13

Doosan B-WACS
Getting Start
Doosan Engine Co.,Ltd.

69-3, Sinchon-dong, Seongsan-gu, Changwon-si, Gyeongsangnam-do,
SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
E: ebiz.engine@doosan.com
Operators have to read carefully this manual and use it in compliance with usage
procedures and safety regulations before starting B-WACS. Doosan Engine owes the
copyright of this manual. Please don’t use this manual for other purposes than B-
WACS.
DOC. No. B-WACS-G001 June 2010

1
Notice!!
Before using B-WACS Monitoring Software, be sure to comply
with „Getting Start‟ procedure!
If there are some troubles when „Getting Start‟ procedure is

progressed, refer to the trouble shooting in Technical Manual
or contact service engineer.
Without the completion of RPM Compensation, B-WACS can‟t

measure the accurate bearing wear. So „RPM Compensation‟
should be done according to this „Getting Start‟ manual and
more detail procedure is described at the „RPM Compensation
Procedure‟ in software manual of B-WACS.

2
1. Turn on the power switch of DMU (Restart DMU Software)
< ECR Console Front Panel > < ECR Console Inside >
The front side of DMU The back side of DMU
Power Switch
USM Port

3
2. Select B-WACS
Click!!
3. Check whether ‘Engine Status’ is ‘Running’ and ‘System’ is

‘linked’

4
4. RPM Compensation
4-1 Click „Maintenance‟ and Run main engine as specified RPM
Specified RPM
※ Recommend Speed
■ 1st RPM Compensation: Dead Slow RPM

■ 2nd RPM Compensation: HALF RPM
■ 3rd RPM Compensation: Navigation Full RPM

5
4-2. Click ‘Start’ in Step 1 if main engine should be run
in 20~50% of nominal speed
4-3. Click ‘OK’ and then Keep main engine RPM for 10 minutes !

6
4-4. Don’t touch the other menu during PRM compensation!
4-5. If RPM compensation is finished, RPM value be displayed

and completion box will be checked.

7
4-6. Do ‘Step 2’ and ‘Step 3’ as ‘Step 1’ procedure
4-7. Check the completion of ‘RPM Compensation’ from ‘Step

1’ to ‘Step 3’

8
4-8. Click ‘Manual Setting’ in Maintenance and click “Upload
RCV” after finishing RPM Compensation
Click!!

9
< System Check Sheet >
No. Task Method Result Note
1 DMU Power Chk. Turn on DMU and check the power OK / NG
2 Select B-WACS Chk. Click the B-WACS in Main screen OK / NG
When engine is running, confirm If Engine Status displays

3 Engine Status Chk. that Engine Status is activated OK / NG “Stop”, refer to the
as “Running” trouble shooting
When “Dislinked” is
Confirm that System Link is activated
4 System Link Chk. OK / NG displayed, refer to the
as “linked”
trouble shooting
Confirm that “Step 1” Completion

OK / NG
is finished
RPM Compensation Confirm that “Step 2” Completion Don‟t change the main
5 OK / NG
Chk. is finished RPM with each Step

OK / NG
is finished
To confirm the „Upload

7 Upload RCV Chk. Click the “Upload RCV” OK / NG RCV, refer to the trouble
shooting
* Trouble shooting is described in the B-WACS Technical Manual

10
Doosan B-WACS
Technical Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
DOC. No. B-WACS-T001 June 2010

1
CONTENT
1. Overview
1.1 Introduction of B-WACS -----------------------------------------------------------------------------3
1.2 Introduction of Manual -------------------------------------------------------------------------------4
2. B-WACS Configuration
5
2.1 System Configuration Diagram -----------------------------------------------------------------------
2.2 System Connection Diagram --------------------------------------------------------------------- 9
2.3 System Monitoring Program ----------------------------------------------------------------------10
3. B-WACS Installation
3.1 Product supplied ---------------------------------------------------------------------------------------12
13
3.2 Mechanical Installation Part -------------------------------------------------------------------------
14
3.3 Electrical Installation Part ----------------------------------------------------------------------------
4. B-WACS Specification
15
4.1 External Measurement ----------------------------------------------------------------------------------
4.2 Specification -------------------------------------------------------------------------------------------16
5. Trouble Shooting ------------------------------------------------------------------------------------------ 17
The copyright of this manual belongs to Doosan Engine Co., Ltd. The
manual which is provided together with B-WACS shall not be used for
other purpose without a consent of Doosan Engine Co., Ltd.

2
1. Overview
1.1 Introduction of B-WACS

B-WACS(Bearing Warning and Control System) is specially developed by Doosan
Engine to measure bearing wear in a low speed diesel engine. B-WACS, which is a
BWM(Bearing Wear Monitoring) System, diagnoses integrated wear status of Main
Bearing, Crank Pin Bearing and Crosshead Bearing. The aims of B-WACS are to
prevent the major bearings from severe damage and to get not the time based
open-up which is time consuming and a risk of initiating failure but the condition
based open-up.
< Fig. 1-1 Principle of B-WACS >
B-WACS has three kinds of main components, SCU(Signal Capture Unit),

SAU(Signal Analysis Unit) and DMU(Data Monitoring Unit).
SCU is installed on the low part of the crosshead guide and measures relative
position between each guide-shoe and the proximity sensor at BDC(Bottom Dead
Center) whenever engine operates.
SAU is installed on the inside of main console in ECR(Engine Control Room). The

3
measured data is analyzed by SAU to determine bearing status such as WARNING,
ALARM and SLOW-DOWN. Analyzed data can be stored up to 5 years for
investigating long term status of bearing.
DMU is mounted on the main console in ECR and offers operator user interface so
that operator can check wear condition of bearings and see the final bearing wear
value and wear trend.
1.2 Introduction of Manual

The objective of this manual is to help operator understand whole system and to
indicate the technical specification or inform operators about it. For this reason,
usage procedure and safety regulation shall be fully understood by reading this
manual before installation and operation of B-WACS.
The technical manual of B-WACS explains the entire system configuration and
specification and summarizes how to install and operate B-WACS. The detail
instructions of B-WACS installation and user program shall be explained in each
installation manual and program manual.
B-WACS manual shall be composed as below
A. Technical Manual (DOC. No. B-WACS-T001)

▣ B-WACS configuration
▣ B-WACS installation
▣ B-WACS specification
B. Installation Manual (DOC. No. B-WACS-I001)

▣ Mechanical Installation Part
▣ Electrical installation Part
▣ Commissioning Part
C. Program Manual (DOC. No. B-WACS-P001)

▣ S/W screen layout
▣ Data monitoring
▣ Alarm handling
▣ System diagnosis & configuration
▣ Maintenance

4
2. B-WACS Configuration
2.1 System Configuration Diagram

B-WACS is composed of 3 main units & 2 sub units. Main units in B-WACS are
SCU(Signal Capture Unit), SAU(Signal Analysis Unit) and DMU(Data Monitoring Unit).
And two sub units, UPS and Power Supply, are the stable source of electric power for
B-WACS.
As SCU has two inductive proximity sensors, a temperature sensor and a control
module, it can measure bearing wear value and send the measured date to SAU. It
analyzes the measured data and then sends the analyzed data to DMU which show
operators the result of wear value and wear trend to operators.
Signal and electric power flow among units in B-WACS is as figure below.
< Fig. 2-1 B-WACS Configuration Diagram >

5
The units for B-WACS shall be as below.
▣ SCU (Signal Capture Unit)

▣ SAU (Signal Analysis Unit)
▣ DMU (Data Monitoring Unit)
▣ UPS (Uninterruptable Power Supply)
▣ Power Supply
2.1.1 SCU(Signal Capture Unit)

A SCU is composed of two inductive proximity sensors, a temperature sensor, a
control module and a bracket. It is made of single unit and installed on the low part
of crosshead guide inside of frame-box and measures the value of position of
crosshead guide-shoe. A SCU is connected to the front and the rear SCU in
st nd
sequence. Exceptionally, the SCU of 1 cylinder is not only connected to 2 SCU
but also connected SAU through Junction Box. The SCUs which are installed in the
engine send the measured data to SAU and receives electric power from SAU.
< Fig. 2-2 SCU >

6
A. Inductive Proximity sensor
Two inductive proximity sensors mounted at both sections of bracket of SCU
measure the BDC (Bottom Dead Center) position of the bottom of guide-shoe.
The two cables of inductive proximity sensors are connected with control
module. When installing a SCU, installer should adjust the distance between
two inductive proximity sensors and the bottom of guide-shoe to 4mm. Adjust
the distance using 4mm shim plate supplied according to the instruction of
installation manual.
Don’t turn the engine, until finishing installation of SCUs and adjustment the
distance between two inductive proximity sensors and the bottom of guide-
shoe. If the distance between two inductive proximity sensors and the bottom
of guide-shoe is not adjusted, the bottom of guide-shoe could collide with the
proximity sensors!
B. Temperature Sensor
The RTD temperature sensor is mounted on the bracket of SCU in order to
improve the accuracy of inductive sensor. The RTD temperature sensor is
released with the control module connected to the cable, therefore, extra
adjustment and handling for the temperature sensor is not necessary. The
aims of temperature sensor are to measure the inside temperature and
calibrate inductive sensors distance with regard to environmental
temperature.
C. Control module
The control module mounted at the low part of bracket is installed on the
inside of engine and has function to input value measured from the proximity
sensors and a temperature sensor. It automatically calculates the BDC
position of crosshead.
The SCU of each cylinder should be connected with a SCU-SCU-MUL cable. In
order to connect SCU to the neighboring SCU, connect connector of control
module to the connector of neighboring control module with SCU-SCU-MUL
Cable. Refer to the installation manual about how to connect SCUs with SCU-
SCU-MUL Cable in detail.

