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MAN B&W

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Installation and Assembly Ident No.: 0743606-1


Mounting and Installation of Electrical Equipment

This document is valid for existing engine Production Specification


types on order as of the date of this docu-
ment: 0743606-1.5

Engine types: September 2015


All two-stroke engine types
Info No: 393826

Structure No: 21-0002

Replaces: 0743196-1
0743363-8
0788967-5
0790468-7

Scope and Field of Application


This MAN B&W Production Specification de-
scribes a uniform mounting procedure for ca-
bleways and cables, cable connections, cable
protection and ground connections on MAN
B&W engine types.

The following workmanship standard must be


followed in order to provide and maintain high-
quality electric cable/wiring installations.

Document history
Date Designer  Checked AC Revision change Revision
2009-09-10 PCM TON 0
2013-07-10 JYA PYB Z3 Text added in section 11 3
2013-10-10 JYA PYB Z3 Note added p.19, pictures added 4
2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany MAN Diesel & Turbo
Registered with the Danish Commerce and Companies Agency under CVR-no. 31611792 (referred to as “MAN Diesel & Turbo”). Teglholmsgade 41, 2450 Copenhagen SV, Denmark
This document is the property of MAN Diesel & Turbo and is to be treated as confidential by the party to whom it has been submitted by Phone +45 33 85 11 00
MAN Diesel & Turbo, and may not be disclosed to any third party without the specific prior written permission of MAN Diesel & Turbo. E-mail mandieselturbo-cph@mandieselturbo.com
This document may be a translation of an original English language document. In case of any discrepancy between the original Web www.mandieselturbo.com
English language document and this translation, it is always the original English language document which shall prevail.
The original English language document may have been replaced by a later version, in which case only such later version shall be valid.
Production Specification 0743606-1.5

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Contents Changes in this revision:


1. References �����������������������������������������������������������������������������3
2. Acceptance criteria�����������������������������������������������������������������3
3. General specification for workmanship standard�����������������3
4. Mounting specification�����������������������������������������������������������4
5. Mounting of cableways (cable trays)�������������������������������������5
6. Cable specification�����������������������������������������������������������������9
7. Cabling �����������������������������������������������������������������������������������9 Section 7 is revised.
8. Screening ����������������������������������������������������������������������������� 14 Section 8 is revised.
9. Tagging��������������������������������������������������������������������������������� 15 Section 9 is revised.
10. Cabinets and junction boxes ����������������������������������������������� 16 Section 10 is revised.
11. Cable glands������������������������������������������������������������������������� 17 Section 11 is new.
12. Installation of electrical equipment (instrumentation)���������20
13. Connections/connectors �����������������������������������������������������22 Section 13 is revised.
14. Protection of electronic equipment�������������������������������������23
15. Installation of frequency converter �������������������������������������23 Section 15 is new.
15.1. Safety Precautions 23
15.2. Connections and installation 24
15.3. Torque 25
16. Tools �������������������������������������������������������������������������������������26
17. Acceptable and not acceptable pictures�����������������������������28
Section 16 is revised.

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

Page 3 of 40

1. References
MAN B&W Production Specification:
No. 0743131-4; Protection of Electronic Equipment.
No. 0743097-8; Zones for Welding and Drilling in Frame box and Bedplate.

MAN Standards:
EN 700AA - Cables, multicore, twisted pair.
EN 700AB - Cables, multicore, twisted pair with individual screen.
EN 700AC - Cables, multicore.
EN 700AE - Cables, multicore.
EN 700AF - Cables, multicore, data.
EN 700AG - Cables, multicore, with certificate.
EN 710AA - Cable Tray, perforated.
EN 710AB - Cable Tray, mech.
EN 710AC - Cable Tray, strap-plate.
EN 710AD - Cable Tray, mech.
EN 710BC - Cable Conduit.
EN 720AA - Cable ties, stainless steel.

International standards:
IEC 60533 - Electrical and electronics installations in ships - Electromagnetic compatibility.
IEC 60092-350 - Electrical installations in ships – Part 350: General construction and test methods
of power, control and instrumentation cables for shipboard and offshore applications

2. Acceptance criteria
All electrical work, cables and instrumentation on engines built by MAN Diesel & Turbo licensees
must be in accordance with MAN Diesel & Turbo drawings and standards but, in certain cases,
some local standards may be applied. All electronic control systems are provided or accepted by
MAN Diesel & Turbo.

