ALPHA Commissioning Manual

Alpha Lubricator System
Installation & Commissioning Manual

MC Engines
This manual is valid for newbuildings as well as retrofit installation on engines in

service. The instructions given are addressed to MAN B&W licensees, retrofit-
and commissioning engineers.
MAN B&W Diesel A/S

Teglholmsgade 41
2450 Copenhagen S - V
Phone + 45 3385 - 1100
Fax + 45 3385 - 1030
E-mail manbw@manbw.dk
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List of contents
List of contents........................................................................................................................................................... 2
Pre-face..................................................................................................................................................................... 3
1.0 System Components ................................................................................................................................................. 4
1.1 Main components................................................................................................................................................. 4
1.2 Spare parts .......................................................................................................................................................... 4
1.3 Tools.................................................................................................................................................................... 4
2.0 Installation Aspects ................................................................................................................................................... 5
2.1 Oil injection valves (Non return valves) ............................................................................................................... 5
2.2 Lubricator units .................................................................................................................................................... 5
2.3 Intermediate boxes .............................................................................................................................................. 5
2.4 Pump Station ....................................................................................................................................................... 5
2.5 Pipe System......................................................................................................................................................... 6
2.6 Angle encoder / trigger ring .................................................................................................................................. 6
2.7 Back-up pick-ups ................................................................................................................................................. 6
2.8 Index transmitter .................................................................................................................................................. 6
2.9 MCU / BCU / SBU................................................................................................................................................ 6
2.10 Electrical Installation .......................................................................................................................................... 6
3.0 Commissioning - Mechanical..................................................................................................................................... 7
3.1 Lubricator units .................................................................................................................................................... 7
3.1.1 Checking of lubricator stroke........................................................................................................................ 7
3.1.2 Filling of N2 in accumulators......................................................................................................................... 7
3.2 Back-up Trigger System check............................................................................................................................. 7
3.3 Pump Station ....................................................................................................................................................... 8
3.4 Flushing ............................................................................................................................................................... 8
3.5 Preparation of timing measurement equipment .................................................................................................... 8
4.0 Commissioning Electrical ....................................................................................................................................... 9
4.1 Tools.................................................................................................................................................................... 9
4.2 Configuration of MCU......................................................................................................................................... 10
4.2.1 Excel sheets .............................................................................................................................................. 10
4.2.3 Check of 24V power supply to MCU, BCU & HMI panel............................................................................. 14
4.2.4 VT 100 Terminal ........................................................................................................................................ 15
4.2.5 Upload Basic program ............................................................................................................................... 15
4.2.6 Upload set-up file....................................................................................................................................... 16
4.2.7 Main LED information ................................................................................................................................ 16
4.2.8 Dip switches for MCU ................................................................................................................................ 16
4.3 Configuration of BCU ......................................................................................................................................... 17
4.3.1 Upload Processor parameters.................................................................................................................... 17
4.3.2 Dip switches for BCU ................................................................................................................................. 17
4.4 Check of HMI panel pump controls and indicators.............................................................................................. 19
4.5 System function test (engine at stand still) ......................................................................................................... 19
4.5.1 Lubricator test............................................................................................................................................ 19
4.5.2 Adjustment of angle encoder & back up pick ups ....................................................................................... 19
4.5.3 Adjustment of index transmitter.................................................................................................................. 20
4.6 System function test with trigger simulator (or engine running)........................................................................... 20
4.7 Alpha Lubricator Safety & Alarm signals ............................................................................................................ 21
4.7.1 Control room.............................................................................................................................................. 21
4.7.2 MCU (HMI panel)....................................................................................................................................... 21
4.7.3 BCU........................................................................................................................................................... 22
4.8 Alpha Lubricator System connections to external systems ................................................................................. 23
4.8.1 Connections in vessel / plant ..................................................................................................................... 23
4.8.2 Requirements on testbed: .......................................................................................................................... 24
5.0 Commissioning - Start-up and running .................................................................................................................... 24
5.1 Checks before start-up of engine ....................................................................................................................... 24
5.2 Checks during start-up of engine........................................................................................................................ 24
5.3 Timing Measurements - running engine ............................................................................................................. 24
5.3.1 De-aeration of pressure transducers .......................................................................................................... 25
5.3.2 Measurement of hydraulic/mechanical delay.............................................................................................. 25
5.3.3 Measurement of individual cylinder injection timing.................................................................................... 26
APPENDIX.................................................................................................................................................................... 27
C_Manual02.doc 01-02-01/MIJ/2310
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Pre-face
The Alpha Lubricator System is a new cylinder lubrication concept for our two
stroke MC engines, and the purpose of this manual is to guide MAN B&W
licensees, retrofit- and commissioning engineers during installation and
commissioning of the system.
This manual describes the main components, installation aspects and

commissioning of the system. The layout of the lubricator units, etc. varies with
different engine sizes, and consequently some of the guidance given may not
be 100% applicable for the specific engine.
For description of the working principles and operation of the system, please
see Alpha Lubricator System, Operation Manual, MC Engines.
4
1.0 System Components

1.1 Main components
Pump station, starter panels, HMI panel, mounting brackets, pipe system
Alpha lubricator units, mounting brackets
Computer panels, MCU, BCU, SBU, boxes, mounting brackets
Terminal (intermediate) boxes for feed back indication on each cylinder
Angle encoder or trigger ring, intermediate box, mounting kit
Index transmitter, connection kit to fuel rack
Back-up tacho pick-up box, mounting kit
Electrical cables, internal / external wiring, cable trays, etc.
Oil injection nozzles with tangential spray direction in cylinder liners
T-connecters / fittings, mini-mess couplings for timing measurement
purposes in each cylinder.
Newbuildings
For newbuildings specified with Alpha Lubricator System all the above hardware
is included in the plant specification for the engine. For details in the various
main sections see section 2.0 Installation aspects.
Retrofit installation
For retrofit installation of Alpha Lubricator System all the above hardware has to
be specified and ordered for the particular engine.
1.2 Spare parts

1 or 2 pcs. lubricator (depending on no. of lubr. per cyl.)
2 pcs. feed back sensor, complete
2 pcs. filter element for pump station
1 or 2 sets of O-rings for lubricator (depending on no. of lubr. per cyl.)
6 pcs. 3A, 3 pcs. 12A ceramic or sand filled fuses 6.3 x 32 mm, for MCU,
BCU & SBU
2 pcs. LEDs (Light Emitting Diodes) for visual feed back indication
1 pc. shaft encoder coupling. (For engines with trigger ring at the turning
wheel 1 pc. of pick up is supplied).
1.3 Tools
1 pcs. N2 pressure setting tool for accumulators.
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2.0 Installation Aspects

