Man D2868 LE433, D2862 LE453, D2862 LE433, D2862 LE423, D2862 LE463 Operating Instructions Manual

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Operating Instructions

MAN Marine Diesel Engines

D2868 LE433 D2862 LE433/453 D2862 LE423/443/463

51.99493-8578 “Translation of the original operating instructions”

Information and Copyright

Subject to technical alterations in the interests of further development.

Reprinting, copying or translating of these instructions, even in part, is forbidden without written permission from MAN. All legal copyrights remain the exclusive property of MAN.

Tel.: +49 911 / 420-1745 Fax: +49 911 / 420-1930

E-Mail: engines.components@de.man-mn.com Internet: www.man-engines.com

Editorial: EMDGG, Technical status: 07.2010

51.99493-8578

Information and Copyright 2.................................................................

Contents 3................................................................................

Preface 4.................................................................................

Instructions 5..............................................................................

Declaration 6..............................................................................

Nameplates 7.............................................................................

Safety regulations 8........................................................................

Commissioning and operation 14..............................................................

Engine views V8-1200 (D2868 LE433) 14...................................................

Engine views V12-1800 (D2862 LE433) / V12-1650 (D2862 LE453) 16..........................

Engine views V12-1550 (D2862 LE423) / V12-1400 (D2862 LE443) / D2862 LE463) 18............

First commissioning 20....................................................................

Commissioning 22........................................................................

Starting 23..............................................................................

Operation monitoring system 24............................................................

Shutting down 98.........................................................................

Page

Maintenance and care 99....................................................................

Lubrication system 99.....................................................................

Fuel system 104..........................................................................

Cooling system 108........................................................................

Alternator 115.............................................................................

Temporary decommissioning of engines 115..................................................

Technical data 116...........................................................................

Troubleshooting table 128.....................................................................

Index 130...................................................................................

Preface

Dear Customer,

these Operating Instructions are intended to familiarize you with your new MAN Diesel engine and how it operates. This manual is supplemented by the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines" and the “Service record book".

Note:

All three publications belong to the engine and must always be kept ready to hand near the en gine in the engine room. Comply in full with instructions relating to operation, prevention of accidents and environmental protection.

MAN Diesel engines are developed and manufactured in line with the latest state of the art. However, trouble-free operation and high performance can only be achieved if the specified maintenance intervals are observed and only approved fuels, lubricants and coolants are used.

Note:

Only use fuels, lubricants etc. in accordance with MAN's regulations. Otherwise the manufacturer's liability for defects will not apply! For basic information on the fuels see the publication “Fuels, Lubricants and Coolants for MAN Diesel Engines". You can find the approved products in the internet under:

https://mmrepro.mn.man.de/bstwebapp/BSTServlet

It is imperative and in your own interest to entrust your MAN Local Service Centre with the removal of any disturbances and with the performance of checking, setting, and repair work.

Yours faithfully, MAN Truck & Bus AG Werk Nürnberg

Instructions

Important instructions which concern technical safety and protection of persons are emphasised as shown below.

Danger:

This refers to working and operating procedures which must be complied with in order to rule out the risk to persons.

Caution:

This refers to working and operating procedures which must be complied with in order to prevent damage to or destruction of material.

Note:

Explanations useful for understanding the working or operating procedure to be performed.

Declaration

Nameplates

In all your correspondence please always quote en gine model, serial number and job number (Order number).

For this reason it is advisable to read off the data from the engine type plates before putting the engine into operation and to enter them in the appropriate spaces.

The engine type plates are on the crankcase (see illustration).

MAN Nutzfahrzeuge Aktiengesellschaft

Type

Engine No. / Engine No.

NI/II

Model

......................................................................

delivered on

......................................................................

installed on

......................................................................

Engine serial number

......................................................................

Order number

......................................................................

Temp. C

MAN Nutzfahrzeuge AktiengesellscMAN Nutzfahrzeuge Aktiengesellschaft

Nürnberg Works, Germany

Job No Rating kW

Power kWWorks No.

Engine No.TypeYear of manufacture.

Eng. speed 1/min

Operating altitude m uNNPower. PS

Speed rpm

Altitude mRating BHP

Serial NoModelYear

−0219

Safety regulations

General notes

Handling diesel engines and the necessary resources is no problem when the personnel commis sioned with operation and maintenance are trained accordingly and use their common sense.

This summary is a compilation of the most important regulations. These are broken down into main sec tions which contain the information necessary for preventing injury to persons, damage to property and pol lution. In addition to these regulations those dictated by the type of engine and its site are to be observed also.