3. General specification for workmanship standard


Each electrical fitter is responsible for the work he is doing and must be trained/educated accord-
ingly.

The engine builder is responsible of delivering the information concerning correct installation of
electrical equipment to the shipyard.

The control system is a computerised system. Therefore, considerations to cabling and wiring
must also be made.

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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All boxes for electronic equipment must be closed when work inside the boxes is not in progress.

Measures for preventing electrostatic discharge (ESD) must be taken when handling and working
with electronics. Electrostatic discharge can damage equipment and impair electrical circuitry. It
occurs when electronic components are improperly handled and can result in complete or inter-
mittent failures.

Cables can be grouped in different interference classes to Electro Magnetic Interference (EMC)
and sensitivity. Cables in different classes are to be laid separately and the distance between the
different classes is to be maximised.

Redundant cable systems are to be mounted in such a way that the two systems are separated.

Cables often act as large effective antennas, carrying common mode currents to the apparatus.
These currents may cause interference not only at the input and output circuits directly connected
to the leads, but also at circuits deeper inside the apparatus.

4. Mounting specification
Electronic hardware, such as MPC-units (Multi Purpose Controller units), tacho amplifier, etc., must
be mounted in the specified cabinets on all MAN B&W engines.

Instrumentation must be as specified according to the drawings for the actual plant concerned.

Cable trays, guards, band steel, supports and cable ties are to be made of the quality according
to the drawings for the actual plant concerned and general MAN Diesel & Turbo specifications.

Positions of the junction boxes are to be arranged according to the drawings and diagrams and
with consideration to the dispatch pattern for the actual plant concerned.

Electrical equipment must be placed in such a way that, as far as practicable, it is not exposed to
the risk of mechanical damage.

Apparatus must be unaffected by vibrations and shocks likely to occur during normal service.
Bolts and nuts securing current-carrying parts must be effectively locked so that they cannot work
loose by vibration.

Electrical equipment must be installed away from locations where flammable gases or vapours
are liable to accumulate, except where the installation of equipment for explosive gas atmosphere
is provided.

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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Electrical equipment must be selected and located so that it is unaffected by water, steam, oil,
and oil fumes to which it is likely to be exposed.

Cable trays are to be fixed to the engine or to ship structure.

5. Mounting of cableways (cable trays)


Cableways must comply with the quality specified in the drawings and be mounted in accordance
with the drawings and diagrams for the actual plant concerned.

The cable trays are to be suitable for use on both sides, i.e. without burrs and sharp edges on
both sides.

The dimensions of the cable trays/wire baskets and supports are to be according, or similar, to
the drawings and diagrams for the actual plant concerned.

Cable trays are to be mounted on cableway brackets fixed to the engine or ship structure on
welded-on brackets. The brackets must be fully welded to the engine structure (see figure 1) be-
fore heat treatment. If welded-on brackets are missing, threaded holes can be drilled on engine
structure for fastening to the engine with bolts (see figure 2) according to specified drawings.

Important! No drilling or welding is allowed in strengthening elements. See Production Recom-


mendation no. 0743097-8.

Figure 1: Welded-on brackets. Figure 2: Bracket bolted to engine.

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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Figure 3: Mounting wire basket on control Figure 4: Wire basket mounted on engine.
panel.

Wire baskets (see figure 3 and 4) can be used where suitable. They are highly recommend-able
because dirt does not build up easily. Wire baskets are to be mounted on cableway brackets that
are fixed to the engine or ship structure on already welded-on brackets. This should be fully welded
to the engine components (see figure 3) before heat treatment. If welded-on brackets are missing,
thread holes can be drilled and cut on engine components to facilitate bolted fastening brackets
for cableways (see figure 5).

Important! No drilling or welding in strengthening elements is allowed.

Figure 5: Extended wire basket. Wire basket mounted on cableway bracket.

Wire baskets can be extended to achieve sufficient length, (Figure 5).

The dimension of the wire baskets and supports must be according or similar to the drawings and
diagrams for the actual plant concerned.

Date Designer  Checked AC Revision change Revision


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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

Page 7 of 40

When mounted near hot/warm surfaces, distance pieces must be added between the hot/warm
surface and the cable tray, so as to avoid heating up and damaging of the cables.

Figure 6: Avoid sharp edge at cable tray Figure 7: Avoid edge on cable tray end.
ends.
In some positions it may be suitable to use “Drawn Arc Stud-Welding” and clamps for fastening
the cable trays to the engine component. The Drawn Arc Stud-Welding method requires particu-
lar techniques and welding equipment.