2.1 Oil injection valves (Non return valves)
For newbuildings the cylinder liners are delivered with tangential oil injection
valves. One of the valves in each cylinder is designed / prepared for measuring.
The measuring valve is equipped with two mini-mess couplings, one for cylinder
pressure measurement and one for injection pressure measurement. This way
the timing of the lubricator system can be checked.
Detail drawings: MS 05, MS 64.
For retrofit installation the oil injection valves, fittings and mini-mess couplings
have to be designed specifically for the engines cylinder liner design.
Regarding the modification procedure for existing cylinder liners with the old
traditional oil injection valves, please contact MBD-C, Technical Service Dept.
2.2 Lubricator units

The lubricator units are installed close to the oil injection valves. The position
differs with engine size, depending on space availability, and the design
comprises two lubricators for 90-70 bore and one lubricator for 60-35 bore
engines.
Detail drawings for new buildings: MS 63.
The lubricators for a particular engine have been specified with a certain stroke,
which is based on the desired basic cyl. oil feed rate at MCR. The distance
piece length in all lubricators can be checked against a calculation of the basic
cyl. oil feed rate. See paragraph 3.1.1 Checking of lubricator stroke.
The lubricator units are equipped with accumulators, which have to be

pressurized with nitrogen before entering service.
Regarding pressure filling with nitrogen please see section 3.1.2 and Instruction
book Volume II paragraph 903-2.1.
2.3 Intermediate boxes

These terminal boxes, of which there are one per cylinder, are equipped with
feed back LEDs for each lubricator. They are installed usually on the middle
gallery and mounted on a small plate or angle iron.
Note! Two electrical diodes (type 1N4007 1000V, 1A or similar) has to be
installed in the screw terminal. See electrical drawings.
2.4 Pump Station

The pump station is a complete unit, which is supplied by a subcontractor. The
unit is as standard supplied with starter panels and HMI panel included. See
makers instruction manual. The unit can be installed on the engine or in the
ships hull structure. Detail installation drawings: MS 00 / MS 64.
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2.5 Pipe System

The pipe system comprises a filling line, a de-aeration line, common rail supply
& return lines, branch pipes to / from the lubricator units, lubricator pipes to the
cylinder liners. Arrangement drawings: MS 00 / MS 05 / MS 63 / MS 64.
The pipe system must be flushed clean before first start-up of the system. See
section 3.4.
2.6 Angle encoder / trigger ring

The angle encoder is installed in the fore end of the engine and connected to
the crankshaft by means of an intermediate shaft. An oil seal towards the bed-
plate is included in the arrangement. For electrical adjustment, please see
section 4.5.2.
In case the fore end of the crank shaft is not available, a trigger ring is installed
in the aft end of the engine.
Detail drawings for new buildings: MS 54, Instruction 1142960: Angle encoder
and Mounting kit.
2.7 Back-up pick-ups

Two back-up pick-ups are installed at the turning wheel in the aft end of the
engine. The pick-ups marker plate is mounted and adjusted to be detected at
TDC cyl. 1. In case of an installation with trigger ring, the two marker pick-ups
are included in this arrangement. Detail drawings for new buildings: MS 46
2.8 Index transmitter

The Index transmitter is connected to the fuel rack and adjusted to cover the full
mechanical range of the system. The arrangement usually includes an
adjustable mechanical link, but can also comprise a belt transmission.
For electrical adjustment of the index transmitter, please see section 4.5.3.
2.9 MCU / BCU / SBU

The boxes for the control units are installed on the engine.
The computer boards (prints) are delivered separately in protected packing, and
they must be installed carefully after all other installation work incl. mounting of
cables in the boxes has been completed. Please follow Alpha Shipmates
handling instructions carefully. Detail drawings: MS 44.
2.10 Electrical Installation

The delivered hardware is prepared with cable glands. All cable glands, which
are not in use after completion of wiring must be replaced with blind plugs.
All wiring must be marked with labels in accordance with the electrical drawings.
Electrical drawings: MS 00 / MS 33.
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3.0 Commissioning - Mechanical

3.1 Lubricator units
3.1.1 Checking of lubricator stroke

The calculation described below is based on Microsoft Excel 2000, but an
earlier Excel version or manual calculation is sufficient.
Basic cyl. oil feed rate

This calculation serves to check the layout of the stroke limiter (distance piece)
in the displacement end of the lubricator.
Fill in the EXCEL sheet Basic_adj.xls in the Appendix, and insert the desired
basic cyl. oil feed rate at 100 % MCR load of the engine.
The calculated stroke should match the length of the stroke limiters in the
lubricators. Carry out adjustments, if required.
3.1.2 Filling of N2 in accumulators

Condition: Atmospheric pressure on the oil side of accumulators.
For newbuildings we recommend that the pressure setting of accumulators is
done before the lubricator units are mounted on the engine.
Pressure setting
0.7 l accumulators (inlet side): 25 - 30 bar (0-60 bar press. gauge)
Mount the mini-mess coupling with the drain hose on the lubricator block in
order to obtain atmospheric pressure on the oil side of the accumulator.
0.16 l accumulators (outlet side): 1.5 bar (0-10 bar press. gauge)
Dismantle the accumulators in order to obtain atmospheric pressure on the oil

side.
For use of the standard pressure setting tool, see separate instruction.
3.2 Back-up Trigger System check

Turn the engine to TDC piston # 1 and check that
the marker plate for the back-up pick ups is positioned correctly opposite
the pick ups.
the marker & trigger pick ups are correctly positioned in case of trigger
ring.
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3.3 Pump Station

The pump station has as earlier mentioned been supplied by a subcontractor,
and consequently the preparation for start-up and general operation is
described in the makers instruction manual.
Regarding the installation, check that the unit and pipe system has been
designed and installed in accordance with drawing 0788334-8. See Appendix.
3.4 Flushing
We recommend that flushing of the Alpha lubricator pipe system is done at the
same time as flushing of the other oil systems (system oil, cam shaft oil, fuel
oil).
In the Appendix please find a sketch of the recommended flushing condition of
the pipe system and carry out the following:
1. Install a 15 - 35 full flow filter on the return side of the pipe system just
before the pump station. The outlet must drain into the suction tank.
2. Install flexible hydraulic hoses or U-pipes on the inlet / outlet side of each
Alpha lubricator unit.
3. Fill enough hydraulic oil or thin mineral oil in the suction tank of the pump
station, that the pumps do not run dry, when the pipe system is filled.
4. Remove (or by-pass) the filter(s) on the pressure side of the pump station.
5. Start the pump station in accordance with the makers instructions.
6. Run both pumps, in order to obtain turbulent flow and high temperature.
7. Flush the pipe system for at least 5 hours.
8. Approve the flushing, when a cleaned (or new) filter is still clean after yet
another hour of flushing.
9. Drain off the flushing oil from the pump station and re-establish the pipe
system to normal operation. Open the cylinder oil supply.
10. Start the pump station and adjust the output pressure to 45 bar.
11. All 8 mm lubrication pipes from the Alpha Lubricators to the cylinder liners
must be blown through with compressed air before eventual activation of the
lubricators.
3.5 Preparation of timing measurement equipment
1. Timing measurement equipment consisting of oscilloscope, absolute