Important:

If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrat ing the skin, scalding from hot oil, anti‐freeze being splashed in the eyes etc., consult a doctor immedi

ately.

1. Regulations designed to prevent accidents with injury to persons

During commissioning, starting and operation

D Before putting the engine into operation for the first time, read the operating instructions

carefully and familiarize yourself with the “critical" points. If you are unsure, ask your MAN representative.

D For reasons of safety we recommend you attach a notice to the door of the engine

room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room.

D The engine must be started and operated only by authorized personnel.

Ensure that the engine cannot be started by unauthorized persons.

D When the engine is running, do not get too close to the rotating parts. Wear close‐fitting

clothing.

D Do not touch the engine with bare hands when it is warm from operation - risk of burns.

D Exhaust gases are toxic. Comply with the instructions for the installation of MAN Diesel

engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.

D For safety reasons a separate, functioning red emergency‐stop‐button for each

engine must be installed at every bridge (the engine must stop immediately when

the button is pressed once).

Safety regulations

ËË

D Electrical accessories and equipment from other manufactures may only be

connected without the approval of MAN to the connections provided for the cu stomer or shipyard.

The control of the engine may be adversely affected and thus may lead to property damage or personal injury and is therefore not permitted. MAN assumes no liability for any property damage or personal injury. Connections to the following MAN components are prohibited:

- EDC engine control unit (K-Line, CAN-Bus)

- MAN internal or external throttle lever control system (CAN-Bus)

- Emergency steering control (serial, CAN-Bus)

- Display systems for alarms (serial, CAN-Bus)

Approved connectors on terminal box: X4, X8 and X9.

D Keep vicinity of engine, ladders and stairways free of oil and grease.

Accidents caused by slipping can have serious consequences.

During maintenance and care

D Always carry out maintenance work when the engine is switched off.

If the engine has to be maintained while it is running, e.g. changing the elements of change‐over filters, remember that there is a risk of scalding. Do not get too close to ro tating parts.

D Change the oil when the engines is warm from operation.

Caution:

There is a risk of burns and scalding. Do not touch oil drain plugs or oil filters with bare hands.

D Take into account the amount of oil in the sump. Use a vessel of sufficient size to en

sure that the oil will not overflow.

D Open the coolant circuit only when the engine has cooled down.

If opening while the engine is still warm is unavoidable, comply with the instructions in the chapter entitled “Maintenance and Care".

D Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any ad

ditional hydraulic oil circuit) during the operation. The fluids which flow out can cause injury.

D Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be

filled only when the engine is switched off.

D When using compressed air, e.g. for cleaning the radiator, wear goggles.

D Keep service products (anti‐freeze) only in containers which can not be confused with

drinks containers.

Safety regulations

D Comply with the manufacturer's instructions when handling batteries.

Caution:

Accumulator acid is toxic and caustic. Battery gases are explosive.

2. Regulations designed to prevent damage to engine and premature wear

Do not demand more from the engine than it is able to supply in its intended application. Detailed informa tion on this can be found in the sales literature.

If faults occur, find the cause immediately and have it eliminated in order to prevent more serious damage.

Use only genuine MAN spare parts. MAN will accept no responsibility for damage resulting from the install ation of other parts which are supposedly “just as good".

In addition to the above, note the following points:

D Never let the engine run when dry, i.e. without lube oil or coolant.

D When starting do not use any additional starting aids (e.g. injection with starting pilot).

D Use only MAN‐approved service products (fuel, engine oil, anti‐freeze and anti‐corrosion agent). Pay at

tention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and care".

D Have the engine maintained at the specified intervals.

D Today modern components of diesel injection consist of high‐precision parts which are exposed to ex

treme stresses. The high‐precision technology requires the utmost cleanliness during all work on the fuel system. Even a particle of dirt over 0,2 mm can lead to the failure of components.

D Do not switch off the engine immediately when it is warm, but let it run without load for about 5 minutes

so that temperature equalization can take place.

D Never put cold coolant into an overheated engine. See “Maintenance and care".

D Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.

Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if these instructions are not adhered to.

D Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, coolant tem

perature) function satisfactorily.

D It is advisable to switch off the engine if an alarm of any kind is displayed in the engine monitoring and

diagnostic system. If this is not possible for any reason, the engine should be run no faster than 1200 rpm until the fault is remedied, see page 24.

D Comply with instructions for operation of the alternator. See “Maintenance and care".

D Do not let the seawater pump run dry. If there is a risk of frost, drain the pump when the engine is

switched off.

Safety regulations

3. Regulations designed to prevent pollution

Engine oil and filter elements / cartridges, fuel / fuel filter

D Take old oil only to an old oil collection point.

