angles tab.

Figure 8: 'Edit Engine Data' dialog, 'Crank Angles' tab

In this dialog, the crank shaft layout is specified to enable the system to automatically
detect which cylinder is being measured.
Note: The crank shaft layout defined in this dialog is NOT referring to the actual TDC
positions but instead it is referring to search areas in which the system should expect
to see TDC for the cylinder.
The value entered in the second column adjacent to cyl. no. x should be the crank
angle at which the search for TDC x should stop.
When entering data, the system automatically fills the search band start point into
first column.
In the above example, cylinder no. 1 should be found in the area between 335c.a.
and 35c.a., while cylinder no. 2 should be found in the area between 215c.a. and
275c.a.
The firing order stated in the dialog is the firing order that the system expects given
the entered crank angle search areas. The firing order will evolve as data is entered,
and should off course end up matching the firing order of the engine to be measured
on.
Select the Torsion tab to continue.

Doc. No. 3090644-4

10

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 9: Edit Engine Data dialog, 'Torsion' tab

To automatically compensate for crank shaft twist in high load conditions, data for the
crank shaft torsional stiffness must be entered.
In addition the position of the trigger system must be indicated. If position is Aft and
the trigger system is not mounted on the turning wheel, the Distance to Turning
Wheel & Diameter of Drive Shaft fields must be filled in. The system will then
compensate for twist in the drive shaft.

Figure 10: Edit Engine Data dialog, 'Comments' tab

The comments tab can be used to store information relevant to the engine set-up
and an eventual re-use of the engine set-up for other engines. To easily determine
whether or not the engine set-up can be used on a similar engine, it is recommended
to store information about plant specification and crank throw data.

Doc. No. 3090644-4

11

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Basic System Set-up


In Service Mode, the Setup menu is expanded and the fields are opened for editing.
The I/O menu item opens the I/O Addresses dialog:

Figure 11: The I/O addresses dialog

The addresses in this dialog SHOULD NOT be changed as this will affect the
communication between the PC and the PMI units. Should communication problems
occur, pressing the Default button will restore the standard settings.
The Communication menu item opens the Communication Setup dialog:

Figure 12: The Communication Setup dialog

Here the COM port for communication with the PMI unit is selected. In addition, the
distribution of cylinders on the units input channels is entered here.

Doc. No. 3090644-4

12

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

The Measuring menu item opens the Measuring Setup dialog:

Figure 13: The Measuring Setup dialog

The General Setup section of this dialog defines the sensortypes used with the
system.
The trigger system is defined by the number of pulses and the type of triggering. For
the TDC input, the choices are Low/High (rising or leading edge) or High/Low
(falling or trailing edge). For the Trigger input, an additional choice Double is
available to force the system to make measurements on both the rising and falling
edge of the pulse. This option should only be used with trigger systems that have
stable pulsetrains with a duty cycle of exactly 50% (i.e. encoders), as varying
dutycycles otherwise introduce errors in the measurement data.
The Trigger Timeout defines how long the system should wait for pulses before
returning a timeout error.
The On-line sensors, here referred to as Fixed sensors, are defined by the signal
type and their valid signal range as a percentage of their total range. If the signal
exceeds the high or low limit, the system will report a sensor range error.
The Calibration transducer, here referred to as Portable Transducer, and the pscav
input are defined in the same way. In addition, the pscav input is scaled by entering the
upper range limit for the sensor in the p(scav) Limit field.

Doc. No. 3090644-4

13

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

The Avg. period field in the General Setup section defines how many
measurements the system should use for calculations for one observation. Default
value is 10.
In the Calibration Setup section, the transducer sensitivity found on the transducers
calibration sheet is entered (23C, 250 bar) along with the Avg. Period.
The Check Limits and the Reset Limits are set to a slightly narrower range than the
sensors valid range, with the Reset Limits as the narrowest range.

Doc. No. 3090644-4

14

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Performing Connection test


The PMI On-line set-up programme has a built-in facility for connection test to check
the system prior to engine startup.
After the trunk(s) has been powered up, and the status LED on the trunk is constantly
green, the system is ready to communicate with a computer running the PMI On-line
set-up software.

Establishing connection (Portable version)


The trunk has been prepared for both RS232 and RS422 communication, and
connectors are available on the outside of the trunk.
For RS232 communication, connect a standard null-modem cable to the male D-sub
9 connector on the trunk and flip the S1 switch to the same side as the connector
used.
For RS422 communication, connect a cable to the female D-sub 9 connector on the
trunk and flip the S1 switch to the same side as the connector used.
The S1 switch turns the power supply on & off for the internal RS422/RS232
converter.
Test the connection by selecting Communication -> Test communication. If the
result in the status bar is Unit configured or Unit not configured, the
communication line is OK.
If the result is No connection to PMI unit, check that you are using the correct
communication port on the PC (Setup -> communication), and check the cabling
between the trunk and the PC. Make sure that the S1 switch is in the correct position.

The Connection Test dialog


After establishing connection, enter the connection test dialog by selecting
communication -> Connection test.