The cable tray ends should be bent to avoid sharp ends (see figure 6).

Sharp edges are unacceptable where cables enter a cable-tray. If cables enter the cable tray from
the side, deforming of the cable tray can be necessary (see figure 7).

The distance between cable trays, carrying cables for differential signal, should be as large as
possible and vertical or horizontal direction.

In critical sections, cables can be led through special cableways (cable protecting pipe, see figure
8) to protect them against mechanical damage. But, in general, MAN Diesel & Turbo does not
recommend the use of pipes as cable trays, in particular when there is more than one cable, as
dirt tends to build up in the pipes, eventually damaging the cables.

Where ordinary steel pipes are used as cable trays, the steel pipes are to be drained to avoid ac-
cumulation of oil/fuel inside and the ends to be soft coated to avoid cutting the cables.
MAN B&W Standards for cable trays:
ƒƒ EN710AA - Cable tray, perforated
ƒƒ EN710AB - Cable tray, mech
ƒƒ EN710AD - Cable tray, strap plate

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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2 1 3
Soft lining

Steel pipe
Electrial cable

Figure 8: Cable protecting pipe Protecting pipe with cable support

Flat iron bar to level switch Flat iron bar to pilot valve

Cable trays and cables on HCU (Hydraulic


Cylinder Unit)

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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6. Cable specification
Cables on all MAN Diesel & Turbo engines must be of the quality specified in MAN B&W specifica-
tions or accepted as alternatives in an LOD.
All cables must be shielded according to the wiring diagram.
ME ECS network cables must be of make and type specified by MAN Diesel & Turbo.

7. Cabling
Cables are to be routed in accordance with the dispatch pattern of the specific engine.
Cables are to be mounted according to the drawings and diagrams for the actual plant concerned.
Care should be taken to prevent damage to insulation or distortion of the cable during installation.

Note! Cable producer’s specifications must always be taken into consideration.

All redundant cable systems (tacho and network e.g.) must be mounted separately with a minimum
distance of 1.5 metre. If the minimum distance cannot be obtained, mechanical protection of at
least one of the two redundant cables must be applied. Once the cables reach the frame on which
the controller cabinets are mounted, the cables may be routed together.

The Control Panel, cables and wires are to be installed as straight and short as possible to the
connection points. For redundant systems one of the systems must be lead into the Control Panel
from the top position and the other must be lead into the Control Panel from the bottom position.
Both systems can be lead into the Control Panel from one end (same end) or from each end of the
Control Panel depending on what is the most suitable draw way (only for ME/ME-C/ME-B engine
types).

All cables must by mounted on cable trays/wire basket, see section 6 “Mounting of cableways
(cable trays)”, which are fixed to the engine or the ship structure. Cable trays support and protect
the cables. If the distance from the cable tray to the transmitter is more than 200 mm, and there
is no space for a cable tray, then an oil resistant cable shackle must be used (see figures).

Figure 9: Cable support.

Cable trays/Wire baskets must support the cables, which are NOT to be hanging in cable ties in
horizontal position. Only steel wire ties are to be used in wire baskets for strapping the cables.

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

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All cables must be screened, according to MAN B&W specifications, to avoid electromagnetic
interference. See MAN Standard EN700.

Signal and low-voltage power supply cables (up to 24VDC) can be bundled together with ME-ECS
cables provided that they are category 2 cables according to IEC60533.
Cables from other categories (e.g. 220VAC and 440VAC power) may NOT be bundled together
ME-ECS cables.

Single cables or bundles of cables of different categories which run parallel with ME-ECS cables
for distances exceeding 1 m should be installed with an intermediate free space of minimum 10
cm between ME-ECS cables and these cables of other categories.
Where it is impossible to meet the separation requirements, cables with high shielding effective-
ness in accordance with IEC60092-350 should be used, or cable bundles should be laid in metallic
conduits. These conduits should have a minimum thickness of 1 mm if not otherwise specified.
For 440VAC cables to large consumers (pumps, blowers etc.), cables with high screening efficiency
are not considered sufficient. For these cable runs, physical separation or metallic barriers must
be applied.

Special measures should be taken if power to and from frequency converters are routed in close
proximity of ME-ECS cables. These cables are potentially extremely disturbing to their surround-
ings, and to reduce emissions they must be screened and the separation distance to ME-ECS
cables increased. Separation distances of app. 50 cm should be used. Other precautions in ac-
cordance with IEC60533 Annex C may be required, and effective screening must be proved by
function tests with all systems running.
Frequency converter makers instructions must be followed, both with respect to choice of cables
and installation method, and proper, low impedance screen termination must be ensured in both
ends of all cables to and from the drive.