D Take strict precautions to ensure that no oil or Diesel fuel gets into the drains or the ground.

Caution:

The drinking water supply could be contaminated.

D Filter elements are classed as dangerous waste and must be treated as such.

Coolant

D Treat undiluted anti‐corrosion agent and / or anti‐freeze as dangerous waste.

D When disposing of spent coolant comply with the regulations of the relevant local authorities.

4. Notes on safety in handling used engine oil ∗

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin. Drying, irrit ation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health and safety at work are observed, health risks are not to the expected as a result of handling used engine oil.

Health precautions:

D Avoid prolonged or repeated skin contact with used engine oil.

D Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.

D Clean skin which has been in contact with engine oil.

- Wash thoroughly with soap and water. A nailbrush is an effective aid.

- Certain products make it easier to clean your hands.

- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

D After washing apply a fatty skin cream to the skin.

D Change oil‐soaked clothing and shoes.

D Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly

- Engine oil can endanger the water supply -

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable.

Collect and dispose of used engine oil carefully. For information on collection points please contact the seller, the supplier or the local authorities.

∗ Adapted from “Notes on handling used engine oil".

Safety regulations

5. Special instructions when working on the common rail system

Accident protection

D Risk of injury!

Fuel jets can cut through skin. The atomisation of fuel creates a fire risk.

- When the engine is running never loosen the screw connections on the fuel's

high‐pressure side of the common rail system (injection line from the high‐pressure pump to the rail, on the rail and on the cylinder head to the injector)

- Keep away from the engine when it is running

D Risk of injury!

When the engine is running the lines are constantly under a fuel pressure of up to 1600 bar.

- Wait at least a minute until the pressure in the rail has dropped before loosening a

screw connection

- If necessary check the pressure drop in the rail with MAN‐Cats

D Risk of injury!

- People with pacemaker must keep at least 20 cm away from the running engine.

- Do not touch live parts on the electric connection of the injectors when the engine is

running.

Cleanliness

Today modern components of diesel injection consist of high‐precision parts which are exposed to extreme stresses. The high‐precision technology requires the utmost cleanliness during all work on the fuel sys tem. Even a particle of dirt over 0,2 mm can lead to the failure of components.

The measures described as follows are therefore essential before work begins:

Risk of damage from penetration of dirt!

D Before working on the clean side of the fuel system clean the engine and the engine

compartment. During cleaning the fuel system must be closed.

D Carry out visual inspection for any leakage or damage to the fuel system D Do not spray the high‐pressure cleaner direct onto the electric components, or alternati

vely keep them covered

D Do not carry out any welding or sanding work in the engine compartment during mainte

nance / repair

Safety regulations

D Avoid air movements (any swirling of dust when starting engines) D The area of the still closed fuel system must be cleaned and dried with the aid of com

pressed air

D Remove detached particles of dirt such as paint chippings and insulation material with a

suitable extractor (industrial type vacuum cleaner)

D Cover areas of the engine compartment from which dust particles could be detached

with clean foil

D Wash your hands and put on clean work clothes before starting the disassembly work

When carrying out the work it is essential to comply with the following measures:

Risk of damage from penetration of dirt!

D When the clean side of the fuel system has been opened it is not permissible to use

compressed air for cleaning

D During assembly work loose dirt must be removed with the aid of suitable extractors (in

dustrial type vacuum cleaners)

D Use only fluff‐free cleaning cloths on the fuel system

D Clean tools and working materials before starting to work

D Only tools without any damage may be used (cracked chrome coatings)

D When removing and installing components do not use materials such as cloths, cardbo

ard or wood since these could shed particles and fine fibres

D If any paint chips/flakes off when connections are loosened (from possible over‐coating)

these chippings must be carefully removed before finally loosening the screw connec tion

D The connection openings of all parts removed from the clean side of the fuel system

must be immediately closed up with suitable caps/stoppers

D These caps/stoppers must be packed protected from dust prior to use and after being

used once they must be disposed of

D Following this all the components must be carefully stored in a clean, closed container

D Never use used cleaning or testing liquids for these components

D New parts must not be removed from their original packing material until directly before

use

D Work on removed components may be carried out only at a workplace specially equip

ped for it

D If removed parts are shipped always use the original packing material of the new part

Commissioning and operation

Engine views V8-1200 (D2868 LE433)

(1) Poly-V-belt guard

(2) Air filter

(3) Coolant filler neck

(4) Main fuse for voltage supply

(5) Oil drain valve engine

(6) Oil drain valve gearbox

(7) Oil filler neck

Commissioning and operation

(8) Oil filter

(9) Oil dipstick

(10) Fuel filter

(11) Sea water pump

(12) Engine terminal box EDC

Commissioning and operation

Engine views V12-1800 (D2862 LE433) / V12-1650 (D2862 LE453)