7
D. Bracket
The bracket can assemble inductive proximity sensors, a temperature sensor
and control module as a single unit and make it installed at the low part of
crosshead guide of the inside of engine. In order to install it at engine, two
tap holes are necessary.
2.1.2 SAU(Signal Analysis Unit)

AC 220V main power used in ECR is converted to DC 24V through Power supply.
And then DC 24V is supplied with SAU. SAU supplies DC 24V power to SCUs
installed at the inside of engine through Junction Box. And SAU receives the
measured sensor values from SCUs.
SAU of B-WACS can be used for all kinds of low speed diesel engines from 5
cylinders to 14 cylinders engines without extra terminal box and interface unit.
Irrespective of the number of cylinders, power supply and communication of the
measured data is possible with SCU-SCU-MUL Cable connected. The sensor
values received from SCUs are processed at SAU and are displayed at DMU(Data
Monitoring Unit).
SAU received the measured data from SCUs and then analyze or calculate the
value of bearing wear. In addition, SAU implements RPM compensation and save
the measured long term data and short term date in nonvolatile memory.
< Fig. 2-3 SAU >

8
2.1.3 DMU(Data Monitoring Unit)
The data analyzed at SAU is sent to DMU(Data Monitoring Unit), which is a Touch
Panel PCs, with RS485 communication line. Electric power of DMU receives DC
24V from UPS which is connected as SAU does.
As B-WACS exclusive program is installed at DMU, it displays the bearing wear
status and wear trend of each cylinder. DMU is mounted on the main console of
ECR.
< Fig. 2-4 DMU >

9
2.1.4 UPS
In order to keep normal operation of B-WACS during unexpected power shutdown,
UPS is connected to Power Supply of SAU and DMU. UPS shall be installed at the
place where the console of ECR can be easily connected to SAU and DMU power
supply. UPS is installed in the main console of ECR with DIN-Rail(NS 35/75).
< Fig. 2-5 UPS >

10
2.1.5 Power Supply
Power Supply converts AC 220V of ECR into DC24V and supplies UPS with the
converted power. Power Supply is installed in the main console of ECR with DIN-
Rail(NS 35/75).
< Fig. 2-6 Power Supply >

11
2.2 System Connection Diagram
Below diagram shows the system connection of B-WACS. A solid line is supplied
as a standard cables and a dotted line is option cables.
< Fig. 2-7 B-WACS System Connection Diagram >

12
2.3 System Monitoring Program
B-WACS monitoring program shows the wear value and wear trend of the major
bearings after analyzing sensor measurement data received from SCUs. Alarm shall
appear if wear value is out of wear specifications during engine operation.
Program operators are classified into two different levels as below.

■ Ordinary operator level: Have authority only for access to view functions
(Logon is not necessary)
■ Manager level: Has all authorities for system management (Initial P/W: 6670)
(Logon is necessary)
< Fig. 2-8 B-WACS Monitoring Program Layout >
The program screen is composed of Main Menu, Sub Menu, Screen Window, Tool
Menu, and State Window. Real-time Wear in Monitoring is default screen and by
clicking the selection button in Tool Menu, the operator can see the digital output of
wear value in detail and temperature value from the sensors. According to Main Menu
or Sub Menu, Screen Window is changed such as wear slide graph, wear trend, alarm
setting and rpm compensation etc. The composition of Main Menu and Sub Menu in
monitoring program is as figure below.

13
< Fig. 2-9 Composition of Main Menu and Sub Menu >
2.3.1 Main MENU

The main menu is composed of 4 menus such as monitoring, alarm, system, and
maintenance
A. Monitoring Menu: Display Real-Time Wear, Wear Trend and Sensor

Deviation according to cylinders and output the Report
B. Alarm Menu: Show all Event occurring in B-WACS
C. System Menu: Display System Status and Operation Condition of B-WACS
Components
D. Maintenance Menu: rpm Compensation, Sensor Replacement, Manual
Setting as Chief Level (Manager Level Menu, Logon is necessary)
2.3.2 Sub Menu

Sub Menu is decided according to kind of Main Menu as above picture. Once Main
Menu is selected, Sub Menu is shown at the bottom of Main Menu. In the same
method, Screen Window and tool Menu can be altered according to Sub Menu.
2.3.3 Screen Window

Screen Window shows the Information selected by Sub Menu or Tool Menu.

14
2.3.4 Tool menu
Tool Menu is optional and additional composition If needs be. Users can operate
buttons on Tool Menu to indicate graphs, tables and setting values in Screen
Window.
2.3.5 State Window

State Window shows three status of B-WACS System as below
1) Bearing Status: Display the condition of the three major bearings
- Normal: No detection of wear beyond the warning limits
- Warning: Detection of wear beyond the warning limits
- Alarm: Detection of wear beyond the alarm limit
- Slowdown: Detection of wear beyond the slowdown limit
2) Engine Status: Display the operating state of engine
- Running: During the operation of engine at above 20 rpm
- Stop: engine stop or operation at below 20 rpm
3) System: Display whether or not to link SCU with SAU
- Linked: connection monitoring program with SAU
- Unlinked: Disconnection monitoring program with SAU
< Fig. 2-10 Configuration of State Window >

15
3. B-WACS system Installation
3.1 Products Supplied

Standard products and spare parts shall be supplied by Doosan Engine.
3.1.1 Standard Part
A. SCU (Including Two Inductive Proximity sensors, Temperature sensors,
Control Module and Brackets)
B. SAU
C. DMU (Including B-WACS Monitoring program)
D. Power Supply
E. UPS
F. Cable Gland (Engine Cable Gland)
G. Connection Cable
▣ SCU-SCU-MUL Cable: (Cyl. Number)EA
▣ SCU-JB-MUL Cable: 1EA
▣ SAU-PPC Cable: 1EA
▣ PPC-PS Cable: 1EA
▣ SAU-UPS-POW Cable: 1EA
▣ SAU-SUP-POW Cable: 1EA
H. Shim Plate: 1EA
3.1.2 Spare Part

A. SCU: 1EA
B. SCU-SCU-MUL Cable: 1EA
3.1.3 Option Part

A. Connection Cable
▣ JB-SAU-Power Cable: 1EA
▣ JB-SAU-RS485 Cable: 1EA

16
3.2 Mechanical Installation Part
Before installing B-WACS, refer to installation manuals. Specially, as SCU

is installed at the inside of engine, make sure that engine is locked and
safety precautions should be taken.
Where to install and how to install mechanical installation part unit shall be
summarized as below
< Table 3.1 B-WACS Unit mechanical installation summary >

Installed Installation
How to Install Remarks
Unit Location
Inside engine SCU can be attaching Adjustment of two

SCU low part of by bolting at low part inductive proximity
crosshead guide of crosshead guide sensors is necessary
Inside ECR Be careful to connect

SAU -
Console the cables
On the main
DMU - -
Console in ECR
Inside ECR Install on DIN-rail

UPS -
Console (DR 35/7.5)
Power Inside ECR Install on DIN-rail

-
Supply Console (DR 35/7.5)

17
3.3 Electrical Installation
How to connect the units of electrical installation parts shall be summarized as

below
< Table 3.2 B-WACS Unit electrical installation summary >
Connection
Object Connection method Remarks
Location
Inside Connected by standard

Connect SCU to SCU -
Engine SCU-SCU-MUL cable
Connected by standard Cable gland is

SCU to Junction Box
SCU-JB-MUL cable necessary
External
Engine Connected by standard
SAU to Junction Box JB-SAU-RS485 cable Option item
JB-SAU-POW cable
Connected by standard
SAU to DMU
SAU-PPC cable
SAU to UPS
SAU-UPS-POW cable
-
ECR DMU to Power Supply
PPC-PS cable
UPS to Power Supply
SAU-SUP-POW cable
SAU to AMS System Option item
SAU-AMS cable
In the event that additional tap hole are needed during installation of unit of
B-WACS, it shall be approved by engine builder and a ship maker in
advance

18
4. B-WACS Specification
4.1 Drawings
4.1.1 SCU
<Fig. 4-1 Drawings of SCU >

19
4.1.2 SAU
<Fig. 4-2 Drawings of SAU >

20
4.1.3 DMU
VGA Output
N/A
USB 2.0
LAN Port
RS-485 * 2Port
Power Input(24Vdc)
On/Off Switch
<Fig. 4-3 Drawings of DMU >

21
234mm
Panel Cutout 168mm
Panel
<Fig. 4-4 Panel Cutout of DMU >

22
4.1.4 UPS
<Fig. 4-5 Drawings of UPS>

23
4.1.5 Power Supply
<Fig. 4-6 Drawings of Power Supply>

24
4.2 Specification
4.2.1 SCU
4.2.1.1 Proximity Sensor
- Input Voltage : 10V ~ 30V DC
- Current Consumption : 4 mA ~ 20 mA
- Sensing Range : 0 ~ 10 mm
- Housing Material : Chrome-plated brass
- Weight : 55g
4.2.1.2 Temperature Sensor
- Sensor Type : PT100, Class B, 3 wires
- Body Material : Stainless Steel
4.2.1.3 CONTROL UNIT
- Input Voltage : 15 V to 34 V dc
- Current Consumption @24V : 150mA average (200mA max)
- RS232 Data Format : 115,200, N, 8, 1
- Alarm Outputs
4.2.2 SAU
- Input Voltage : 15 V to 34 V dc
- Current Consumption @24V : 150mA average (200mA max)
- Internal Memory : 16GBytes
- RS232 Data Format : 115,200, N, 8, 1
4.2.3 Panel PC
- Input Voltage : DC24V
- Touch Screen : 5-wire resistive type
- Processor : Celeron M1.5Ghz
4.2.4 UPS
- Input Voltage : 150V – 294VAC
- Output Voltage : 220VAC
- Power : 1150VA/770Watt
- Interface : USB, Serial Port
4.2.5 Power Supply
- Input Voltage : 100 ~ 240VAC
- Input Fuse : 6.3A
- Input Frequency : 45 ~ 65Hz
- Output Voltage : 24VDC

25
4.2.6 Cable
4.2.6.1 SCU-SCU-MUL/SCU-JB-MUL Cable
- Outer Diameter : 7mm
- Temperature Rating : 95˚C
4.2.7 Environmental
4.2.7.1 SCU
CONTROL UNIT
- Enclosure Material : Aluminum
- Gasket Material : Polyurethane
- Cover Screws Material : Stainless Steel
- IP Rating : IP67
- Vibration 5~25 Hz : +/- 1.6mm
25 ~ 100 Hz : +/- 4g to ABS specification
- Operating Temperature : -20℃ top 70℃
- Storage Temperature : -40℃ top 80℃
- Humidity : 20% to 95% non-condensing
Proximity Sensor
- IP Rating : IP67
- Vibration : > 4g
- Operating Temperature : 25℃ ~ 70℃
4.2.7.2 SAU
- Enclosure Material : Aluminum
- Gasket Material : Polyurethane
- Cover Screws Material : Stainless Steel
- IP Rating : IP67
- Vibration 5~25 Hz : +/- 1.6mm
25~100Hz : +/- 4g to ABS specification
- Operating Temperature : -20℃ top 70℃