Where ME-ECS cables pass cables from other cable categories, the pass must be orthogonal to
minimise electromagnetic interference.

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Production Specification 0743606-1.5

Page 11 of 40

Cable runs should be as straight and accessible as possible. Secure easy access for inspection
(see figure 10). Max. two (2) layers of cables.

Figure 10: Cable laid straight. Figure 11: Flame retarding cable straps.

The cables are to be efficiently strapped to the trays, without being damaged, individually or bun-
dled with suitable flame retarding cable straps (Figure 11). It is also possible to use soft coated
(heat and chemist resistance) steel straps to avoid cutting into the cables due to vibration, see
MAN Standard EN720AA Cable ties, stainless steel.

In the top section area, cables can be protected against mechanical damage during engine instal-
lation and overhaul by means of sectional iron or flexible plastic tubing. When applying flexible
tubing, an appropriate set of accessories must be applied to avoid cable damage at entry and
exit of the tube.

Metallic flexible tubing may not be applied because of the sharp edges on the inside.
Flexible tubing should only be applied on vertical cable runs to avoid build-up of oil inside the tube.

When a cable runs through a metallic wall of an apparatus enclosure or a cabinet, it should be
mounted with an appropriate cable gland (see figure 20 and 21).

When a cable runs through a hole in a wall or a floor great care must be taken to avoid sharp
edges, which can cause damage to the cable (see figure 13). Lead capping is not to be used
anywhere in the cable installation. A rubber lip may be mounted on the hole edge to protect the
cable during installation.

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Production Specification 0743606-1.5

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Cables parallel in shared cable straps.

XX

Maximum spacing between cable straps,


determined according to cable diameter
XX ≤ 200 where cable diameter ≤ 20 mm
XX ≤ 400 where cable diameter ≤ 20 mm

Figure 12: Cable jacket protected by rubber Figure 13: Spacing between cable straps.
lip on hole edge.
Spacing between cable ties (Figure 14) is to be max. 200 mm for cables with a diameter up to 20
mm, and max. 400 mm for cables with a diameter greater than 20 mm.

T
Bending radius

D (Cable diameter)

r ≥ x cable diameter, for armoured cable

Figure 14: Cable bending radius.

To avoid damaging the cable, the minimum bending radius for each type of cable is determined
as shown in figure 15. The minimum bending radius depends on whether the cable is armoured
or not. Armoured cables should not be bent to a radius less than eight times the overall cable
diameter. Unarmoured cables must not be bent to a radius of less than six times the overall cable
diameter, see specifications for each type of cable.

Note! Always check cable specifications.

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Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment
Production Specification 0743606-1.5

Page 13 of 40

Figure 15: Sensor installation with Figure 16: Excess cable correctly fixed to tray.
no pigtails.

Cable ends from cable tray to sensor should be laid in suitable length. Hanging pigtails are not al-
lowed anywhere on the engine. If the cable cannot be cut to the correct length, any excess cable
must be fixed to a cable tray by means of at least 3 evenly distributed cable ties, and the coil must
have an acceptable bending radius (see figure 17).

Figure 17: Stripping and ferrule crimping using the correct tools.

All cable ends are to be fitted with a suitable cable ferrule. Use double ferrule if fitting of two wires
in the same terminal is necessary. Always use proper tools for stripping the wires, and proper
crimping tools for the ferrules. Never use ordinary pliers to fit a ferrule (see figure 18).

Note! Soldering is not accepted on cable ends.

All unused cables ends are to be secured in both ends by termination or insulation.

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Production Specification 0743606-1.5

Page 14 of 40

8. Screening
The primary goal of grounding is to ensure personal safety and protection of installations against
damage. Two phenomena, lightning and power system faults, can cause circulation of large cur-
rents, which might create hazardous voltage in installation structures.

Note! These two phenomena are external to installations and the ground is the only path for
currents to return to the sources.

The secondary goal of the grounding system is to serve as a common voltage reference and con-
tribute to the mitigation of disturbances in installations with sensitive and interconnected electronic
and electrical systems.

All cables for the engine automation must be shielded according to the wiring diagram. All signal
carrying cables from junction boxes must be shielded, including DC power supply cables.