(1) Poly-V-belt guard

(2) Air filter

(3) Coolant filler neck

(4) Main fuse

(5) Oil drain valve gearbox

(6) Oil drain valve engine

(7) Oil filler neck

Commissioning and operation

(8) Oil filter

(9) Oil dipstick

(10) Fuel filter

(11) Sea water pump

(12) IEngine terminal box EDC

Commissioning and operation

Engine views V12-1550 (D2862 LE423) / V12-1400 (D2862 LE443) / D2862 LE463)

(1) Poly-V-belt guard

(2) Air filter

(3) Coolant filler neck

(4) Oil drain valve gearbox

(5) Main fuse

(6) Oil drain valve engine

(7) Oil filler neck

Commissioning and operation

(8) Oil filter

(9) Oil dipstick

(10) Fuel filter

(11) Sea water pump

(12) IEngine terminal box EDC

Commissioning and operation

First commissioning

When putting a new or overhauled engine into operation for the first time pay attention to the “Installation instructions for MAN marine diesel engines" without fail.

It is recommended that new or overhauled engines should not be operated at a load higher than about 75% maximum load during the first few hours of operation. Initial run-in should be at varying speeds. After this initial run-in, the engine should be brought up to full output gradually.

Caution:

Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc."). Otherwise the liab ility for defects will become null and void!

Filling with fuel

Caution:

Fill the tank only when the engine is switched off. Pay attention to cleanliness. Do not spill fuel. Use only approved fuels, see brochure Fuels, lubricants etc.".

Filling-in of coolant

Fill the cooling system of the engine with a mixture of drinkable tap water and anti-freeze agent on the ethylene glycole basis or anti-corrosion agent. See Publication “Fuels, Lubricants and Coolants for MAN Diesel Engines".

D Pour in coolant slowly via expansion tank, see page 110 D Coolant filling quantity - see “Technical data", from page 101

Commissioning and operation

Seawater pump

Do not let seawater pump run dry!

Make sure that all valves / cocks in the seawater circuit are open.

If there is a risk of frost, drain the seawater pump.

Refilling with oil

The engines are as a rule supplied without oil. Pour oil into engine via filler neck, see page 103.

Caution:

Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Overfilling will result in damage to the engine.

Oil filling quantity - see “Technical data", from page 101.

Commissioning and operation

Commissioning

Before daily starting the engine, check fuel level, coolant level and engine oil level and replenish, if neces sary.

Caution:

Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc."). Otherwise the liab ility for defects will become null and void!

Checking oil level

Check engine oil level only approx. 20 minutes after the unit has been switched off.

DPull out dipstick (arrow)

D wipe it with a clean, lint-free cloth

D and push it in again up to the stop

D Pull out dipstick again

The oil level should be between the two notches in the dipstick and must never fall below the lower notch.

Caution:

Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Overfilling will result in damage to the engine.

Ensure utmost cleanliness when handling fuels, lubricants and coolants.

Oil

MAX

MIN

Commissioning and operation

Starting

Danger:

Before starting make sure that no-one is in the engine's danger area.

Caution:

When starting do not use any additional starting aids (e.g. injection with starting pilot).

There are two possibilities to start the engine: using the ignition lock or using the Start" button.

Starting via the ignition lock:

Ensure that the gearbox is in neutral.

Insert the ignition key and turn it to position I". Readiness for operation is indicated by an indicator lamp lighting up.

Turn ignition key on until stop (position “III" depending on starter lock) starter is activated.

Lube oil pressure must build up at the oil pressure gauge. If it does not, switch off the engine immediately.

Do not operate starter for longer than 10 seconds at a time.

After ignition of the engine, release the starter button and adjust control lever for desired speed.

If engine fails to start, release the key, wait about 30 seconds, then operate starter again.

For repeated starting turn the key back to “0".

If the engine is kept idling for long periods it may cool down and thus start to emit white or blue smoke. We therefore recommend that you do not let the engine idle for more than 5 minutes. It is well known that with any internal combustion engine wear is higher during idling. Prolonged idling is harmful to the environment.

Starting via the button:

Ensure that the gearbox is in neutral.

Press the “IGN ON/OFF“ button. Readiness for operation is indicated by an indicator lamp lighting up.

Actuate “Engine Start“ button. Starter runs up and the control light goes out.

Lube oil pressure must build up at the oil pressure gauge on the display. If it does not, switch off the engine immediately.

Do not operate starter for longer than 10 seconds at a time.