26
5. Trouble Shooting
■ Sensor data is out of spec. (3.0 ~ 4.0mm)
- Check point: Distance between inductive proximity sensor and guide-shoe
- Action step
. Action 1: Confirm the measured sensor data in ‘Sensor Data’ of ‘Maintence’
. Action 2: Readjust the distance with 4mm shim plate
< Fig. 5-1 Check the gap with sensor data >
< Fig. 5-2 Adjust distance between sensor and guide-shoe with 4mm shim plate >

27
■ System Status in DMU Software displays ‘Dislinked’
Connection status of system

(Linked, Dislinked)
< Fig. 5-3 System status of B-WACS >
- Check point: SAU Power, SAU-DMU cable

- Action step
. Action 1: Open the cover of SAU. Confirm whether the SW1 turn on or not,
turn on the SW1 and then look at the LED lamp on board.
. Action 2: Check the cable connector between SAU and DMU.
. Action 3: Change the communication line between SAU and DMU
. Action 4: Replace SAU with new one.
< Fig. 5-4 Switch and lamp position of SAU >

28
■ Engine Status in DMU Software display ‘Stop’
Operating status of engine

(Running, Stop)
< Fig. 5-5 Engine status of B-WACS >

- Check point: SAU Power, SCU Power, B-WACS Parameter
- Action Step
. Action 1: Open the cover of SAU. Confirm whether the SW1 turn on or not,
turn on the SW1 and then look at the LED lamp on board.
. Action 2: If the SW2 turned off, turn it on.
. Action 3: Input the firing order correctly and click the ‘Update’ button
< Fig. 5-6 Check the firing order and click ‘Update’ button >

29
■ Temperature sensing data error
- Check point: SCU Power, SCU-SCU-MUL cable
- Action Step
. Action 1: Check the cable connection between Junction Box and SAU as
Drawings
. Action 2: Open the cover of SAU and confirm whether the SW2 turn on or not,
turn on the SW2
. Action 3: Check the connector and SCU-SCU-MUL cable between SCU and
SCU. Especially, confirm whether the wire is broken or not.
. Action 4: Replace the SCU on which the temperature sensor is mount with
spare SCU.
. Action 5: Check the voltage of Junction Box which is connected with SCU.
If the voltage value is less than 25V, raise the voltage of UPS
< Fig. 5-7 Normal status of temperature sensor >

30
< Fig. 5-8 Error status of temperature sensor >

31
BLANK
Doosan B-WACS
Installation Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
This manual has to be read carefully and used in compliance with usage procedures
and safety regulations before installing all units of B-WACS. Doosan Engine owes the
copyright of this manual. Please don‟t use B-WACS and the manual for other purposes.
DOC. No. B-WACS-I001 January 2010

1
CONTENT
1. Overview
1.1 Introduction ------------------------------------------------------------------------------------------------- 3
1.2 Supplied Products ---------------------------------------------------------------------------------------- 4
1.3 Precaution in Installation -------------------------------------------------------------------------------- 8
2. Mechanical Parts
2.1 Overview -----------------------------------------------------------------------------------------------------9
2.2 Entire Mechanical Block Diagram ------------------------------------------------------------------ 10
2.3 Installation of Mechanical Parts ----------------------------------------------------------------------------
11
2.3.1 SCU (Signal Capture Unit) Installation ------------------------------------------------------- 11
2.3.2 SAU (Signal Analysis Unit) Installation -------------------------------------------------------13
2.3.3 DMU (Data Monitoring Unit) Installation ---------------------------------------------------- 14
2.3.4 UPS Installation ---------------------------------------------------------------------------------- 15
2.3.5 Power Supply Installation ---------------------------------------------------------------------- 16
2.4 Mechanical Drawings -------------------------------------------------------------------------------- 17
3. Electrical Parts
3.1 Overview -------------------------------------------------------------------------------------------------------
31
3.2 Entire Electrical Block Diagram -------------------------------------------------------------------- 32
3.3 Installation of Electrical Parts -------------------------------------------------------------------------33
3.3.1 Engine Inside -------------------------------------------------------------------------------------- 33
3.3.2 Engine Outside ----------------------------------------------------------------------------------- 36
3.3.3 Engine Control Room -----------------------------------------------------------------------------39
3.4 Electrical Drawings ----------------------------------------------------------------------------------- 42
4. Commissioning
4.1 Overview ------------------------------------------------------------------------------------------------- 43
4.2 Commissioning Procedure ---------------------------------------------------------------------------------
44
4.3 RPM Compensation ------------------------------------------------------------------------------------ 47
4.4 Sensor Readjustment --------------------------------------------------------------------------------------
50
4.5 Manual Setting --------------------------------------------------------------------------------------------51

2
1. Overview
1.1 Introduction
This document contains important information as well as warning and safety instructions
regarding properly installing mechanical and electrical parts and commissioning of B-WACS.
Note that this manual is read thoroughly and then B-WACS should be set up in compliance with
installation procedures.
This manual is largely composed of 4 parts as Figure 1-1 below. Mechanical installation part
explains how to install the components of B-WACS. Electrical installation part provides the
information about connecting the cable and power line of each unit of B-WACS. The last chapter,
Commissioning Part describes B-WACS software parameter settings, RPM Compensation
procedures, and Check List for commissioning procedure. Refer to each chapter for detailed
information.
Content
1. Overview
2. Mechanical Installation Part
3. Electrical Installation Part
4. Commissioning Part
< Fig. 1-1 Main contents of Installation manual>
The WARNING symbol ( ) means that operators have to be careful for safely setting up B-
WACS. Before installing B-WACS, Installation & Software Manual should be carefully read and
then, installation work has to be done with reference to these manuals. Please note that Doosan
Engine is not responsible for accidents or problems happening when the safety instructions
don‟t be followed.

3
1.2 Supplied Products
1.2.1 Standard Products

The standard products as below will be supplied when purchasing B-WACS, check the kind and
quantity of products.
Part No. Fig. Quantities
Refer to the
SCU explanation
in the low
part of figure
- Less than 8 cylinders: (Cyl.Number+1) EA

- More than 8 cylinders: (Cyl.Number+2) EA
SAU 1EA

4
DMU 1EA
※ DMU Software has been installed at DMU
Power
1EA
Supply
UPS 1EA

5
Cable
2EA
Gland
- Engine Cable Gland: 2EA
Refer to the
Connecting explanation
Cable - SCU-SCU-MUL Cable in the low
. Less than 8 Cylinder: (Cyl. Number)EA part of figure
. More than 8 Cylinder: (Cyl. Number + 1)EA
- SCU-JB-MUL Cable: 1EA
- SAU-DMU-COM Cable: 1EA
- UPS-SAU-POW Cable: 1EA
- UPS-DMU-POW Cable: 1EA
- POWER SUPPLY Cable: 1EA
- PS-UPS-POW Cable: 1EA
Shim
1EA
plate
※ Thickness : 4mm

6
1.2.2 Spare Parts
SCU 1EA
Refer to the
Cable in the low
part of figure
- SCU-SCU-MUL Cable : 1EA

7
1.2.3 Option Parts
Refer to the
Cable in the low
part of Fig.
- JB-SAU-POWER Cable: 1EA

- JB-SAU-RS485 Cable: 1EA
1.3 Precaution in Installation
B-WACS should be installed by qualified engineers according to manuals and drawings. In case
of drilling holes or other processing works during installing B-WACS, previous permission of
Doosan Engine is needed.
The relevant actions for safety such as wearing protective safety equipment have to be taken
before setting up B-WACS. Ensure that there are not any garbage and metal chips inside
engine after SCU installation and poor ventilation while at work. Engine must be stopped and
locked during SCU installation.

8
2. Mechanical Parts
2.1 Overview
Mechanical Parts explains how to install units of B-WACS which consists of SCU(Signal
Capture Unit), SAU(Signal Analysis Unit), DMU(Data Monitoring Unit), UPS, and Power Supply.
Other components except SCU are installed outside engine or at ECR(Engine Control Room),
but SCU is set up inside engine.
Protective safety equipment has to be worn and safety precautions are followed before installing
SCU. Don‟t leave any other materials such as garbage and metal chips which are produced
during installing of B-WACS inside engine, and remove all dirty things which left inside of engine
after installing SCU. All units including SCU have to be installed properly according to manuals
and drawings, refer to Electrical Parts for connection of power supply and installation of
communication lines.
There are 4 parts such as Overview, Block Diagram, Installation, and Drawings as Figure 2-1
below in this chapter.
2. Mechanical Parts
2.3.1 SCU Installation

2.1 Overview
2.3.2 SAU Installation

2.2 Entire Mechanical Block Diagram
2.3.3 DMU Installation

2.3 Installation of Mechanical Parts
2.3.4 UPS Installation

2.4 Mechanical Drawings
2.3.5 Power Supply Installation
< Fig. 2-1 Main sections of Mechanical Parts >

9
2.2 Entire Mechanical Block Diagram
The components of B-WACS such as SCU, SAU, DMU, Power supply and UPS are installed at
inside engine and ECR as Figure 2-2 below. In other words, SCU is only set up inside engine
and other units are installed at ECR. SCU is placed between two adjacent cylinders at the lower
part of guide shoe rail. If the number of cylinders is more than 8, SCU should be installed which
is one plus the total number of cylinders. DMU is fixed on ECR Console panel in order for
operators to easily monitor bearing wear values and trends. SAU, UPS, and Power Supply are
also installed inside of ECR Console.
< Fig. 2-2 Mechanical block diagram of B-WACS>

10
2.3 Installation of Mechanical Parts
2.3.1 SCU (Signal Capture Unit) Installation
SCU consists of two proximity sensors, a temperature sensor, a control box receiving signals
measured from sensors, and the bracket which is fixed needs to be attached. B-WACS is
provided to customer as a unit which is assembled. The shape of bracket is a little different
according to the type of engine but functions of SCU are the same.
Before installing SCU, make sure that engine should be „locked‟. The installation
should be carried out by qualified engineer.
1) Check the holes for mounting SCU

Refer to the drawings and confirm the holes where SCU is installed because the location of
hole is different according to the engine type. There are two holes (M10, Tab hole) drilled in
the vertical direction at the bottom of Crosshead Guide for fixing the bracket of SCU and
another additional one or two cable clamp holes in the horizontal direction for fixing SCU-
SCU-MUL Cable as below Figure 2-3.
< Fig. 2-3 SCU mounting holes and cable clamps >
After completing the installation of SCU, remove all metal chips and other materials
which may cause critical damages like scratches on engine driving parts. Don‟t drop
any other materials on engine bedplate or crankcase and leave any tools after
installing SCU.