pressure transducers with adaptor for mini-mess, amplifiers, cables, PC,
printer, etc. must be available. An example of timing equipment is specified
in the Appendix.
2. Check that two mini-mess couplings are installed on all cylinder units in a
convenient position at the cylinder oil injection valve for measuring.
3. Assemble the two pressure transducers with the adaptors for the mini-mess
couplings.
4. Install the adaptors with pressure transducers in the mini-mess couplings
and tighten only by hand.
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5. Connect the cables between the pressure transducers and the amplifiers,
while making sure that the contact plugs are absolutely clean. Use the
cleaning agent.
6. Adjust the scale on the amplifiers so that they match the calibration value,
stamped on the pressure transducer elements. (See also certificate from
maker).
7. Connect the amplifiers to the oscilloscope by means of the COAX cables.
8. Prepare the 220 V power source.
4.0 Commissioning Electrical

We recommend that all installation incl. wiring is completed 32 hours prior to
engine start up in order to allow time for electrical checks / tests / simulation and
correction of potential mechanical / electrical errors.
4.1 Tools
For electrical commissioning of Alpha Lubricator System the following tools are
necessary:
Configuration of MCU
PC, serial cable RS232, Excel sheets, Set-up programme, Basic
program, Set-up file, VT 100 Terminal.
Configuration of BCU
Philips Winisp flash programme, set-up file.
Testing
Timing measurement tools (See specification in Appendix)
Trigger simulator (See specification in Appendix)
Normally the MCU and BCU are configured specifically for the engine before
shipment from MBD Copenhagen. These procedures are described in section
4.2 and 4.3.
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4.2 Configuration of MCU
4.2.1 Excel sheets

The following two excel sheets with specific engine data are to be filled out in
order to generate relevant parameters for the MCU set-up program.
Index transmitter adjustment

The injection rate during MCU control is adjusted to be proportional to the
engine MEP.
The excel sheet calculates the MinIndexLevel and MaxIndexlevel parameter
after various engine data have been entered.
See example in Appendix.
Engine kinematics / Timing

The injection timing of the cylinder oil is calculated to start during each pistons
upward stroke, when the top piston ring passes the oil quill.
The point of reference in the timing calculation is defined as
The distance between the edge of the top piston ring for piston # 1 in TDC
position and the location of the oil quill in the cylinder liner.
The timing of the remaining cylinder units is calculated from the crankshaft
angles, the firing order, various physical sizes and the number of trigger pulses
of the angle encoder / trigger ring.
The excel sheet calculates the Crank angle for injection for each cylinder.
See example in Appendix.
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4.2.2 Set-up program

The windows based program is started by pressing lubsetup.exe. The program
consists of three sheets, Basic set-up, timing and rate. The sheets, which are
shown in the following can be used as an examples.
Basic set-up sheet, example
Data notes
Oil pressure sensor range and temperature sensor range are calibration
values. They must be set to the values, which apply for the sensors on
the pump station.
RPM Run: Minimum rpm value at which the MCU detects that engine is
running.
Pump stop time: Number of seconds the pump station is running after the
engine has stopped.
Pre-lubrication: Setting of automatic sequence, when the aux. blowers
are activated during preparation for start-up.
Test: Manual sequence of pre-lubrication, when the PRE-LUB button is
activated on the HMI panel.
Modbus parameters: Use the values in the example.
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Timing sheet, example
Data notes
Firing order / Injection angle: To be filled in according to results from the
excel sheet Engine Kinematics / Timing.
Total trig count: Number of trigger pulses per revolution. For angle
encoder the number is usually 2048, for trigger ring the number is usually
720, however this must be confirmed.
Hydraulic delay: Delay from feed back signal to actual oil injection. Use a
value from a previous similar engine. To be confirmed by means of
timing measurements.
Offset markers: To be used in case of trigger ring.
Injection offset 1 & 2: The angle at which the system starts to get ready
for the next injection on a given cylinder. Default value is 30 degrees.
Interval between 1 and 2 inj. offset: Number of injections between the
two different injection positions. Default value is 0.
13
Rate sheet, example
Data notes
LCD Options:
External flag - To be selected, if LCD action is controlled externally.
External signal - To be selected, if LCD action is partly controlled
externally. Hold time is controlled by the Alpha Lubricator System.
Internal - To be selected, if LCD action is fully controlled internally.
On / Off - Manual selection of LCD action.
Oil amount: Extra oil feed rate during LCD action. Default value 25%.
Deviation: Value in % fuel index deviation to activate LCD.
Average time: Time parameter during detection of fuel index
deviation.
Injection calculation: The MCU calculates and compensates for the time
between activation of solenoid valve to feedback signal, if relative is
selected.
Min. / Max. index level: Values for index transmitter calibration, to be
filled in according to the excel sheet Index transmitter adjustment.
Max. / Min. feed rate are 200 % and 40 % respectively, unless otherwise
stated in specification.
Revs. per injection: Number of revolutions between cyl. oil injections at
MCR for the engine. Normally this number is 4.
14
After filling in all data in the set-up program the set-up file for the MCU is
generated. Make sure that no fields are empty.
We recommend that a new folder in an appropriate directory is created on the
PC for the specific engine. Save the file as e.g. Engine_ID.txt.
An example of a txt. file is shown in the Appendix. Here, a description of the
configuration parameters is also included.
4.2.3 Check of 24V power supply to MCU, BCU & HMI panel
This procedure is to be done before initial powering up of the system,
irrespectively if the purpose is configuration prior to shipment or after installation
on the engine has been completed.
On the SBU board disconnect plug FJ34 and FJ35.