To avoid electromagnetic interference, the shield has to be connected to ground in both ends. The
ground connection is to be as short as possible and with a maximum ground area to obtain a low
impedance connection to ground, preferably using circumferential grounding. Cable shields must
be grounded by means of EMC cable glands or similar low impedance grounding arrangements
that are installed in the junction boxes. In the switchboard or alarm system panel placed in the
control room the cable screen can be connected to ground bus bar or the chassis using screen
clamps or cable ties.
The shield may NOT be connected to ground using a pigtail.

Figure 18: Wrong screen termination using pigtails.

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Production Specification 0743606-1.5

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Yard cables often consist of an inner screen and an outer steel wire braiding. In case of a connec-
tion with this type of cable, the inner screen must be connected in the cable gland or the chassis
for EMC protection, and the outer steel wire braiding must be connected to the frame for personal
safety.

Removing insulation from cables must be done with care to prevent damage to the cable cores.
In critical sections, cables are to be protected against heat and/or mechanical damage armoured
hoses or heat shields may be required for this purpose.

Lock nuts on cable glands must have proper electrical contact with a metal surface. All ground-
ing points must be clean, free from paint and oxides or other insulating layers. A serrated washer
must be used when connected. Corrosion protection spray or paste is applied at each contact
point before final assembly.

All protection wires (earth wire) must be correctly grounded.

9. Tagging
Each cable must be marked in both ends with suitable cable marking labels according to the
electrical documentation (see figure 19).

Figure 19: Cable marking labels.

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Production Specification 0743606-1.5

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10. Cabinets and junction boxes


Junction boxes are to be as specified or similar quality / design (see figure 20) as specified in
MAN Diesel specifications or accepted on LOD. Junction boxes must be of adequate mechani-
cal strength and rigidity in order to not to be affected by distortions and vibrations of the engine
constructions, or by any other damage likely to occur.

Figure 20: Junction box.

The position of the junction boxes is to be arranged according to the relevant drawings and dia-
grams and with consideration to the dispatch pattern for the actual plant concerned.

Adequate conditions for maintenance and inspection of junction boxes must be ensure.

Locking of bolts and nuts carrying junction boxes is recommended.

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Production Specification 0743606-1.5

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11. Cable glands


Cables to junction boxes are to be fitted with an EMC type cable gland. It is vital that the cable
screen is fitted correctly in the gland (see figure 21).

For network and power cables, the screen is to be led into the box and also terminated in the cable
gland with the contact spring. Heat shrink tubing must be fitted over the screen (see figure 22).

General guidelines for cabling work in junction boxes:


ƒƒ Distance from the terminal block to the junction box inner wall must be minimum 60 mm,
at least 3 sides. If the terminal row is divided into sections, and wires are led between the
sections, the distance between the sections must be minimum 60 mm.
ƒƒ Maximum distance for unsupported cable must not exceed 40 mm. However from cable
gland to next support a distance of 60 mm is allowed.
ƒƒ Cables must be supported internally in the junction boxes by a rubber coated support bar.
ƒƒ Cables must be tied to the support bar every 30 mm
ƒƒ Spare cores must be tied to the support bar in the same way as used cores – and insulated
or terminated.
ƒƒ If support bars are omitted, the cable cores must be bundled and tied together with cable
ties every 30 mm. Furthermore the bundle must be arranged in a way that it under no cir-
cumstances can touch any of the internal parts of the box or the box it self under normal
engine running.
ƒƒ Individual cores must be cut to correct length; excessive core length is not accepted
ƒƒ Cables and individual cores minimum bending radius must be observed
ƒƒ Unused holes and cable glands in all junction boxes and gland plates must be plugged to
prevent dirt from entering junction boxes and cabinets. General cleanliness is to be main-
tained at all times.
ƒƒ To ensure that the applied cable ties will not break pre-maturely due to the environment,
cable ties material should be “Heat Stabilized Nylon 6.6” or similar, and the maker should
have marine approvals for the cable ties.

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Production Specification 0743606-1.5

Page 18 of 40

Screen
Heat shrink tubing

Body
Screen Screen

Grommet
Screen Cable gland
skintorp
Cable gland
Lock nut MS-SC16
HSK-M-EMV
Cable Cable

Figure 21: Screen fitted correctly in gland. Figure 22: Screen fitted with heat
shrink tubing.

SUPPORT BAR

TERMINAL BLOCK
30 mm

CABLE TIE

CABLE GLAND

Figure 23: Junctions box design with correct installed support bar and sufficient space for
correct cable support and ties.