11
2) Install SCU
When installing SCU, loosen proximity fixing bolts a little for moving two proximity sensors in
order to adjust the distance between proximity sensors and guide shoe with a shim plate.
The bracket should be tightly fixed to crosshead guide with a spanner as Figure 2-4 below
and a locking washer has to be used in order to prevent the loosening of bolts from engine
vibration.
< Fig. 2-4 Fixation of a bracket to crosshead guide >
After fixing the SCU on the crosshead guide, fix the SCU-SCU-MUL Cable with cable clamps.
More detailed instructions on the cable connection are introduced in Electrical Parts chapter.
3) Adjust the distance between a proximity sensor and Guide shoe with a shim plate.
Regulate the distance from a proximity sensor to Guide shoe at BDC with a 4mm shim plate.
How to adjust the gap is following as below.
① Turn engine carefully until Guide shoe comes to BDC.

② Insert 4mm shim plate and adjust the gap which is about same thickness of a 4 mm
shim plate by moving proximity sensors.
③ Fix proximity sensors to crosshead Guide shoe with proximity sensor fixing bolts.
④ Remove a 4 mm shim plate.

12
< Fig. 2-5 Adjustment of the gap with a 4 mm shim plate >
2.3.2 SAU (Signal Analysis Unit) Installation
SAU is a unit which analyzes the value measured by sensors. It is installed on the main console
in ECR. Remove upper cover of SAU and then fix the SAU on ECR Console with 4 bolts (M6
size) as Figure 2-6 below. It is recommended that SAU is installed at the place where SAU is
easily connected with Power supply and DMU.
M6 Bolt Fixing
M6 Bolt Fixing
< Fig. 2-6 SAU Installation in main console of ECR >

13
2.3.3 DMU (Data Monitoring Unit) Installation
DMU is a Panel PC with a touch screen and is supplied including DMU Software. DMU provides
the interface between B-WACS and users and shows the results calculated in SAU on the
screen of it. Install DMU on ECR Console panel where users easily operate DMU and at the
same time its location is near SAU, UPS and Power Supply.
< ECR Console Front Panel > < ECR Console Inside >
DMU Front DMU Rear
Power Switch
DMU
Fixing Bolt
< Fig. 2-7 DMU Installation >

14
2.3.4 UPS Installation
UPS is a device which makes B-WACS work properly for a certain period of time when power
turns off suddenly, which is located Inside of ECR Console. UPS will operate with about 30
minutes while the power supply of B-WACS shut down. After installation of UPS, confirm the
input & output voltage of UPS with a multi-meter. The range of input voltage is 24~30VDC and
that of output voltage is 24~30VDC. (Recommended voltage: 28VDC)
DIN-Rail
UPS
< Fig. 2-8 UPS installation >

15
2.3.5 Power Supply Installation
Power Supply converts AC220V input voltage to DC24V output voltage used for operating SAU
and DMU. Install Power supply on the DIN-Rail inside ECR console. After installation of Power
supply, confirm the input & output voltage of power supply with a multi-meter. The range of Input
voltage is 200~240VAC and that of output voltage is 24~30VDC. (Recommended output
voltage: 28VDC)
In case an ambient temperature is higher and its load is full, keep installation
clearances such as 40mm on top, 20mm on the bottom, and 5mm on the left and
right side. And if there is any heat source near power supply, 15mm clearance is
recommended.
DIN-Rail
Power
supply
< Fig. 2-9 Power supply installation drawing>

16
2.4 Mechanical Drawings
2.4.1 Quantity of SCU per cylinder

17
2.4.2 Outline Drawing of SAU(Signal Analyze Unit) - I

18
2.4.3 Outline Drawing of SAU(Signal Analyze Unit) - II

19
2.4.4 Outline Drawing of SCU (Signal Capture Unit)

20
2.4.5 Outline Drawing of SCU Bracket

21
2.4.6 Outline drawing for DMU(Data Monitoring Unit)

22
2.4.7 Outline drawing for Power Supply

23
2.4.8 Outline drawing for UPS

24
2.4.9 Outline drawing for SCU-SCU-MUL Cable

25
2.4.10 Outline drawing for SCU-JB-MUL Cable

26
2.4.11 Outline drawing for SAU-DMU-COM Cable

27
2.4.12 Outline drawing for UPS-SAU-POW Cable

28
2.4.13 Outline drawing for UPS-DMU-POW Cable

29
2.4.14 Outline drawing for POWER SUPPLY Cable

30
3. Electrical Parts
3.1 Overview
Electrical Parts provides the information about connecting SCU, SAU, DMU, Power Supply, and
UPS with Communication and Power Cable completely. It is largely composed of Engine Inside
Connection, Engine Outside Connection and Engine Control Room (ECR) connection.
Engine inside connection explains how to connect the cables of all SCUs, and Engine outside
connection shows connections of SCU, Junction Box, and SAU. The last part, Engine control
room connection, explains how to connect the cables of SAU, DMU, Power Supply and UPS in
the engine control room.
In connecting to outside engine, Junction Box to SAU Power Cable and Junction Box to SAU
RS485 cable are option items not basic items to be supplied. Connecting cable for SAU and
Junction Box are option item.
There are 4 parts such as Overview, Block Diagram, Installation, and Drawings as Figure 3-1
below in this chapter
3 Mechanical Parts
3.1 Overview
3.2 Entire Mechanical Installation Diagram
3.3 Installation of Electrical Parts

3.3.1 Engine Inside Connection
3.4 Mechanical Installation Drawings
3.3.2 Engine Outside Connection
3.3.3 Engine Control Room Connection
< Fig. 3-1 Main sections of electrical parts >

31
3.2 Entire Electrical Block Diagram
After installating of B-WACS, connect communication & power cables between components of
B-WACS according to the wiring diagram as Figure 3-2 below. All SCUs are connected with
SCU-SCU-MUL Cables which have communication and power lines together. The other
st
components of B-WACS except SCU are installed in ECR. 1 SCU is connected to SAU through
Junction Box. The cable which connects SCU to Junction Box is supplied as standard items, but
the RS485 cable and 24VDC Power cable between SAU and Junction Box are not supplied.
AMS (Alarm Monitoring System) cable is also not supplied.
Ensure that the electrical power supply is isolated and the UPS is switched off before
wiring connection works and maintenance are regularly carried out.
< Fig. 3-2 Entire electrical block diagram >

32
3.3 Electrical Connection Diagram
3.3.1 Engine Inside

The details of inside engine connection of Electrical Parts are as below
3.3.1 Inside Engine Connection
A. SCU-SCU-MULCable Connection
Connection between SCUs
B. How to Fix SCU-SCU-MUL Cable
1) How to connect SCU-SCU-MUL Cables

SAU provides the 24VDC power to SCUs installed at each cylinder through Junction
st
Box. As Figure 3-3 below, SCUs should be connected to the next SCU in sequence. 1
SCU should be connected to Junction Box through Cable Gland.
< Fig. 3-3 SCU connection diagram >

33
< Fig. 3-4 SCU-SCU-MUL Cable connection >
2) How to clamp SCU-SCU-MUL Cables

After mounting the SCU bracket on the crosshead guide, fasten SCU-SCU-MUL cable
with cable clamp. In order to prevent loosening from engine vibration, it is needed to
use a locking wire on cable clamp as Figure 3-5 below. Fix SCU-SCU-MUL Cable by
using clamps at the intervals of less than 100cm in order to prevent cable from
dropping as Figure 3-6 below. While installing SCU-SCU-MUL Cable, pay special
attention not to touch crank throw of crankshaft while engine operates.
< Fig. 3-5 Clamping SCU-SCU-MUL Cable >

34
< Fig. 3-6 SCU- SCU-MUL Cable installation between cylinders with cable clamps >
When connecting SCU-SCU-MUL cables between cylinders, clamp the SCU-

SCU-MUL cables with cable clamps within 1 meter and use locking washers.

35
3.3.2 Engine Outside
st
In the Engine Outside parts, 1 SCU is connected to SAU through Junction Box as Figure 3-
7 below. Refer to the wiring diagram for B-WACS for wiring connections in Junction Box.
< Fig. 3-7 A Cable from SCU is connected to ECR through Junction Box>
The detailed information about Engine Outside Connection is as follows
3.3.2 Engine Outside Connection
1) Connecting SCU to Junction Box
① How to Install Cable Gland
② How to connect SCU to Junction Box
2) Connecting Junction Box to SAU
① How to connect Junction Box to SAU
② How to fix Junction Box to SAU

36
1) Connecting SCU to Junction Box
① How to install Cable Gland
In order to connect SCU with Junction Box, a hole for cable gland hole is needed.
Cable gland is provided as standard products. Cable gland should be installed on
st
bedplate wall of engine foreside. Through cable gland, 1 SCU-SCU-MUL cable in
cylinder 1 is connected with SCU-JB-MUL cable.
< Fig. 3-8 Installing cable gland on bedplate wall >
② How to connect SCU to Junction Box

SCU is connected to Junction Box with SCU-JB-MULL Cable through cable gland
fixing on cable trays. But if there is no cable tray on the engine plate, use L or U
bracket as Figure 3-8 above in order to fix the cable. The details of connecting SCU-
JB-MUL Cable are as below.
< Fig. 3-9 Terminal Block connection of SCU to Junction Box >

37
2) Connecting Junction Box to SAU
① How to connect Junction Box to SAU
In order to connect cable from Junction Box to SAU, use JB-SAU-Power cable(2.0㎟
x 2) and JB-SAU-RS485 cable(0.75㎟ x 2 twist pair). When connecting Junction Box,
use the end of cable with pin type terminal. The method to connect Junction Box with
SAU is as Figure 3-9 below. Note that JB-SAU-POWER cable and JB-SAU-RS485
cable are option items and not provided with B-WACS.
< Fig. 3-10 Terminal connection diagram of Junction Box and SAU>

38
② How to Fix JB-SAU-POWER Cable
Tie JB-SAU-POWER cable to the tray tightly with cable ties as Figure 3-11 below.
< Fig. 3-11 Fixing JB-SAU-POWER cable with cable ties on cable tray >
3.3.3 Engine Control Room

Engine Control Room Part shows how to connect SAU, DMU, Power Supply and UPS in the
engine control room.
The connections of Engine Control Room Cable are as below.
1) SAU and DMU connection
2) SAU and UPS connection
3.3.3 Engine Control Room Connection 3) SAU and AMS connection
4) DMU and UPS connection
5) Power Supply connection

39
< Fig. 3-12 SAU Electrical Installation >
1) SAU and DMU connection

Connect tightly C1 port of SAU and COM1 port of DMU with SAU-DMU-COM cable in
order to connect SAU and DMU(Panel PC). Cable wirings are should be done by wiring
diagram.
2) SAU and UPS connection

UPS is a backup power supply for SAU and DMU in case of unexpected situations
such as a power failure. C3 port of SAU is connected to UPS with UPS-SAU-POW
Cable.
3) SAU and AMS connection

The cable for connecting SAU to AMS is not supplied with B-WACS, and signal output
terminals such as system fail, alarm, and slowdown should be connected with 0.75㎟ x
6 Cable. The cable is tied with pin type terminal through cable gland.