On the MCU board disconnect plug FJ1.
On the BCU board disconnect plug FJ1.
In the starter panel for pump station disconnect the connecter for HMI panel.
Turn on the 24 V power supply for MCU and BCU.
Check that the 24 V polarity for plug FJ1 on MCU and BCU respectively is
correct, i.e. + 24 V on terminal 1 for both units.
Insert plug FJ1 on the MCU board - observe that the main LED lights up and
flashes red / green.
Insert plug FJ1 on the BCU board - observe that the main LED lights up and
flashes red / green.
Insert plug FJ35 on the SBU board - observe in the lower right corner that
the power +24 V LED and Master LED light up.
Insert plug FJ34 on the SBU board - observe in the lower right corner that
the power +24 V LED and Back-up LED light up.
Check that the 24 V polarity on the HMI connecter is correct, i.e. +24 V on
terminal 2.
Insert the HMI connecter and check that the HMI panel does not show
OFFLINE in the display. The upper bar graph will be flashing, if the MCU is
not programmed
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4.2.4 VT 100 Terminal

A VT100 Terminal is part of the standard Windows software on a PC and the
Hyper Terminal can be found in the Programs directory Accessories and
Communications.
Connect the PC to the MCU by means of the serial cable and start the VT100
terminal. The settings for the serial port in PC are:
Bits pr. Second: 38400

Data bits: 8
Parity: None
Stop bits: 1
Flow control: none
Transmit / Receive Protocol : Xmodem
Press [Space] on the PC key board and the screen will display a menu as
follows:
(/) Alpha Lubricator
(1) Transfer of set-up data
(2) Connection Test
(3) System & alarm status
(4) Feedback failure status
(5) Mechanical delay
(6) Logged alarms
(7) Logged feedback alarms
(8) Revision menu
(9) MBD Development menu
(R) Reset
4.2.5 Upload Basic program

The PC is connected to the MCU by means of the RS 232 serial cable and the
VT 100 terminal is started.
Press [R] following [Y], [ASD] and [Ctrl-U]. Send / transfer the E-prom file called
type_cyl.epr from the PC to the MCU by means of menus in the VT100
terminal program. Make sure to use Xmodem protocol. When the file is
transmitted to the MCU, press [Ctrl-P] after confirming that calculated and read
checksums are equal. Now the basic program is uploaded to the MCU board.
16
4.2.6 Upload set-up file

The PC is connected to the MCU by means of the RS 232 serial cable and the
VT 100 terminal is started.
Press [1] following [1]. Send / transfer from PC to MCU the text file, which was
generated from the set-up programme and saved on your computer. When the
file is transferred, ignore the command type password, which is displayed for a
few seconds. Press [Y]. Now the new configuration parameters are uploaded.
In case of trouble with up / downloading process, see instruction Users Guide

to Code load by Alpha Shipmate Development.
4.2.7 Main LED information

On the MCU and BCU a main LED is positioned in the upper left corner. The
status of the unit is given as follows:
Green light: Normal condition.

Red Light: Alarm condition.
Red / green flashing: The MCU / BCU is not configured.
4.2.8 Dip switches for MCU

Three double 4-position dip switches are available on the MCU board, SW 1,
SW 2 & SW 3. The dip switches represent binary values of 1, 2, 4 & 8,
respectively, when counting from the left. A switch in the up - position is ON,
and OFF in the down - position.
SW1 position 1 & 2 are used to define the Baud rate, at which the MCU
communicates via a serial connection with a PC.
SW1.1-2: OFF -> 38400 Baud
SW1.1: OFF, SW1.2: ON -> 19200 Baud
SW1.1: ON, SW1.2: OFF -> 9600 Baud
SW1.1-2: ON -> 4800 Baud
SW1.1-2 is to be set to OFF
SW1.3-8, SW2.1-8 and SW3.1-6 are presently not used, and the positions are
not relevant.
SW3.7 is to be set to OFF (Multiple trigger systems).

SW3.8 is to be set to ON (MCU revision C and later)
OFF (MCU Null-Series)
17
4.3 Configuration of BCU
4.3.1 Upload Processor parameters

Connect the PC to the BCU by means of the serial cable and start the Philips
WINISP program.
1. Set switch SW3 on the BCU in position: [Program]
2. Push reset button (SW4) on the BCU. (The lamp will turn off).
3. In the Philips WINISP program key in the following data:
a. Chip : 89C51RD+
b. Port : Choose COM1 or the relevant port setting
c. Osc : 22 Mz
d. Vector : FC
e. Status :0
4. Warning! If parameter 3d and 3e are not set to FC and 0 respectively, the
single processor chip 89C51RD+ may be permanently damaged.
5. Erase Blocks by opening the [Erase Blocks] menu. Erase the first three
blocks (32 k), by marking the three blocks and press the [ERASE!]
button.
6. Load the program file by means of the [Load File] menu.
7. After loading the status display should read: File loaded ok.
8. Press [Program Part] and the new program file will be uploaded to the
BCU.
9. When the uploading is completed (see Status Display), set switch SW3
on the BCU in position: [Normal] and interrupt the power supply. The
green light will turn on, and the BCU is ready for operation.
4.3.2 Dip switches for BCU

Two double 4-position dip switches are available on the BCU board, SW1 and
SW2. The dip switches represent binary values of 1, 2, 4 & 8, respectively,
when counting from the left. A switch in the up - position is ON, and OFF in the
down - position.
SW1 position 1 4
Injection rate with BCU in control
Generally a BCU take-over should result in a cylinder feed rate increase of 50

%, which in case of a MCU Basic feed rate of 4 rev. / inj. corresponds to a
BCU injection rate of 3 rev. / inj.
Example:
If SW1.1-2 is ON and SW1.3-4 is OFF, the injection rate will be 3 rev. / inj.
18
SW1.5 - 8
Detection rate (BCU take over from MCU)
The lowest injection rate the MCU can perform before the BCU takes over is set
on these positions
This parameter is to be set to 10 rev/injection.
Example:
If SW1.6 and SW1.8 are ON and SW1.5 and SW1.7 are OFF, the lowest
injection rate is 10 rev. / injection for the MCU, before BCU will take over
control.
10
SW2.1-4.
Number of cylinders for the engine
SW2.5
Not used.
SW2.6
BCU board revision
The revision is stated on the board below the MAN B&W logo, as BCU-250-X
where X is the revision.
For installations with revision B, SW2.6 must be OFF.
For other installations SW2.6 must be ON.
SW2.7
Slow down output
The slow down output switch (BCU terminal J8.3, 4) is NC (normally closed) if
SW2.7 is ON and NO (normally open) if SW2.7 is OFF.
SW2.8.
Number of Lubricators
For installations with one lubricator on each cylinder SW2.8 must be ON.
For installations with two lubricators on each cylinder SW2.8 must be OFF.
Important !
Before proceeding with section 4.4 4.6, please make sure that Section 4.2.3
has been carried out.
19
4.4 Check of HMI panel pump controls and indicators

On the starter panels for pump station turn both control switches to
Remote.
On the HMI panel press [PUMP1] and observe that pump 1 on the pump
station is running.
Press [STOP] and repeat the test for pump 2.
Check that both pumps can run simultaneously and that the HMI control
buttons are not active, if the pump station control switches are turned to
Local.
Check that the oil pressure reading on the HMI panel corresponds to the
local pressure gauge reading on the pump station.
Check that the oil temperature reading on the HMI panel corresponds to the
local temperature gauge reading on the pump station.
4.5 System function test (engine at stand still)

