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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
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
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.
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
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.
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.
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.
Figure 2: DIP switches found under the metal boxes on the PMI units
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
SW1.4
OFF
OFF
ON
ON
Baudrate
9600 bps
19200 bps
38400 bps
<currently not supported>
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
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
x
x
5267Q02
ON
OFF
x
x
5267Q03
Table 4: Recommended switch settings for Signal Conditioners
x
x
To edit the command line, right-click on the new shortcut and select Properties:
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.
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.
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.
10
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.
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.
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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:
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.
12
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.
13
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.
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15
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.
16
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.
17
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.
18
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.
19
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.
20
Additional functionality
Starting the main PMI program in Service Mode extends the Calculated Values table
with an extra column showing the Blowback Pressure.
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.
21
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.
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.
22
After changing the input type, it may be necessary to boot the unit twice, and to
restart the PMI On-Line set-up program.
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.
23