40
4) DMU and UPS connection
DMU should be normally operated in case of the sudden shut down of power supply for
a while. Power ports of DMU are connected to UPS with UPS-DMC-POW cable.
5) Power Supply connection

As the power source of DMU and SAU are 24VDC, Power Supply provides DMU and
SAU with 24VDC through UPS. At the time, PS-UPS-POW cable is used in order to
connect Power Supply to UPS. Refer to Figure 3-13 below for detailed information.
< Fig. 3-13 SAU wiring to UPS, Power Supply and DMU >

41
3.4 Electrical Drawings

42
4. Commissioning
4.1 Overview
This chapter describes how to do RPM Compensation based on the engine speed after
installing B-WACS and confirmation of system status. In addition, the sensor readjustment
procedure shall be described for sensor replacement and checking.
4. Commissioning
4.1 Overview
4.2 System Checking 4.2.1 Preparation
4.3 Sensor Readjustment 4.2.2 Visual Inspection
4.2.3 Power Supply Checking

4.4 RPM Compensation
4.2.4 System Checking

43
4.2 Commissioning Procedure
4.2.1 Preparation
1) B-WACS Units
- SCU, SAU, DMU, Power Supply, and UPS Installation
2) B-WACS Cables
- SCU-SCU-MUL Cable, SCU-JB-MUL Cable, SAU-DMU-COM Cable, UPS-SAU-POW
Cable, UPS-DMU-POW Cable, POWER SUPPLY Cable, PS-UPS-POW Cable
4.2.2 Visual Inspection
< Table 4.1 Visual Inspection Sheet >
Inspection Item Execution of Inspection
- Cover should be closed after installing

SCU, SAU
- No defect and damage on appearance is allowed
- No defect and damage shall be allowed
- Cable label shall be attached

All Cables
*SCU-JB-MUL Cable and JB-SAU-POWER cable shall be
connected with pressure connection terminal
- Confirm if connector in low part of SCU is tightly fixed

SCU-SCU-MUL Cable
- Fix cable on the bedplate wall with clamp
- Connect to the outside engine with cable gland
- Fix cables on the outside wall with tie using L(U) bracket
SCU-JB-MUL Cable
- Confirm if the end of cable is finished with pin type terminal
- Confirm if it is connected to the designated JB terminal
JB-SAU RS485 Cable - Confirm if communication cable 0.75㎟ * 2 is used
JB-SAU POWER Cable - Confirm if power supply cable 2.0㎟ * 2 is used
*Supplied by Ship Maker - Confirm if the end of cable is finished with pin type terminal
- Confirm if SAU J5(HMI) Port and DMU(Panel PC) COM1 Port are
SAU-DMU-COM Cable connected
- Tightly fix cable with cable tie and cable duct
- Connect to system fail, alarm, slowdown signal output terminal

SAU-AMS Cable
of SAU with communication cable 0.75㎟ * 6
* Supplied by Ship Maker
- Confirm if the end of cable is finished with pin type terminal

44
4.2.3 Power Supply Checking
1) Preparation
① Tool: Multi-meter tester
② All units (SCU, SAU, DMU, UPS, Power Supply) turn off
2) Power supply test procedure
The power of B-WACS units should be turned on in order:
UPS  Power Supply  SAU  DMU  SCU
In case output voltage is more than 250V or less than 200V, stop the power supply
test and contact the service engineer.
< Table 4.2 Power Supply Inspection Sheet >
Main Power Input Measured Main Power should be in OK / Checked by

1
Check the range 200 ~ 240 VAC NG Multi-meter
Power Supply Measured Power Supply Output OK / Checked by

2
Output Check should be in the range 28 ~ 30 VDC NG Multi-meter
UPS Input Measured UPS Input should be in the OK / Checked by

3
Check range 28 ~ 30 VDC NG Multi-meter
UPS Output Measured UPS Output should be in the OK / Checked by

4
Check range 28 ~ 30 VDC NG Multi-meter
DMU Power Measured DMU Power Input should be OK / Checked by

5
Input Check in the range 28 ~ 30 VDC NG Multi-meter
Switch on the SW1 in SAU and check

SAU Booting OK / Visual
6 LED status. LED should be flicked
Test NG inspection
up/down
SCU Input Measured SCU Power Input should be OK / Checked by

7
Power Check in the range 26 ~ 30 VDC NG Multi-meter

45
4.2.4 Function checking
Turn on the DMU power, and then select Diagnosis menu in DMU software. Record the
input value on B-WACS Initial Test Sheet after inputting the data of engine information &
Alarm limit line.
Operate Diagnosis menu by executing B-WACS monitoring system. After confirming if all
sensors in SAU, SCU, and inside SCU are active on screen, record the result on B-
WACS Initial Test Sheet.
< Table 4-3 Function Check Sheet >
1 Select B-WACS Chk. Click the B-WACS in Main screen OK / NG
2 Select O-WACS Chk. Click the O-WACS in Main screen OK / NG
Engine Status Chk. Confirm that Engine Status is activated

3 OK / NG Depend on engine status
In B-WACS as “Running”
System Link Chk. Confirm that System Link is activated

4 OK / NG “Dislinked” is system Error
in B-WACS as “linked”

OK / NG
is finished
RPM Compensation Confirm that “Step 2” Completion

5 OK / NG Do “RPM Compensation”
Chk. is finished

OK / NG
is finished
Click the “Upload RCV” and Confirm

The file, “RoughCalData.txt”, in the
6 Upload RCV Chk. OK / NG
Directory “C:\B-WACS\SetupData”
is updated

46
4.3 RPM Compensation
4.3.1 Execution Procedure

1) System Installation and Check
Refer to Mechanical Installation Part and Electrical Installation Part for system
installation, and execute according to the system checking items of Manual 4.2.4.
2) Engine Driving and B-WACS Power Application
For RPM calibration, engine shall turn 1,000 times in stable speed (RPM) of 3 types
without stopping.
Accordingly, recommend that it shall be done during engine trial operation at factory or
on sea. In the event it is installed on ship in operation first, certain speed should be kept
during service intentionally. The speed range of 3 types shall be as below
<Table 4.4 RPM Calibration Speed Section and Range >
Speed Section Speed Range Reference
Step 1 20-50% of nominal speed Dead Slow
Step 2 50-80% of nominal speed Half
Step 3 80-100% of nominal speed Navigation Full

47
3) Manual Calibration
< Fig. 4-1 RPM Compensation Screen of B-WACS Monitoring Program>
Manual calibration shall be executed by obtaining 1,000 data 1 times in each section.
User starts manual calibration by clicking start button on below menu at the relevant
speed.
When clicking “start button” for step1, the below warning message appears. User
shall operate it after fully understanding the detail.
The completion time of step 1 shall be automatically calculated by the system, and
completion check box on the right shall be checked after step 1 operation,
When the engine speed is not kept due to unexpected problems while executing
each step, Click “stop button” and then complete calibration preparation. In such a
situation, re-calibration work is possible with “start button”
When each step calibration is completed, “Start Button” and “Stop Button” become
inactive. When re-work for the completed step is needed, click “Again Button”, then it
becomes initialized.

48
<Fig. 4-2 Output message of calibration work completion>
Manual calibration shall be completed by executing step 2 & 3 in the same method.
Precise calibration shall be automatically executed after manual calibration is
finished.
4) Automatic Calibration
After manual calibration is completed, the calibration is automatically done by B-
WACS. The result shall be shown on the log file of system.

49
4.4 Sensor Replacement
1) Confirm if proximity sensor & SCU-SCU-MUL Cable contact Guide shoe and
Crank throw when Guide shoe comes to the location of BDC by engine turning.
2) Confirm if the nut and bolt of proximity sensor are tightly assembled
3) Confirm if SCU-SCU-MUL Cable is correctly connected to external terminal of
SCU.
4) Turn the turning gear by 720 degrees.
5) Select manual setting menu of maintenance item after execute B-WACS Monitoring
Program on DMU of ECR, and then check the status of sensors.
< Fig. 4-3 Sensor Replacement Screen >
Warning appears when IPS sensor is over 4.0mm or less than 3.0mm. In the case, readjust
the relevant sensor‟s Shim, and turn turning gear by 720 degrees. When there is no problem
with clearance in DMU, record clearance & temperature of each sensor on B-WACS Initial
Test Sheet.