In the starter panel next to the HMI panel turn the control mode switch to
MCU.
Start the pump station locally.
Connect your PC to the MCU, plug J51 by means of the serial RS232 cable.
Start the Hyper terminal in accordance with section 4.2.4.
Open the menu Connection Test
4.5.1 Lubricator test

Set Lubricator 1A ON and observe that the feed back LED # 36 for
lubricator 1A on the MCU board is lit.
Repeat simulation of all remaining lubricators and check their corresponding
feed back LEDs. This procedure will also reveal any trouble with signals to
solenoid valves in the lubricators (red LED in the connection plug) and the
signal to the feed back LEDs in the intermediate boxes. See also Hyper
terminal menu 4.
4.5.2 Adjustment of angle encoder & back up pick ups

Turn the engine to TDC piston # 1 and check that the LED on the
intermediate box locally at the angle encoder lights up. Adjust the angle
encoder in accordance with section 2.6, if necessary. Check on the MCU
board that LED D35 at plug J1 is lit.
Check on the MCU board that the back-up pick-up signals are present at
plug J2, LED D41 and J5, LED D37.
Check on the BCU board that the back-up pick-up signals are present at
plug J30, LED D58 and LED D35.
Turn the engine away from TDC 1. Check on the MCU board that LED D39
at plug J10 flickers.
After turning away from TDC 1, check that the MCU and BCU LEDs
mentioned in the above are turned off.
In case of an installation with trigger ring, check that the signals and the
corresponding LEDs are present in accordance with the electrical drawings.
20
4.5.3 Adjustment of index transmitter

Adjust the index transmitter mechanically / electrically so that the current is
4.0 mA, when the fuel rack is in 0-position and 20.0 mA, when the fuel rack
is in max. position (mechanical stop).
Fine tune the setting by means of the gain- and off-set- adjustment screws
on the forward end of the index transmitter.
Check on the HMI panel that the scale for the injection rate matches the fuel
rack position approximately at various % MEP. Carry out potential
adjustment of the MCU parameters MinIndexLevel and MaxIndexLevel.
4.6 System function test with trigger simulator (or engine running)
Connect the trigger simulator to the MCU in accordance with the connection
diagram in Appendix. If a trigger simulator is not available this test must be
carried out at low load shortly after start-up of the engine.
MCU.
Adjust rpm on the trigger simulator to an appropriate level and check that
the pump station automatically starts up.
all lubricators are operating correctly.
no critical alarms are displayed in the HMI panel (Hyper terminal menu 3
& 4).
BCU and check that
both pumps are running and that the pressure is still acceptable. (See
Operation manual).
all lubricators are operating correctly.
common alarm is activated (several other alarms may be present).
the BCU in control indication lamp next to the HMI panel is lit.
Auto, and check that
the BCU in control indication lamp is turned off.
the system is lubricating correctly with the MCU in control.
only one pump is running on the pump station.
Remove the wire for feedback indication on plug L3, terminal 4 in the SBU
and observe that
common alarm is activated.
alarm 5 & 6 are displayed in the HMI panel
the BCU automatically takes over the control after a while
the BCU in control indication lamp is lit
alarm 5 & 6 are disabled after BCU take-over
The BCU finally activates the slow down output signal (NO) on plug J8,
terminal 3 & 4.
Re-connect the wire on plug L3, terminal 4 in the SBU and turn the control
mode switch back to Auto. Check that the
system returns to normal MCU operation
the slow down output signal disappears from plug J8, terminal 3 & 4
21
common alarm disappears (if no other alarms than # 5 & 6 were present
before the disturbance was introduced).
Simulate all alarms by following the alarm list. See below. Check external
connections in accordance with the table section 4.7, Alpha Lubricator System
connections to external systems.
4.7 Alpha Lubricator Safety & Alarm signals
4.7.1 Control room

Alarm system signals Safety system signals
Common alarm Slow down
MCU power failure
BCU power failure
Slow down
MCU system failure
BCU system failure
BCU in control
4.7.2 MCU (HMI panel)

Feedback, lubricator 1A,1B,2A,.....14B ALr1,ALr2,...ALr28
Angle encoder marker (or Marker 1 from Trigger ring) Alr 29
Marker 1 from BCU (or Marker 2 from Trigger ring) Alr 30
Trigger from angle encoder (or Trigger 1 from Trigger ring) Alr 31
Trigger 2 from Trigger ring (not available with angle Alr 32
encoder
Engine stop Alr 33
LCD Alr 34
BCU alive Alr 35
Ahead / astern Alr 36
Pre-lubrication Alr 37
Oil temperature high Alr 38
Oil pressure low Alr 39
Speed deviation between marker / trigger Alr 40
Low fuel index Alr 41
Index transmitter cable failure Alr 42
Marker 2 from BCU (not available with trigger ring) Alr 43
BCU in control Alr 44
22
4.7.3 BCU
Alarm LEDs on the BCU are placed in upper right corner. The LEDs are
numbered from right to left.
LED 1 Flywheel marker 1

LED 2 Flywheel marker 2
LED 3 Flywheel marker 1 and marker 2
LED 4 One lubricator feedback failure
LED 5 Two lubricators on same cylinder feedback failure
LED 6 Alive signal from MCU
LED 7 Engine stop signal
LED 8 Internal failure
23
4.8 Alpha Lubricator System connections to external systems
4.8.1 Connections in vessel / plant

Signal From To Description Remarks
Slow down BCU Safety If lubrication fails on one or Relay
system more cylinders. NO/NC
MCU MCU Alarm If one or more system Relay NC
common System failures are detected in the
alarm MCU.
MCU Power MCU Alarm If the 24 V power to MCU Relay NC
fail System board is interrupted.
SBU Power SBU Alarm If the 24 V power to SBU Relay NC
BCU Power BCU Alarm If the 24 V power to BCU Relay NC
MCU fail BCU Alarm If alive signal from MCU Relay NC
System fails or if a critical failure
has been detected.
BCU fail BCU Alarm If one or more transmitter Relay NC
System signals to BCU is (are)
defective.
BCU in ctrl SBU Alarm If BCU has taken over Relay NC
System control.
Engine Stop Safety MCU/BCU Engine stop signal, closed, Relay NO
system when engine is stopped.
LCD Governor MCU Optional Relay NO
system
Astern Safety MCU Astern signal, closed, Relay NO
system when engine is running
astern
Pre- ECR MCU Activates pre-lubrication in Relay NO
lubrication console 30 sec., when aux. blowers
are started.
Low oil level Pump Alarm If oil supply to pump Relay NO
station System station fails.
24
4.8.2 Requirements on testbed:
Engine stop signal Two separate NO dry contacts from governor

system to MCU & BCU.
Common alarm signal NC dry contact from MCU to alarm panel.
Slow down signal For safety reasons we recommend that a

NO or NC dry contact is connected from BCU
to the safety panel.
5.0 Commissioning - Start-up and running