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All cabinets, junction boxes and enclosures must have permanently installed markings/signs made
from an oil- and heat-resistant material as brass or aluminium.

Rubber dampers between junction boxes and supporting structure are not recommended. The
quality of the junction box, the installation in the junction box and the parts used in the assembly
does not demand such a device. If rubber dampers are requested from third part (owner), ground-
ing between junction boxes and supporting structure must be installed.

Standard wire ferrules (insulated):


ƒƒ Ferrules are used to ensure a reliable electrical connection, when terminating conductors in
terminal blocks. Fraying and breaking of wire strands is prevented, and the possibility of an
unreliable connection is minimized. Insulated ferrules prevent conductor breakage due to
bending, wire stress or vibration, while facilitating wire insertions into a terminal block clamp.
Ferrules are thin-walled copper tubes, which are mechanically crimped onto the ends of
stranded wires. They are the preferred alternative to twisting wire strands or tinning the wire
end before terminating into a terminal block.
ƒƒ The terminal block is made for mounting only one ferrule in each terminal. Please note that
ferrule length must be in accordance with terminal block maker requirements.

Figure 24: Twin and single ferrules.

Twin wire ferrules:


ƒƒ Twin wire ferrules are used, when two wires have to be terminated in the same terminal.
ƒƒ There is space enough for two wires & two wire covers in this ferrule, which make the wire
connection similar to an unbroken loop.

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Production Specification 0743606-1.5

Page 20 of 40

12. Installation of electrical equipment (instrumentation)


Instrumentation to be as specified according to the MAN B&W drawings for the actual plant con-
cerned.

All panels to be installed as specified according to the drawings for the actual plant concerned or
in accordance with agreement between the owner/shipyard and MAN Diesel & Turbo.

Before installing electronics in enclosures, all machining of the enclosure must be completed; no
drilling, welding, filing or sanding must be carried out in the enclosures after installation of the
electronics due to the risk of contamination with metallic particles. The inside of the enclosures
must be cleaned for residues after machining before installing the electronics.

Before starting work with electrical equipment the electrician must ensure that the chassis is
electrically connected to ground. If no wrist strap is available, the electrician must ground himself
by touching the metal part of the chassis.

Figure 25: Correctly wired.

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Figure 26: Correctly installed cable end. Figure 27: Incorrectly installed (core over
sharp edge.

When installing electronics where screen termination is done on a toothed ground bar, the cable
screen must be folded back over the cable jacket. Approximately 3 cm of the screen is folded back,
and a 2-4 cm piece of heat shrink tubing is fitted over the screen ends, leaving approximately 2
cm of the screen ready for termination.
The cable end is then strapped to the most appropriate tooth by means of 2 cable ties.

Figure 28: Tacho Amplifier cabling - no excessive wires!

Note! After finishing cabling in a cabinet it is important that the interior of the cabinet is vacu-
umed for small pieces of metal and cable residue to avoid short circuits in the electron-
ics.

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Production Specification 0743606-1.5

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13. Connections/connectors
Cable connections to instruments/equipment must be as specified in the MAN Diesel drawings
for the actual plant concerned.

Note! For network and power cables, the screen is to be led into the box and terminated in the
cable gland with the contact spring. The screen must extend to approximately 2 - 3 cm
from the cable end. Shrink tubing must fitted over the screen as specified in the Instruc-
tion.

Screws and nuts securing current-carrying parts must be effectively locked so that they cannot
work loose by vibration.

Connectors at the ends of the cables are an integral part of the various circuits; a poor connector
spoils an otherwise good cable.

All connectors are to be marked with name and number.


Screw terminals are to be tightened with a special torque wrench to 0.5-0.6 Nm (2.5 mm2 termi-
nals), so that they cannot work loose by vibration. Larger screw terminals require higher torques
(refer to manufacturers documentation). All screws in wire terminals must be correctly tightened,
also in un-used terminals.

Figure 29: Wire supports in cabinet.

Wires to be fastened to the supports already mounted in the junction/connection boxes. The wire
support is to prevent the wire from hanging from the connectors on the electronics (see figure 28).

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Production Specification 0743606-1.5

Page 23 of 40

14. Protection of electronic equipment


Protection of the electronic equipment as specified in MAN B&W Production Specification No
0743131-4; Protection of Electronic Equipment.

All electrical equipment must be handled properly and with precaution to prevent electrostatic
discharge (ESD) damaging. ESD can damage equipment and impair electrical circuitry and result
in complete or intermittent failure.