50
4.5 Manual Setting
1) To log-in „Manual Setting‟, administrator privileges should be needed (Initial PS: 6670).
Administrator can set „B-WACS Main Parameter‟, „Firing Order‟, „Relay Test‟ and see
the sensor raw data. But It highly recommended to contact Doosan Engine service
engineer in case of changing main parameter.
2) Refer to the B-WACS Program Manual for more detail information.
< Fig. 4-4 Manual Setting Screen >
- Copyright -
The copyright of this manual belongs to Doosan Engine Co.,Ltd. The O-WACS system which is
provided together with this manual shall not be used for other purpose without a consent of

51
BLANK
Doosan B-WACS
DMU Software Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
This manual has to be read carefully and used in compliance with usage procedures
and safety regulations before installing all units of B-WACS. Doosan Engine owes
the copyright of this manual. Please don’t use B-WACS and the manual for other
purposes.
DOC. No. B-WACS-S001 June 2010

1
CONTENT
1. Introduction
1.1 DMU Software Overview ------------------------------------------------------------------------------- 3
1.2 DMU Software Manual Introduction ----------------------------------------------------------------------
3
2. Screen Layout
2.1 DMU Software Screen Composition ---------------------------------------------------------------------
4
2.2 Status Window -------------------------------------------------------------------------------------------------
5
2.3 Menu Introduction ------------------------------------------------------------------------------------------6
2.4 Toolbar & Screen Window ----------------------------------------------------------------------------------
6
3. Software Composition
3.1 Monitoring -----------------------------------------------------------------------------------------------------
7
3.1.1 Real-Time Wear ---------------------------------------------------------------------------------------
7
3.1.2 Wear Trend ---------------------------------------------------------------------------------------------
8
3.1.3 Report ---------------------------------------------------------------------------------------------------
10
3.2 Alarm ----------------------------------------------------------------------------------------------------------11
3.2.1 Alarm List ----------------------------------------------------------------------------------------- 11
3.2.2 Event List ----------------------------------------------------------------------------------------- 12
3.3 System -------------------------------------------------------------------------------------------------------14
3.3.1 Diagnosis ---------------------------------------------------------------------------------------3.3.2
14
3.3.2 Configuration ------------------------------------------------------------------------------------ 15
3.4 Maintenance ----------------------------------------------------------------------------------------------------
18
3.4.1 RPM Compensation ---------------------------------------------------------------------------------
18
3.4.2 Sensor Replacement --------------------------------------------------------------------------------
20
3.4.3 Manual Setting -------------------------------------------------------------------------------------21
4. Software Setting
4.1 Commissioning Check Sheet ------------------------------------------------------------------------------
24
4.2 RPM Compensation Procedure --------------------------------------------------------------------------
25
4.3 Sensor Replacement Procedure ----------------------------------------------------------------------31

2
1. Introduction
1.1 DMU Software Overview
DMU Software is a B-WACS monitoring software, which shows measured bearing wear data
such as wear values and sensor deviation values of all cylinders in real time. It has already
been set up at DMU (Data Monitoring Unit) by the manufacturer, so this software doesn’t have
to be installed in DMU. DMU, a component of B-WACS, provides a touch screen for handling
DMU Software. When DMU is turned on, this software automatically starts without additional
settings.
Before starting DMU Software, confirm the communication line between DMU and
SAU(Signal Capture Unit). Alarm Limit, Min/Max RPM, and Firing Order are fixed at
the installation of B-WACS, but DMU Software can correctly measure the bearing
wear after completing RPM compensation.
1.2 DMU Software Manual Introduction
This manual is supplied together with B-WACS and is largely composed of 4 chapters. The first
chapter, Introduction sector briefly introduces total composition of the manual. In chapter 2, this
gives a screen layout and details of all screens. There are functions and components of every
menu in chapter 3. The last chapter, Software Setting describes commissioning procedures and
its operation procedures after installing B-WACS and DMU Software.
CONTENT
1. Introduction
2. Screen Layout
4. Software Setting
< Fig 1-1 Main contents of DMU Software manual >
Please contact Doosan Engine if there is any trouble or problems with the software
installed at DMU or RPM Compensation procedures of B-WACS.

3
2. Screen Layout
2.1 DMU Software Screen Composition
User-friendly interface of DMU Software is made in order to monitor the combined physical wear
of the crosshead bearings, crankpin bearings and main bearings. Status Window at the top of all
menus as Figure 2-1 below shows three status of B-WACS System such as a condition of the
three major bearings, an operating status of engine, and a connection status of system. Main
Menus including Sub Menus are located at the right of the screens in order for users to easily
select Menus. Screen Window and Tool Bar are changed according to the menu which is
selected by users. To quit DMU Software or change other programs, click ‘Quit’ Button
( ).
When the program starts, Real-Time Wear screen of Monitoring menu is a default screen
displaying wear values of bearings with bar graphs and related tool bars like RPM,
temperatures & wear values of all sensors.
Status Window Quit Button
Main Menus
Sub Menus
Screen Window
Tool Bar
Current Time
< Fig. 2-1 DMU Software Layout >

4
2.2 Status Window
Status Window shows a wear status of bearings, an operating status of engine, and a
connection status of system when DMU Software is in operation as Figure 2-2 below. It is
always displayed at the top of the screen regardless of menus.
Wear status of bearings Connection status of system

(Normal, Alarm, Slowndown) (Linked, Dislinked)
Operating status of engine Ending of DMU

(Running, Stop) Software
< Fig. 2-2 Composition of Status Window >
1) Bearing Status
If some problems occur in bearings, Bearing Status shows the status of bearings with
Alarm and Slowdown as its color and text. Especially if Alarm and Slowdown happen,
additional pop-up window will come on at the same time as below Figure 2-3. Refer to
Table 1 - Alarm IDs & Descriptions on the page 14 about alarm information.
- Normal ( ): Normal status of not detecting any wear beyond the warning limits
- Alarm ( ): Alarm status above Alarm limits
- Slowdown ( ): Slowdown status above Slowdown limits
< Fig. 2-3 Alarm & Slowdown Windows >

5
2) Operating status
- Running ( ): it shows an engine is running
- Stop ( ): it shows an engine stops
3) System status
- Linked ( ): Monitoring Program is connected with SAU of B-WACS
- Dislinked ( ): Monitoring Program is not connected with SAU of B-WACS
2.3 Menu Introduction
The menus consist of 4 main menus and 10 sub menus at DMU Software as below Figure 2-4.
Monitoring menu give the information of bearing wear status. And Alarm menu shows all events
including alarms and event. Communications of B-WACS can be checked and engine
information can be entered at the System menu. There are several functions such as RPM
compensation, Sensor replacement, and Manual setting at the Maintenance menu.
< Fig. 2-4 Menu composition of B-WACS Monitoring Program >
2.4 Tool Bar & Screen Window
Tool Bar and Screen Window are automatically changed by the menu. Its parameters can be
entered with a touch pad.

6
3.1 Monitoring
3.1.1 Real-Time Wear

As Real-Time Wear is a default screen of DMU Software, the users intuitively knows wear status
of bearings with bar graphs. There is a unit of wear[mm] at the left side of the screen and
cylinder numbers at the top side of the screen. The ‘F’ character means fore side and ‘A’ does
after side of an engine. The number of cylinders on this screen is automatically changed if
entering cylinder numbers on the ‘Total Cyl. No.’ of Manual Setting screen. Either Wear Value
mode or Wear Deviation mode in Real-Time Wear can be selected.
Show the number of cylinders and the

position of sensors (Fore/After)
Display wear values with bar graphs
Wear Mode (Value/ Deviation)
Output of rpm Output of Selection

wear value & temp. of Cyl.
< Fig. 3-1 Real-Time Wear >
Please complete RPM compensation in order to check the exact results because
we are not sure that wear data are perfect before RPM compensation.

7
In order to get correct wear values of all cylinders, users have to input exact parameters and
complete RPM compensation. Wear values are shown as bar graphs whose colors are green,
yellow, and red. And the colors of bar graphs are the same colors of Bearing Status of Status
Window.
- Normal ( ): It shows a normal status with a green bar

- Alarm ( ): It shows an alarm status with a yellow bar
- Slowdown( ): It shows a slowdown status with a red bar
1) Wear Value
Wear Value mode displays filtered wear values from sensors of all cylinders in real time.
Filtered values mean that a simple filter was applied as indicated below in order to minimize
the influence of noise and established as a moving average which updates every time a new
sensor value.
New Filtered = old Filtered * (1 - 0.05) + new Value * 0.05
2) Wear Deviation
Wear Deviation mode shows Deviation Value of each sensor. Sensor Deviation is defined as
the difference between the individual sensor and the average of the others sensor signal.
For example, the deviation of sensor no. 5 engine with a 5 cylinder engine is as below.
D5 = w5 - (w1 + w2 + w3 + w4 + w6 + w7 + w8+ w9 +w10)/9
3.1.2 Wear Trend
Wear Trend shows wear trends for a certain period of time. In this mode, the time scale can be
changed by clicking the buttons ( , ) and the scale of wear value [mm], temperature [°C],
and RPM on the y-axis can be also changed by clicking buttons ( , ). The graph can be
enabled or disabled by selection the sensor button.
 : Decrease the distance of time on the x-axis (Maximum: 50 sec.)

 : Increase the distance of time on the x-axis (Maximum: 10 min.)
 : Automatically adjust scale of y axis
 : Increase the range on the y axis
 : Decrease the range on the y axis

8
Cylinder Selection
Wear Value Axis
RPM & Temp. Axis
Display Mode
X/Y Axis Range Adjustment Choice of all sensors
< Fig. 3-2 Wear Trend >
1) Real Time
In this mode, it shows wear values of all cylinders in real time for the time scale which is
between 50 seconds to 10 minutes. It is possible to select sensors which users want to show
in the graph by using sensor enable button ( ). For example RPM is shown as a bold
green line and the temperature of cylinder no. 1 as a bold red line. Lines on the screen are
shown against the sun as time passes.
2) Long Term
This mode shows average of filtered wear values at the interval of 6 hours. It is possible to
set the start time and the end time by using the Pop-Up window as Figure 3-3 below which
gets activated

9
< Fig. 3-3 Time Setting Screen in Long Term mode >
3.1.3 Report
Save Button
< Fig. 3-4 Report >
The information such as engine info, log, filtered value trend, and current status on this screen
can be saved by selecting SAVE Button. If items which need to be saved are selected and then
SAVE Button is pushed, selected items will be automatically filed as the format of
Report_[current date].xml in Root folder of D drive(USB). In order to select all items, check a
check box of All Items. If Report files need to be generated for a certain period of time, the start
time and the end time should be entered. The message box as Figure 3-4 above will be shown
after finishing saving files.