5.1 Checks before start-up of engine
Press the PRE-LUB button on the HMI panel, and check that all lubricators
are operating correctly by watching the LEDs (feed back signals) for each
cylinder.
Check visually from the scavenge air receiver that all non return valves are
injecting cylinder oil into the cylinder liners. Wear eye protection !
Check that the cooling water system for the oil cooler on the pump station is
correctly installed and that the valves in the supply -and return lines are
open.
Check on the HMI panel that the cylinder oil feed rate individual adjustment
is set to the desired value (default = 100 %). Normally the setting during
breaking-in of the piston rings and cylinder liners is 200 %.
5.2 Checks during start-up of engine

1. Check that the cyl. oil pressure on the pump station automatically builds up
to the required 50 bar.
2. Observe that all LEDs are flashing in the intermediate boxes for the Alpha
lubricators
3. Check that no alarm is detected on the HMI panel.
4. Check that the oil temperature and pressure stabilises on a normal service
value.
5.3 Timing Measurements - running engine

The timing measurements are to be taken at least at two different loads, 50
% and 100 %.
The timing measurement curves are to be taken for all cylinders. The
curves should appear approximately like the example shown in the
appendix.
25
5.3.1 De-aeration of pressure transducers

1. Start by checking the timing equipment, which has been prepared in
accordance with section 3.5. The two pressure transducers are to be
positioned in cylinder 1. Tighten the adapters in the mini-mess by hand only.
2. The engine should run with at least 50 % load in order to obtain acceptable
readings.
3. Carry out de-aeration by opening the adapter venting valve for the pressure
transducer mounted in the mini-mess for the lubricator injection pressure.
Close the venting valve, when oil flows out.
4. Re-locate the pressure transducer with adapter, which has just been vented,
to the position for the cylinder pressure. The unit is filled with oil and is not to
be vented again.
5. Install the other pressure transducer with adapter in the mini-mess for the
lubricator injection pressure. Carry out de-aeration according to item 3.
6. Power up the timing equipment and adjust the scales on the oscilloscope so
that the size of the pressure curves match the display.
Warning! Never disconnect the communication cable between a pressure
transducer and an amplifier, which is operating. You may damage the
equipment !
5.3.2 Measurement of hydraulic/mechanical delay

The hydraulic/mechanical delay [OffsetMecDelay] is a MCU configuration
parameter, which is to be recorded and up-loaded to the MCU before the actual
timing measurements are recorded. Please note that the engine has to be
stopped for up-loading of MCU. The value is to be inserted in ms/2.
1. Mount one pressure transducer with adapter in the mini-mess for lubricator
injection pressure cyl. 1.
2. Connect the oscilloscope measuring probe channel 1 to the lubricator
injection pressure transducer cyl. 1.
3. Connect the oscilloscope channel 2 to plug J1, terminal 4 (Feedback
indication signal for injection cyl. 1) and plug J14, terminal 2 (ground) and on
the MCU.
4. Measure the time between the first flank of channel 2 and the point at which
the pressure curve starts to build up for channel 1. This time interval is
defined as the hydraulic/mechanical delay.
26
5.3.3 Measurement of individual cylinder injection timing
1. Mount the two pressure transducers with adapter in the mini-mess for
lubricator injection pressure cyl. 1. Carry out de-aeration in accordance with
paragraph 5.3.1.
2. Connect the oscilloscope channel 1 to the lubricator injection pressure
transducer cyl. 1 and channel 2 to the cylinder pressure transducer cyl. 1.
3. When a set of curves have been recorded for one cylinder, move the two
pressure transducers in the adaptors to the next cylinder without
disconnecting the communication cables.
4. Do not carry out de-aeration of channel 2, after a moving the equipment
from one cylinder to another. If the signals are drifting, clean the connections
with the cleaning agent, while making sure that the amplifiers are turned off.
5. Carry out the timing measurements by recording sets of curves successively
for all cylinders in a series.
6. Evaluate the timing measurement curves as follows: The cyl. oil injection is
to start approximately 1 ms before piston ring # 1 passes the oil quill. In
other words, the injection pressure curve (channel 1) should cross the cyl.
pressure curve (channel 2) approximately 1 ms before its maximum.
7. Carry out potential timing adjustments on the MCU configuration parameter
[C_InjOffset(0)]. This value is inserted in degrees x 10 and is set as default
to 300.
27
APPENDIX
Cylinder oil feed rate - Basic adjustment
Vessel/Plana Stena, 1250, engine # 1 (CW) Lloyds no.:
Number of cylinders: 7 Eng. type: S60MC-C Builder/no.: HHI
Lubricator type: Alpha MEP/LCD: Both
Date: 00.10.29 Place: Testbed HHI-EMD Visit by: CLK / ASD
Condition:
Basic adjustment: Levers/handles in zero position.
- MEP feature: To be adjusted at 100% MCR.

- LCD feature: Not active.
___________________________________________________________________
* S * D * G * R * * N * 60 * C * 0.9
Feed rate calculation Q=
P * 4 * 1000
___________________________________________________________________
(Value: 0.9 = hydraulic efficiency)
Insert values in the blue boxes:
D = Piston diameter (mm): 5,5

G = Number of lubricating points per cylinder: 6
R = Ratio of injections per revolution: 0,25
= Specific density of cylinder oil at C:
N = Revolutions per minute at MCR: 105
C = Number of cylinders: 7
P = Power at 100% MCR (BHP): 21490
----------------------------------------------------------------
S = Stroke (mm), if known :
Q = Cylinder oil feed rate (g/BHPh), if known : 1,1
----------------------------------------------------------------
Calculated values:
Q = Cylinder oil feed rate (g/BHPh), calculated :

S = Stroke (mm), calculated : 17,78
(NB: Default value (0.94) used for cyl. oil density)
Oil consumption in litres per day (litres/day): 604
2300/2001-02-01
MAN B&W Diesel A/S 2310/2001-02-01
Load transmitter adjustment

Fixed pitch propeller
1) Fill in the engine data, etc. in the grey boxes

Four corresponding values for engine load and fuel index must be entered in the table.
If data for engine load and fuel index is not available the values are to be taken
from the testbed report from a similar engine.
2) The two software values Min- and MaxIndexLevel for the load transmitter
calibration will be calculated
Plant: Lind 172 Engine K90MC

Pe MCR (kW): 45735 Number of cyl. : 10
nf MCR (rpm): 94 Piston diameter (m): 0,9
Date/Name 2000.12.11/2310/MIJ Stroke (m) : 2,55
Fuel
% load Index *
25,5 62 MinIndexLevel [4 ma]: -20,5
50 84
100 124
88 110 MaxIndexLevel [20 mA]: 140,2
Mech.
stop 162
MAN B&W Diesel A/S 2310/2001-02-01
Alpha Lubricator
Engine Kinematics / Timing
1) Fill in the grey boxes. - The remaining values will be calculated.