Doc. No. 3090644-4

15

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 14: The setup tab in the connection test dialog

After opening the dialog, the program will automatically request the present set-up
from the unit. This operation may take a few seconds, after which the set-up is shown
in the dialogs setup tab.
Selecting Read will make the software request the set-up again.

Doc. No. 3090644-4

16

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 15: The input tab in the connection test dialog

Switching to the Input tab makes it possible to see the actual values returned by the
measuring chains. The data shown in Figure 15 corresponds to a system with 6
cylinders, an active pscav signal and a disconnected Calibration Box. Disconnecting
pscav will bring ch. 7 down to 0 mA, while connecting the Calibration Box will bring ch.
8 up to 12 mA.
Idle inputs from the Signal Conditioners will be represented as app. 12 mA.

Doc. No. 3090644-4

17

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 16: The Network tab of the connection test dialog

Selecting the next tab, Network, brings up a dialog in which the present network setup can be seen.
To se the set-up press Read.
From this information it is possible to see whether or not the unit is correctly set-up
on the address DIP switch under the metal box on the unit.
If the set-up does not correspond to the actual situation, the power to the trunk must
be disconnected, and the switch setting corrected.

Doc. No. 3090644-4

18

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 17: The Calibration Box tab in the connection test dialog

In the Calibration Box dialog the function of the charge amplifier in the Calibration
Box can be verified.
Note: Check of the charge amplifier can only be done with the presence of trigger
signals.

Doc. No. 3090644-4

19

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Figure 18: The Buttons and Lamps tab of the connection test dialog

The Buttons and Lamps tab can be used to test the Calibration Box. From this
dialog it is possible to turn the lamps on and off, or even make them blink. Further, a
press on the Start Measurement button on the box will be indicated on the green
Start lamp/button as if the button on the screen was actually pressed. As there is no
hold function, performing this test will either take 2 persons or a laptop computer
connected to the trunk so that the screen is visible from the Calibration Box.

Doc. No. 3090644-4

20

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Additional functionality
Starting the main PMI program in Service Mode extends the Calculated Values table
with an extra column showing the Blowback Pressure.

Figure 19: The extended Calculated Values table

To calculate the Blowback Pressure the pmi_on.ini file found in the PMI program
directory must be edited.
In the [Extra] section, the parameter Blowback Angle must be defined, e.g.:
[Extra]
Blowback Angle=138,3

The calculation point would normally be the point where the scavenge ports are
starting to open, and the value should be entered in degrees C.A. after TDC.

Doc. No. 3090644-4

21

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

Troubleshooting
Test Communication reports No connection to PMI unit
When trying to test the communication, No connection to PMI unit is reported.
Cause: The communication has not been correctly connected or set-up.
First, check that the software has been set-up to the correct COM port.
Second, check the power supply to the ADAM converter. If you are connecting
directly to the portable trunk via a null-modem cable, check the position of the SW1
switch.
In systems where the converter is powered from the Alphacomm unit, no power
indicates that the sensor supply fuse F2 has been blown on the Alphacomm. This
could indicate short circuits in the installation. Therefore, disconnect trigger system,
Pscav sensor and Signal Conditioners (unplug J29, J22 & J16) before replacing the
fuse.

Incomplete pressure curves


Pressure curves from the on-line sensors are being cut, resulting in observations
similar to the one shown in Figure 20.

Figure 20: Pressure curve clipping

Cause: Most likely the gain setting in the Signal Conditioners is wrong. Refer to Table
4 for correct switch settings.
Secondary cause could be dirt in sensor connector, causing the signal to drift beyond
the capabilities of the automatic drift compensation. Clean the sensor connector and
socket.

Connection test dialog reports values in V instead of mA


The Input test dialog in the connection test is showing V instead of mA, and idle
inputs from the on-line sensors are not app. 12.
Cause: Most likely the Input type DIP switch found under the metal box on the PMI
unit is incorrectly adjusted. Refer to Input type selection on page 6 for correct
settings.

Doc. No. 3090644-4

22

PMI On-line System, Set-up & commissioning

MAN B&W Diesel

After changing the input type, it may be necessary to boot the unit twice, and to
restart the PMI On-Line set-up program.

Connection test dialog reports 0 mA or 0 V on all channels


The Alphacomm unit is not measuring anything on its input channels.
Cause: Most likely, the sensor supply fuse F2 is blown due to short circuits in the
installation. Therefore, disconnect trigger system, Pscav sensor and Signal
Conditioners (unplug J29, J22 & J16) before replacing the fuse.
If i.e. 3 channels are measuring 0 mA while the rest is OK, one of the Signal
Conditioners are either disconnected, wrongly connected or defect.

Pscav is incorrect
The measured scavenge air pressure does not match the actual pressure.
Cause: Most likely the input scaling does not match the signal. Check that the
p(scav) Limit in the PMI set-up matches upper range limit for the sensor.
On an ME engine check that the ACU2 output scaling matches the PMI set-up.

Doc. No. 3090644-4

23

You might also like