If no ESD-preventive wrist strap is available, personnel must be grounded by touching the metallic
part of the chassis.

Cables and electronic devices must be protected against mechanical damage during assembly
and normal overhaul of engine.

15. Installation of frequency converter

15.1. Safety Precautions


The voltage of the frequency converter and motor is dangerous whenever connected to mains.
Incorrect installation of the motor or frequency converter may cause death, serious personal injury
or damage to the equipment. Consequently, the instructions in this specification, as well as national
and local rules and safety regulations, must be complied with.

Safety Regulations:
1. The mains supply to the frequency converter must be disconnected whenever repair work
is carried out. Check that the mains supply has been disconnected and that the necessary
time has elapsed. Lock the mains breaker with a padlock. Make sure that other voltage
inputs have been disconnected, such as external 24 V DC.
2. [Off] button on the frequency does not disconnect the mains supply and consequently it
must not be used as a safety switch.
3. The equipment must be properly earthed, the user must be protected against supply voltage
and the motor must be protected against overload in accordance with applicable national
and local regulations.

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Production Specification 0743606-1.5

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Before doing service on the frequency converter wait at least the amount of time indicated below:

Table 1: Time indication - unless otherwise are specifeid by the VFD maker.

Voltage Power Waiting Time

90 - 200 kW 20 minutes
380 – 500 V
250 - 800 kW 40 minutes
55 - 315 kW (frame size D) 20 minutes
525 - 690V
355 - 1200 kW 30 minutes

15.2. Connections and installation


Use only braided screened motor cables and braided screened control cables. The screen mate-
rial must be metal, not limited to but typically copper, aluminium or steel. There are no special
requirements for the mains cable.

Connect the screen at both ends for motor cables as well as for control cables.
Avoid terminating the screen with twisted ends (pigtails). It increases the high frequency imped-
ance of the screen, which reduces its effectiveness at high frequencies. Use EMC cable glands
on motor and clamps on frequency converter.

EMC gland
Motor terminal box
EMC cable clamp
Power input
Motor output

Figure 30: VFD installation. Figure 31: Motor installation.

The VFD drive will provide short circuit protection for the motor cable. The VFD are connected to
IT-Grid, it means that built-in RFI-filters must be disconnected. The mains cable must be short
circuit protected by means of fuses or circuit breaker.

Please note that leakage current may occur in frequency converter installation. To make the instal-
lation properly, check frequency maker and local rules.

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15.3. Torque
When tightening electrical connections, it is important to tighten with the correct torque. Torque
that is too low or too high results in a bad electrical connection. Use a torque wrench to ensure
correct torque. See manufactures data sheet for information about the correct torque.

Nm/in-lbs

Figure 32: Always use a torque wrench to tighten the bolts.

Table 2: Recommended torque for terminals, unless otherwise are specified by the maker.

Torque Bolt size

19-40 Nm M10
(168-354 in-lbs)
8.5-20.5 Nm M8
(75/181 in-lbs)

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16. Tools
To effectively tighten and cut standard, light-heavy and heavy cross section Pan-Steel® type
MLT ties, type MLTC/MLTFC coated ties, and type MLTDH double wrapped ties, special tools are
recommended:

Figure 33: Panduit GS4MT Figure 34: Phoenix Contact Unifox-CT M7,9

It can be difficult to see the difference between original and copy strips, but the double arrows
point out where to look.

The risk with copy-strips:


ƒƒ Copy strips might be pulled back a little after cutting and locking, thereby allowing the small
ball to run over the cut edge.
ƒƒ Bigger change for sharp ends.

The cause of this can be:


ƒƒ The ball is too small, the sloping cavity is too long, or the line cut is too close to the ball
catcher.
ƒƒ Cutting injuries.

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Production Specification 0743606-1.5

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Original with insulation. Original with insulation. Original without Insulation.

The pictures below, is all copy strips with insulation

The ball is
behind the catch.
The cut edge/line
would be there.

Heat shrink tubing tools and accessories are needed to ensure good workmanship.

Heat resistance

Heat Tubing Heater Drain wire Heater set Heat Gun. Heat Gun
Shrink. with Heat Type: Type:
Tubing Shrink PHG 500-2 SKILL 8003AA

Crimping tools:
ƒƒ The tools for the two types are the same, simply multiply by two times the square mm of
the wire thickness when choosing tool size “or closest to”.
ƒƒ Two times 1.5 = 3 square mm. However, the tool will give you the choice between 2.5 and
4 square mm. Then use size 2.5.