2) The actual crank angle for injection in each cylinder will appear in the blue boxes
Plant: Lind 172 Engine 10K90MC

Crankshaft radius (1/2 stroke), (mm) : 1275
Connecting rod length (mm) : 3510
Engine revolution, MCR (rpm) : 94
Distance from oil quill to cyl.liner face (mm): 769
Thickness of shims (mm): 7
Distance from liner face to top piston ring (Piston in
TDC) without piston rod shims [mm] : 52
Number of trigger pulses / revolution 2048
Distance from TDC 1 top piston ring to oil quill (mm): 724
Specific crankshaft angle for injection cyl. 1 304,0
Injection
Angle
Crank- trigger Crank
Firing between
shaft number angle for
order each
angle (-30 injection
cylinder
degrs.)
1 28,8 0 1559 304,0
8 52,2 28,8 1723 332,8
7 33,3 81 2020 25,0
3 25 114,3 161 58,3
5 41,6 139,3 303 83,3
9 45,5 180,9 540 124,9
4 27,2 226,4 799 170,4
2 26,2 253,6 954 197,6
10 59,9 279,8 1103 223,8
6 20,3 339,7 1444 283,7
Specification
Timing measurement equipment for Alpha Lubricator System
MAN B&W Diesel A/S commissioning engineers use

the following equipment for timing adjustment:
Absolute pressure transducer element:

Kistler A/G, type 4075A200 0 - 200 bar
Seal for pressure transducer element:

Kistler A/G, type 1135A
Adapter for Mini-mess:

MBD drawing xxxxxxxx-x.
Cable:
Kistler A/G, type 4763A20 20 m / element
Amplifier
Kistler A/G, type 4603B 1 piece / element
Additional equipment:
Cleaning agent for transducers:

Kistler A/G, type 1003
Portable oscilloscope, 2 channels,
COAX cable for connection between charge amplifiers and oscilloscope.
PC or portable printer for documentation purposes.
220 V source
Please note that two sets of pressure transducers are required for the timing
measurements / adjustments.
2000.11.22
2300 / THH / MIJ
1.27_010112.txt
C_ShipPlantName=Gudrun Maersk
C_NameOfEngineBuilder=Hyundai
C_EngineType=10K90MC-C
C_NameOfCommissioner=MIJ/2310
C_DateOfCommissioning=01.01.12
C_EngineNo=AA0952
C_MCUVersion=1.27
C_Comment1=ok
C_Comment2=ok
C_Comment3=ok
C_Comment4=ok
C_Comment5=ok
C_TsampleLCDDetect=100
C_OneLubOnEachCyl=FALSE
C_NoOfTestSequensPRELUBRICATION=12
C_TestIntervalTimePRELUBRICATION=8
C_NoOfTestSequensTEST=200
C_TestIntervalTimeTEST=8
C_CylInjectionOrder[0]=6
C_Interval2InjOffset=0
C_MinIndexLevel=-19
C_MaxIndexLevel=125
C_InjRateAlgorithm=mep
C_InjRateCalculation=relative
C_MaxFeedRate=200
C_MinFeedRate=40
C_InjOffset[0]=255
C_InjOffset[1]=255
C_ShaftTorsion[0]=0
C_ShaftTorsion[1]=0
C_ShaftTorsion[2]=0
C_ShaftTorsion[3]=0
C_ShaftTorsion[4]=0
C_ShaftTorsion[5]=0
C_ShaftTorsion[6]=0
C_ShaftTorsion[7]=0
C_ShaftTorsion[8]=0
C_ShaftTorsion[9]=0
C_ShaftTorsion[10]=0
Page 1
1.27_010112.txt
C_InjTime=100
C_ModeLCD=internal
C_IndexDevValueLCD=20
C_IndexDevTimeLCD=10
C_HoldTimeLCD=30
C_LCDOilAmount=25
C_ScuffingOilAmount=100
C_ModeMecDelay=adaptiv
C_Mecdelay[0]=0
C_Mecdelay[1]=0
C_Mecdelay[2]=0
C_Mecdelay[3]=0
C_Mecdelay[4]=0
C_Mecdelay[5]=0
C_Mecdelay[6]=0
C_Mecdelay[7]=0
C_Mecdelay[8]=0
C_Mecdelay[9]=0
C_Mecdelay[10]=0
C_Mecdelay[11]=0
C_Mecdelay[12]=0
C_Mecdelay[13]=0
C_OffsetMecDelay=6
C_LCD=FALSE
C_AliveFrequencyAlarm=30
C_AlarmDelay=10
C_OilTempHighAlarm=70
C_OilPresLowAlarm=35
C_MaxPLubOil=60
C_MaxTOilInlet=600
C_RPMMCR=1040
C_NCyl=10
C_RpmRun=100
C_MinRpmAlarm=150
C_MaxRpmDeviationAlarm=100
C_IndexLowAlarm=3
C_PumpIntervalTime=43200
C_PumpStopTime=600
C_TrigPosCh1[0]=9
C_TrigPosCh1[1]=199
C_TrigPosCh1[2]=341
C_TrigPosCh1[3]=577
C_TrigPosCh1[4]=836
C_TrigPosCh1[5]=991
C_TrigPosCh1[6]=1140
C_TrigPosCh1[10]=0
Page 2
1.27_010112.txt
C_TrigPosCh1[11]=0
C_TrigPosCh1[12]=0
C_TrigPosCh1[13]=0
C_TotalTrigCh1=2048
C_TrigPosCh2[0]=0
C_TrigPosCh2[1]=0
C_TrigPosCh2[2]=0
C_TrigPosCh2[3]=0
C_TrigPosCh2[4]=0
C_TrigPosCh2[5]=0
C_TrigPosCh2[6]=0
C_TrigPosCh2[7]=0
C_TrigPosCh2[8]=0
C_TrigPosCh2[9]=0
C_TrigPosCh2[10]=0
C_TrigPosCh2[11]=0
C_TrigPosCh2[12]=0
C_TrigPosCh2[13]=0
C_TotalTrigCh2=2048
C_TrigSystemMode=angleencoder
C_Rev_pr_Inj=400
C_ModbusUnitNo=1
C_ModbusBaudRate=9600
C_ModbusStopBit=1
C_ModbusParity=none
C_ModbusDataBit=8
C_ModbusProtocol=ansii
C_ModbusInterface=rs232c
C_ModbusHandshake=none
C_InjectionAngle[0]=3106
C_TDCMarker1Offset=0
C_TDCTrigger1Offset=0
C_TDCTrigger2Offset=0
Page 3
Description of MCU configuration parameters
Parameter name Description