10
In order to print the report, Print button is used. If the Print button is clicked, pop up window for
selecting of print drive is showed. After selecting print drive, click OK button. For printing the
report, the installation of print drive should had been finished
Pop-up window
For printing
Print Button

11
3.2 Alarm
All events including alarms are recorded automatically in order to show the event list of the B-
WACS system on this screen. Items of the list can be scrolled by pushing the buttons
( ). The detailed information is offered by the maker according to the selected item.
The articles on the list are as below.
 No.: Alarm generation order

 ID: Identification number of Alarm
 Date: Alarm generation date and time
 Cyl.: Cylinder number of generating an alarm
 Pos.: Sensor position (Fore or After)
 Status: bearing state (Normal, Warning, Alarm, Slowdown)
 Check: Whether the alarm is checked or not
3.2.1 Alarm List

Alarm list contains all alarms such as Warning, Alarm, and Slowdown happening at B-WACS.
The item of the list can be shifted by clicking Selection Button ( or ).
< Fig. 3-5 Alarm List >

12
3.2.2 Event List
Event List Window displays all Events including Alarm and Slowdown in numerical order as
below Figure 3-6. Refer to Table 1 on the next page for ID and related descriptions. The more
detailed information for event, for example, is shown as below Figure 3-7.
< Fig. 3-6 Event List >
< Fig. 3-7 Description of Event List >

13
<Table 1 Alarm IDs & Descriptions >
ID Name Description
1 SENSOR VALUE ALARM Alarm is set because sensor Value exceeded the Alarm Limit
2 SENSOR VALUE ALARM RELEASE Alarm is released because Sensor Value is normal
3 SENSOR VALUE SLOWDOWN Slowdown is set because sensor Value exceeded the Slowdown Limit
4 SENSOR VALUE SLOWDOWN RELEASE Slowdown is released because sensor Value is normal
5 SENSOR VALUE WARNING Warning is set because sensor Value exceeded the Warning Limit
6 SENSOR VALUE WARNING RELEASE Warning is released because sensor Value is normal
7 SENSOR DEVIATION ALARM Alarm is set because sensor deviation value exceeded the Alarm Limit
8 SENSOR DEVIATION ALARM RELEASE Alarm is released because sensor deviation value is normal
9 SENSOR DEVIATION SLOWDOWN Slowdown is set because sensor deviation value exceeded the Slowdown Limit
10 SENSOR DEVIATION SLOWDOWN RELEASE Slowdown is release because Sensor deviation value is normal
11 CYLINDER DEVIATION ALARM Alarm is set because cylinder deviation value exceeded the Slowdown Limit
12 CYLINDER DEVIATION ALARM RELEASE Alarm is released because cylinder deviation value is normal
13 RPM COMPENSATION ERROR During fine RPM compensation
14 RESERVED RESERVED
15 SYSTEM COMMUNICATION ERROR Communication time out between SCU and SAU
20 ROUGH RPM COMPENSATION START Rough RPM Compensation is stated
21 ROUGH RPM COMPENSATION END Rough RPM Compensation is ended
22 FINE RPM COMPENSATION START FINE RPM Compensation is started
23 FINE RPM COMPENSATION END FINE RPM Compensation is ended
24 CHANGE ALARM LIMIT Change of Alarm Limit : Filtered Sensor Value (Fine)
25 CHANGE ALARM LIMIT Change of Alarm Limit : Sensor Deviation (Fine)
26 CHANGE ALARM LIMIT Change of Alarm Limit : Cylinder Deviation (Fine)
27 CHANGE SLOWDOWN LIMIT Change of Slowdown Limit : Filtered Sensor Value (Fine)
28 CHANGE SLOWDOWN LIMIT Change of Slowdown Limit : Sensor Deviation (Fine)
29 CHANGE WARNING LIMIT Change of Warning Limit
30 CHANGE ALARM LIMIT Change of Alarm Limit : Filtered Sensor Value (Rough)
31 CHANGE ALARM LIMIT Change of Alarm Limit : Sensor Deviation (Rough)
32 CHANGE ALARM LIMIT Change of Alarm Limit : Cylinder Deviation (Rough)
33 CHANGE SLOWDOWN LIMIT Change of Slowdown Limit : Filtered Sensor Value (Rough)
34 CHANGE SLOWDOWN LIMIT Change of Slowdown Limit : Sensor Deviation (Rough)

14
3.3 System
3.3.1 Diagnosis
At this screen, operation status of SCU is shown as below Figure 3-8. The condition of the unit
are classified into two categories such as Normal and Error.
 Normal: Normal status without errors

 Error: Non-operational status that the unit is not working or needs to be repaired or replaced
< Fig. 3-8 Normal Status of SCUs>
If an error occurs in SCU, it is marked with red-outline and error message is showed as below
Figure 3-9.

15
< Fig. 3-9 Error Status of SCU >
3.3.2 Configuration
Configuration screen is consisted of two columns such as Engine information and Alarm limits.
The values of these items can be changed with the virtual keyboard which is automatically
shown by clicking the input data. Engine information and alarm limits be set at the manufacturer,
refer to the Table 2 below. Don’t change the Alarm Limit without permission of authority.
< Table 2 Alarm & Slowdown Limits >
Description Wear Value
Alarm limit, filtered sensor value ±0.5 mm

Alarm limit, sensor deviation ±0.4 mm
Alarm limit. cylinder deviation ±0.3 mm
Slow down limit, filtered sensor value ±0.7 mm
Slow down limit, sensor deviation ±0.5 mm

16
How to change these data through a virtual keyboard is following as below. First, please select
and click the item which needs to be entered, and a virtual keyboard can be shown as below
Figure 3-10. Finally, enter new data through this keyboard and click INPUT Button.
< Fig. 3-10 Configuration & Screen Keyboard >
After inputting new value of each item on this screen, the value can be saved by clicking
‘DMUSAU’ Button of Tool Bar. At this time, if there is any data which was saved before, a
pop-up window as Figure 3-11 will be shown in order to inform users that only current data are
saved and at the same time old ones are deleted.
Any change of alarm limits by anyone but administrators or authorized representatives

from Doosan Engine is strictly prohibited in order to directly influence the alarm
standards of B-WACS.

17
< Fig. 3-11 Download in Configuration >
All limits of B-WACS have complied with guidelines established by MAN. DMU  SAU
Button ( ) sends the data such as Engine information and alarm limit to SAU. On
the contrary, SAU  DMU Button ( ) receives the data such as Engine information
and alarm limit from SAU.
- SAU  DMU ( ) Button: From Engine information in SAU Memory to DMU

- DMU  SAU ( ) Button: From Engine information in DMU to SAU Memory

18
3.4 Maintenance
3.4.1 RPM Compensation
Three steps of RPM Compensation have to be completed in order for B-WACS to be working
properly. RPM Compensation can be carried out only while an engine is operating. If en engine
stops, it is not possible for operators to compensate B-WACS because buttons for RPM
Compensation become disabled. Each step has to be performed at the same RPM as Figure 3-
12 below and last for more than 10 minutes.
Process Bar of RPM Compensation
< Fig. 3-12 RPM Compensation >
Check that main parameters, the number of cylinders, and min/max RPM are
correctly entered before starting RPM Compensation.

19
When pushing Start Button, the pop-up window is shown. This Warning window notices that
RPM compensation will take about 10 minutes at the 20 ~ 50% of normal speed in the first step
of RPM Compensation as Figure 3-13 below.
< Fig. 3-13 Warning Window >

When the RPM compensation is completed, all progress-bars of each step are filled up and
then RPM values are written and checkboxes of Completion are checked below Figure 3-14.
< Fig. 3-14 PRM Compensation Completion >

During the compensation, Process Bar displays what it has achieved so far. Three steps of RPM
Compensation have to be carried out in correct order (Step 1  Step 2  Step3), Start the first
step of RPM compensation at Dead Slow RPM, the second one at Half RPM, and the last one
at Navigation Full RPM.

20
3.4.2 Sensor Replacement
When any SCU of B-WACS is not working properly, it should be implemented with Sensor
Replacement of Maintenance in DMU Software after sensor is replaced in SCU. At this time,
administrator privileges should be needed in order to log in. Please comply with the installation
manual of B-WACS and sensor replacement procedures on page 33. Once SCU is replaced,
select the changed SCU and push Replace Button as Figure 3-15 below. After completing
Sensor Replacement, a pop-up window will be shown in order to inform the users about the
completion of Sensor Replacement and users should check whether the event list contains this
replacement or not. Please note that RPM Compensation don’t need to be done if Sensor
Replacement had been done.
The procedures of SCU replacement have to be followed by service engineers of

Doosan Engine according to the installation manual of B-WACS. Please note that
users are completely responsible for accidents happening while users replace SCU at
their disposal.
Selection of failed SCU

Compensation 진행바
Completion of SCU Replacement

Compensation 진행바
< Fig. 3-15 Sensor Replacement >

21
3.4.3 Manual Setting
< Fig 3-16 Manual Setting >
In order to log in on this screen, administrator privileges should be needed. All items of Manual
Setting are fixed at the installation of B-WACS, and so only administrators can change these
parameters if need be.
1) Main Parameter
- Total Cyl. No: the total number of cylinders applying B-WACS
- Max. RPM: Set the value more than MCR
- Min. RPM: Set the value less than Minimum RPM
2) Firing Order
When user selects the Total Cyl. No. in B-WACS Main Parameter, the numbers of firing
order are automatically activated. The number at the left side of Firing Order such as 1, 2,
3, … ,14 means a cylinder number on the basis of the engine’s fore side.
Please refer to Engine Specification or contact Doosan Engine for changing of main
parameters and firing orders.