This range of tools


must not be used l for
ferrules in spring
loaded terminal blocks
ONLY for use with
screw terminal type.

This type crimping tool must Do not use this type of crimping tool
be used for ferrules in spring for ferrules in spring loaded terminal blocks
loaded terminal blocks ONLY for use with screw terminal type.

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Production Specification 0743606-1.5

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17. Acceptable and not acceptable pictures


Acceptable NOT Acceptable

Nice and smooth - Acceptable Sharp edges and lead wrapping not acceptable

Nice and smooth - Acceptable Cables bend over sharp edge - Not acceptable

Nice and smooth - Acceptable No installation of pipes for cabling as it is dificult


to make an inspect, and pipes will be filled with
moist

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Thrust bearing sensor cable - The only places to Thrust bearing sensor cable - May not be
use a pipe pressed or fixed in this way

Cable sagely arranged in cable trays - No cable fitting in gangway area


Acceptable

Acceptable protection - Cable easy to inspect Do not use this protection - Cable difficult to
inspect and sharp edges inside

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Cableway with distance and in few layers Poor support - Many layers - No distance

Use cable tray as near as possible Cables have to be fixed to aviod heavy weight
in plug

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Main starting valve correct installation Main starting valve - No pigtial or airborne cable

Starting air dist. valve correct installation Starting air dist. valve - No pigtail or airborne
cable

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

HPS - Correct installation HPS - Cable plug to be turned down 90º.


Cable pigtails must be avoided - Cable trays
are missing

Cables shielded from bursts from relief valves - Cable and terminal boxes have to be protected
Acceptable against fire and explosion from relief valve

Cables must enter from bottom of junction box No cable entry from top of junction box allowed.
- Acceptable Cables too short causing too small bending
radius at gland.

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Cables put into terminal boxes - Acceptable Cables arranged with different lengths and
bends close to gland - Not Acceptable

Wire fixed correctly to bar Wires not supported or strapped, resulting in big
risk of short circuits and insulation faults -
Not Acceptable

Gland mounting - Acceptable Gland mounting - Not acceptable

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2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Excessive wire length, incorrect screen


termination for yard cables - Not Acceptable

Wires & cables cut to length, strapped to Excessive wire length, unused wires not correct-
supports and wires to each connector strapped ly terminated or insulated - Not Acceptable
together

Missing wiring strapping - Not Acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

LOP internal wiring nicely strapped to supports Wiring unprotected and subjected to wear at
and wiring protected against wear at corner - the corner - Not Acceptable
Acceptable

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2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Wires strapped to supports and protected Wiring touching inside of junction box -
where relevant - Acceptable Not Acceptable

Excessive wire length, wires touching the inside


of junction box, incorrect screen termination for
yard cable - Not Acceptable

Excessive wire length, wires touching inside of


junction box, unused cable glands not sealed -
Not Acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Excessive wire length, wires touching inside of


junction box, wring screen termination, unsealed
cable glands - Not Acceptable

Correct screen termination, wires protected Excessive wire length, wires touching inside of
against wear – Acceptable junction box, insufficient strapping, unsealed
cable glands - Not Acceptable

Excessive wire length, wires touching inside of


junction box - Not Acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Wires subjected to wear by DIN rail -


Not Acceptable

Wires cut to length, strapped to support bars


and protected against wear - Acceptable

Excessive wire length, no support, wires


subjedted to wear by DIN rail - Not Acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

Tailbox short wires, bundled with cable ties and Tailbox excessive wire length - No cable ties -
arranged with no contact with box - Acceptable Wires touching box - Not acceptable

Tailbox short wires, bundled with cable ties and Tailbox excessive wire length - No cable ties -
arranged with no contact with box - Acceptable Wires touching box - Not acceptable

Tailbox excessive wire length - No cable ties -


Wires touching box - Not acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

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Production Specification 0743606-1.5

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Acceptable NOT Acceptable

TSA cabling short wires, neatly bundled with Excessive wire length, wires touching inside of
cable ties - Acceptable box - Not Acceptable

Wires cut to length and strapped - Acceptable Excessive wire length, wires touching inside of
box, illegal cable protection tubing applied -
Not Acceptable

TSA cabling with excessive wire length -


No Acceptable

Date Designer  Checked AC Revision change Revision


2015-09-16 LKOL JYA Z3 Section 11 and 15 are new 5

Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743606-1 Mounting and Installation of Electrical Equipment