c_RpmRun [10*rpm] Minimum rpm value for the system to
regard the engine as running.
c_AliveFrequencyAlarm [sec/100] Max. interval between BCUs alive
signals before failure detection.
c_InjOffset[0] [degrees/10] Angle of trigger point before injection
position.
c_InjOffset[1] [degrees/10] Secondary angle of trigger point in
case of an injection sequence with two
different injection angles. The primary
angle of trigger point is set by
[c_InjOffset[0]].
c_Interval2InjOffset [rpm] Interval in rpm for activation of
secondary angle of trigger point.
c_IndexLowAlarm [%] Low alarm value for fuel index.
c_OilTempHighAlarm [C] High alarm value for oil temperature.
c_OilPresLowAlarm [bar] Low alarm value for oil pressure.
c_ModeMecdelay [adaptive, fix] See c_Mecdelay[xx].
c_Mecdelay[xx] [msec/2] Mechanical delay in lubricators. If
c_ModeMecDelay is set to adaptive,
this value will be calculated
automatically.
c_OffsetMecDelay [msec/2] Mechanical/hydraulic delay in pipe
system/injectors. Time delay measured
between feedback signal and pressure
peek at the injection valve.
c_InjTime [msec/2] Holding time for the activation signal to
lubricators.
c_NCyl Number of cylinders for engine.
c_AlarmDelay [sec] Time between the failure detection to
alarm is activation.
c_MaxRpmDeviationAlarm [rpm/10] Maximum deviation for calculated rpm
for individual marker/trigger signals.
c_MinIndexLevel [%] Index level at 4 mA. (Normally negative
value.)
c_MaxIndexLevel [%] Index level at 20 mA
c_InjectionAlgorithm [mep, kw, rpm] Selection between injection algorithm.
Choose between: mep, load or rpm
proportional lubrication mode.
c_ModeLCD [external_flag, External_flag: LCD is activated if LCD-
external_signal, internal, manual] input is ON.
External_signal: LCD is activated in
c_HoldTimeLCD after LCD-input is de-
activated.
Internal: LCD is calculated from load
transmitter signals (fuel index).
Manuel: LCD is set to c_LCD.
c_LCD [true, false] Forced LCD
True: LCD active,
False: LCD not active
c_IndexDevValueLCD [%], LCD trigger level in per cent fuel index
within the time limit set by
c_IndexDevTimeLCD
c_IndexDevTimeLCD [sec]. LCD deviation time.
c_HoldTimeLCD [min] LCD activation time.
c_LCDValue [%] Amount of extra lubrication in per cent
of actual feed rate, when LCD is
activated.
c_MinRpmAlarm [rpm/10] Lower alarm limit for engine speed.
c_RPMMCR [rpm/10] Rpm value at MCR.
c_MaxPLubOil [bar] Oil pressure at 20 mA.
c_MaxTOilInlet [C] Max. sensor temperature.
c_OneLubOnEachCyl [true, false] Number of lubricators per cylinder
True: One lubricator
False: Two lubricators
c_NoOfTestSequencePre-lubrication Number of activation of each lubricator,
during automatic Pre-lubrication.
c_TestIntervalTimePre-lubrication Speed of sequence. Time until
[10 ms] activation of the next lubricator during
automatic pre-lubrication.
c_NoOfTestSequenceTEST Number of activation of each lubricator,
during manual Pre-lubrication.
c_TestIntervalTimeTEST [10 ms] Speed of sequence. Time until
activation of the next lubricator during
manual pre-lubrication.
c_CylInjectionOrder [x] [Cyl. n - 1] Cylinder injection order, starting with
the first cylinder to be injected after
TDC # 1. The [x] indicates a
successive output-number for injection.
The SW counts from 0, i.e. all cylinder
numbers in the firing order have been
subtracted by 1.
c_ShaftTorsion [x] [1/10 degrees] Shaft torsion at 100 % load, following
the c_CylInjectionOrder.
c_PumpIntervalTime [sec] The two pumps run alternately and
shift every c_PumpIntervalTime time.
c_PumpStopTime [sec] Stop delay time of pump station active
pump, when engine stops.
c_TrigPosCh1[x] Injection trigger number (angle) for
cylinder[x]. The number equals
c_InjOffset+(c_TrigPosCh1[xx]/c_Total
TrigCh1)
c_TrigSystemMode [angle encoder, Selection of trigger / marker system.
trigger ring]

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Alpha Lubricator System

Installation & Commissioning Manual

This manual is valid for newbuildings as well as retrofit installation on engines in

MAN B&W Diesel A/S

This manual describes the main components, installation aspects and

1.0 System Components

1.2 Spare parts

2.0 Installation Aspects

2.2 Lubricator units

The lubricator units are equipped with accumulators, which have to be

2.3 Intermediate boxes

2.4 Pump Station

2.5 Pipe System

2.6 Angle encoder / trigger ring

2.7 Back-up pick-ups

2.8 Index transmitter

2.9 MCU / BCU / SBU

2.10 Electrical Installation

3.0 Commissioning - Mechanical

3.1.1 Checking of lubricator stroke

Basic cyl. oil feed rate

3.1.2 Filling of N2 in accumulators

Dismantle the accumulators in order to obtain atmospheric pressure on the oil

3.2 Back-up Trigger System check

3.3 Pump Station

3.5 Preparation of timing measurement equipment

1. Timing measurement equipment consisting of oscilloscope, absolute

4.0 Commissioning Electrical

4.2 Configuration of MCU

4.2.1 Excel sheets

Index transmitter adjustment

Engine kinematics / Timing

The point of reference in the timing calculation is defined as

4.2.2 Set-up program

Basic set-up sheet, example

Timing sheet, example

Rate sheet, example

On the SBU board disconnect plug FJ34 and FJ35.

4.2.4 VT 100 Terminal

Bits pr. Second: 38400

Transmit / Receive Protocol : Xmodem

4.2.5 Upload Basic program

4.2.6 Upload set-up file

In case of trouble with up / downloading process, see instruction Users Guide

4.2.7 Main LED information

Green light: Normal condition.

4.2.8 Dip switches for MCU

SW1.1-2 is to be set to OFF

SW3.7 is to be set to OFF (Multiple trigger systems).

4.3 Configuration of BCU

4.3.1 Upload Processor parameters

4.3.2 Dip switches for BCU

Generally a BCU take-over should result in a cylinder feed rate increase of 50

This parameter is to be set to 10 rev/injection.

4.4 Check of HMI panel pump controls and indicators

4.5 System function test (engine at stand still)

4.5.1 Lubricator test

4.5.2 Adjustment of angle encoder & back up pick ups

4.5.3 Adjustment of index transmitter

4.7 Alpha Lubricator Safety & Alarm signals

4.7.1 Control room

4.7.2 MCU (HMI panel)

LED 1 Flywheel marker 1

4.8 Alpha Lubricator System connections to external systems