22
3) Relay Test
Check the relay signal between B-WACS and AMS (Alarm Monitoring System) by using
On/Off Button. When ‘On’ button is clicked, Lamp turn on and relay is activated as below
Figure 3-17.
< Fig 3-17 Relay Test >
4) Sensor Data
- The screen showing communication data of sensors which are components of SCU.
Sensor Data window shows the SAU Date, Sensor Value and Temperature value each
cylinder.
5) Other items
- Sensor Trig: Upload sensor values measured from SCU to SAU
- Sensor Upload: Upload sensor values measured from SAU to DMU
- SAU Time Set: Synchronize DMU software time based on window O/S time
- Up Run Time: Save the Engine running time from DMU into SAU

23
6) Tool bar
- Update: Update main parameters and firing orders which were entered by users. When
the Update have done, Notice message window is shown up
- Factory Reset: Reset all current items and related memory of SAU to zero and during
factory reset mode, the progress bar is show the Factory Reset
Progress below Figure 3-18.
< Fig 3-18 Factory Reset >
- Upload RCV: Upload values after the completion of Rough Calibration. After completed,
Notice window show up
- System Version: It shows the current version of B-WACS monitoring software

24
4. Software Setting
4.1. Commissioning Check Sheet
< Table 3 Commissioning Check Sheet>
Item No. Task Method Result Note
Main Power Measured Main Power should be in Checked by

1 OK / NG
Input Chk. the range 200 ~ 240 VAC Multi-meter
Power Supply Measured Power Supply Output should Checked by
2 OK / NG
Output Chk. be in the range 24 ~ 30 VDC Multi-meter
Measured UPS Input should be in the range Checked by
3 UPS Input Chk. OK / NG
24 ~ 30 VDC Multi-meter
Measured UPS Output should be in the Checked by
Power 4 UPS Output Chk. OK / NG
range 24 ~ 30 VDC Multi-meter
DMU Power Measured DMU Power Input should be Checked by
5 OK / NG
Input Chk. in the range 24 ~ 30 VDC Multi-meter
SAU Booting Switch on the SW1 in SAU and check LED
6 OK / NG
Test status. LED should be flicked up/down
SCU Input Measured SCU Power Input should be Checked by
7 OK / NG
Power Chk. in the range 24 ~ 30 VDC Multi-meter
Upload Min RPM Data and check the value Checked by
8 Min RPM Chk OK / NG
(ex. Min RPM : 25) Engine Spec.
Upload Min RPM Data and check the value Checked by
9 Max RPM Chk. OK / NG
Internal (ex. Min RPM : 100) Engine Spec.
Para-
Upload Firing Order Data and check Checked by
meters 10 Firing Order Chk. OK / NG
the value (ex. Firing Order: 1-5-3-4-2-6) Engine Spec.
Upload Alarm Limit Data and check Checked by

11 Alarm Limit Chk. OK / NG
the value Engine Spec.
Click 1st “Start” button and wait about 10
1st RPM
12 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
is correctly Uploaded, the task is OK
Click 2nd “Start” button and wait about 10
2nd RPM
RPM 13 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
Comp- is correctly Uploaded, the task is OK
ensation Click 3rd “Start” button and wait about 10
3rd RPM
14 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
is correctly Uploaded, the task is OK
After finishing RPM Compensation, Wear
15 Wear Value Chk. OK / NG
value should be in the range +/- 0.25mm
System Fail Click “System Fail Alarm” set button.
16 OK / NG
Alarm Chk. If the AMS alarm is set, the task is OK
Refer to
Bearing Wear Click “Alarm” set button.
Alarm 17 OK / NG Installation
Alarm Chk. If the AMS alarm is set, the task is OK
Manual
Bearing Wear Click “Slowdown” set button.
18 OK / NG
Slowdown Chk. If the AMS alarm is set, the task is OK

25
4.2. RPM Compensation Procedure
DMU Software should be used after RPM Compensation in compliance with procedures of RPM
Compensation as Figure 4-1 below, if DMU Software needs to be used after installing B-WACS.
Start
① Factory Reset Initialize input data
② Input Main Parameter Refer to Engine Spec.
③ Input Firing Order Refer to Engine Spec.
Manual Setting ④ Update Parameters Save and check input parameters
Engine Turning Rotate the engine over two times
⑤ Check Sensor Data Check transfer of Sensor Data
⑥ Restart System Restart of S/W program
⑦ Input Engine Info Refer to Engine Spec.

Configuration
⑧ Download/Upload Save/check of Engine Info & Limits
⑨ Compensation RPM . Fix the screen

1. Check „Engine Running‟
RPM ※ Compensation RPM Range
2. Click „Start‟ button
Compensation 3. Check Process Bar st
Step 1 : Dead Slow RPM
4. Finish Compensation
nd
at Step1 Step 2 : Half RPM
5. Repeat Compensation rd
at Step 2 & Step3 Step 3 : Navigation Full RPM
Alarm ⑩ Check Event List Check the result of Compensation
End
< Fig 4-1 RPM Compensation Procedures of B-WACS >

26
1) Factory Reset
2) Update main parameters and firing orders

27
3) Engine turning, check sensor data, and restart B-WACS monitoring software
4) Input engine information and upload

28
5) Complete RPM Compensation
① Please check that Engine status is Running on State Window of DMU Software. If en
engine stops, it is not possible for operators to RPM compensate because buttons for
RPM Compensation become disabled.
① Check Running
② Chick Start
Button
② When pushing Start Button, the pop-up window is showed which means it begins to get
data for over 10 minutes under the same speed as the picture below.

29
③ During the compensation, Process Bar displays what it has achieved so far. It takes over
10 minutes to compensate RPM every step.
③ Check Process Bar
Any change of screens during RPM Compensation is strictly prohibited. If the screen is
changed, it has to go back to this screen before completing the step of RPM
Compensation, or DMU Software have to be initialized by clicking Factory Reset
Button on Manual Setting screen and then RPM Compensation is completed again.
④ If RPM Compensation is completed, RPM will be showed and a check box of Completion
will be checked automatically.
⑤ After completing the first step of RPM Compensation, finish the other two steps as the
same way.

30
④ Check RPM & Completion
„Step
⑤⑤ 2‟ 및 „Step
Complete 2 &실행
Step 3‟ Step 3
6) Check the result of Compensation on the event list
⑩
⑫

31
4.3 Sensor Replacement Procedure
Sensor Replacement Procedures of B-WACS are following Figure 4-2 below in numerical order.
Please refer to Installation Manual of B-WACS for SCU replacement before completing Sensor
Replacement.
Start
① SAU/SCU Power OFF . Dip Switch Setting of new SCU is

same to that of Defective SCU
(Refer to Figure 4-3 & Table 4)
② Remove Defective SCU
. There are powers of SCU & SAU in
SCU
SAU (Refer to Figure 4-4)
Replacement ③ Install new SCU
. Fasten fixing bolts loosely in order
to move sensors up and down while
④ Adjust Shim adjusting a shim
※ Please refer to Installation Manual
⑤ SCU/SAU Power ON for detailed information
Engine Turning Rotate the engine over two times
Manual Setting ⑥ Check Sensor Data Screen Check transfer of updated Data
Sensor ⑦ Sensor Replacement
Replacement Select SCU & Click Replace Button

⑧ Click Replace Button
Alarm ⑨ Check Event List Check the result of Compensation
End
< Fig. 4-2 Sensor Replacement Procedure >

32
< Fig. 4-3 SCU Dip Switch >
SCU Power Switch SAU Power Switch
< Fig. 4-4 SAU >

33
< Table 4 Dip Switch Binary Code in SCU >
SCU No. Dip Switch Setting SCU Binary Number Code Remark
1 0-0-0-0-1-0
2 0-0-0-1-0-0
3 0-0-0-1-1-0
4 0-0-1-0-0-0
5 0-0-1-0-1-0
6 0-0-1-1-0-0
The last of Dip
Switches means
the terminating
7 0-0-1-1-1-0 resistance.
Please note that

8 0-1-0-0-0-0 the terminating
resistance of the
last SCU has to be
„ON‟
9 0-1-0-0-1-0
10 0-1-0-1-0-0
11 0-1-0-1-1-0
12 0-1-1-0-0-0
13 0-1-1-0-1-0
14 0-1-1-1-0-0

34

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Doosan B-WACS

Doosan Engine Co.,Ltd.

DOC. No. B-WACS-G001 June 2010

If there are some troubles when „Getting Start‟ procedure is

Without the completion of RPM Compensation, B-WACS can‟t

DOC. No. B-WACS-G001 June 2010

The front side of DMU The back side of DMU

DOC. No. B-WACS-G001 June 2010

3. Check whether ‘Engine Status’ is ‘Running’ and ‘System’ is

DOC. No. B-WACS-G001 June 2010

4-1 Click „Maintenance‟ and Run main engine as specified RPM

■ 1st RPM Compensation: Dead Slow RPM

DOC. No. B-WACS-G001 June 2010

DOC. No. B-WACS-G001 June 2010

4-5. If RPM compensation is finished, RPM value be displayed

DOC. No. B-WACS-G001 June 2010

4-7. Check the completion of ‘RPM Compensation’ from ‘Step

DOC. No. B-WACS-G001 June 2010

DOC. No. B-WACS-G001 June 2010

No. Task Method Result Note

1 DMU Power Chk. Turn on DMU and check the power OK / NG

2 Select B-WACS Chk. Click the B-WACS in Main screen OK / NG

When engine is running, confirm If Engine Status displays

Confirm that “Step 1” Completion

Confirm that “Step 3” Completion

To confirm the „Upload

* Trouble shooting is described in the B-WACS Technical Manual

DOC. No. B-WACS-G001 June 2010

Doosan Engine Co.,Ltd.

DOC. No. B-WACS-T001 June 2010

5. Trouble Shooting ------------------------------------------------------------------------------------------ 17

DOC. No. B-WACS-T001 June 2010

1.1 Introduction of B-WACS

< Fig. 1-1 Principle of B-WACS >

B-WACS has three kinds of main components, SCU(Signal Capture Unit),

DOC. No. B-WACS-T001 June 2010

1.2 Introduction of Manual

B-WACS manual shall be composed as below

A. Technical Manual (DOC. No. B-WACS-T001)

B. Installation Manual (DOC. No. B-WACS-I001)

C. Program Manual (DOC. No. B-WACS-P001)

DOC. No. B-WACS-T001 June 2010

2.1 System Configuration Diagram

< Fig. 2-1 B-WACS Configuration Diagram >

DOC. No. B-WACS-T001 June 2010

▣ SCU (Signal Capture Unit)

2.1.1 SCU(Signal Capture Unit)

< Fig. 2-2 SCU >

DOC. No. B-WACS-T001 June 2010

DOC. No. B-WACS-T001 June 2010

2.1.2 SAU(Signal Analysis Unit)

< Fig. 2-3 SAU >

DOC. No. B-WACS-T001 June 2010

< Fig. 2-4 DMU >

DOC. No. B-WACS-T001 June 2010

< Fig. 2-5 UPS >

DOC. No. B-WACS-T001 June 2010

< Fig. 2-6 Power Supply >

DOC. No. B-WACS-T001 June 2010

< Fig. 2-7 B-WACS System Connection Diagram >

DOC. No. B-WACS-T001 June 2010

Program operators are classified into two different levels as below.

< Fig. 2-8 B-WACS Monitoring Program Layout >

DOC. No. B-WACS-T001 June 2010