After starting the engine, let go of the Start button and set the adjustment lever to the desired speed.

If the engine has not started, wait approx. 30 seconds before pressing the Start" button again to operate the starter motor.

Commissioning and operation

Operation monitoring system

Caution:

Do not exceed the maximum permissible engine tilt. If faults occur, find their cause immediately and have them eliminated in order to prevent more serious damage!

If an engine / gearbox alarm is displayed on the monitoring devices, the engine is to be turned off or, i.e. operated at low load at max. 1200 rpm. When the following alarms are displayed

- engine oil pressure / reduction of lubrication oil pressure

- engine coolant temperature / overheating of engine coolant

- engine charge-air temperature the engine is to be turned off immediately and the cause of the fault properly remedied, i.e. in a specialist workshop. Do not put this engine into operation again until the fault has been eliminated.

The engine is equipped as series standard with a monitoring and diagnostic system MAN-Marine-Dia gnose-System (MMDS.

On the control console and alternatively on other control consoles, the following display devices are avail able for monitoring operation:

1. Engine room panel, see page 26

CAN bus-controlled display devices:

2. CAN-Bus round instruments, see page 29

3. Display device MMDS-CLC 6.5, see page 33

4. MMDS-CLC 6.5 ship's alarm display, see page 48

Display units supported by PC:

5. Display device MMDS-CMS, see page 55

For operation and speed adjustment, MAN provides the following equipment:

6. Drive lever control system Marine Power Control (MPC), see page 75

6.1. Mobile navigating console, see page 88

7. Optional: emergency unit Em (Emergency), see page 92

7.1. Override button for MMDS-CR and MMDS-BE3 systems, see page 96

Commissioning and operation

Differences in operating parameters of engines and gearboxes

Differences in parameters can be observed on identical engines, irrespective if they are installed in one boat or in different boats (boat series), such as

D pressures D temperatures D speeds D fuel consumption D injection quantity D Load D relative load D control head signal D oil level of engine and gearbox D engine coolant level D battery and charging voltage

The same applies to a single V-engine (e.g. exhaust temperatures before turbine, l.h. and r.h. side cylinder banks).

These differences may be caused by

D component tolerances of the mechanical and electrical engine components D design-related influences on engines (this applies especially to the exhaust temp.) D external influences such as fuel supply, air supply and coolant supply D installation conditions, hull characteristic and flow, exhaust system D differences in the propeller and stern gear.

Under normal conditions this does not have any negative impact on the engine's operating safety. If the op erating parameters are in an impermissible range, this is indicated by appropriate alarms of the diagnostic system.

The same applies to the gearbox parameters.Please note that especially differences in the oil temperature may arise on gearboxes running in clockwise or anticlockwise direction.

Commissioning and operation

1. Engine room panel (integrated LC display “IGN ON/OFF"-button, Start"-button, “Set+ Set-"-button and emergency stop switch)

The engine room panel is optionally available and serves to display engine and gearbox data, as well as system information. In order to obtain the full functionality of an engine room panel, as well as the display additional function buttons are integrated for the control of the ignition. starting the engine and for engine speed adjustment.

(1) Set +

(2) Set -

(3) Emergency stop

Function “Ignition ON/OFF" (5) (yellow button)

After activated ignition at the control console, the ignition in the engine room is switched on and off with the yellow buttons “IGN ON/OFF" (5). If the ignition is not activated at the bridge or flybridge, the button has no function.

(4) Start

(5) ING (Ignition)

Activation of the ignition is indicated by the internal yellow lighting of the button. Only when the ignition has been activated at the bridge is the yellow button “IGN ON/OFF" (5) of the engine room panel enabled.

Caution:

Ignition off ⇒ engine stop

Commissioning and operation

Function “Start" (4) (green button)

With the ignition switched on, the engine can be started by pressing the green button “Start" (4). The button lights up green when the ignition is switched on.

Function “Stop" (5) (yellow button)

Actuation of the yellow button “IGN ON/OFF" (5) stops the engine.

Function “Emergency stop“ (3)

Pressing the emergency stop switch (3) in the cover of the terminal box shuts the engine down immedi ately. To unlock the emergency stop switch (3), turn the cap of the switch clockwise. Then the ignition must be switched off and on again, in order to restart the engine.

Engine speed adjustment:

Function “Set +" (1)

By actuating the button “Set +" (1) with the engine running, the engine speed is increased.

Function “Set -" (2)

By actuating the button “Set -" (2) with the engine running, the engine speed is reduced.

Activation of the intermediate speed function:

Press “Set +" and “Set -" simultaneously, until both buttons flash. To confirm, press both buttons again. Both buttons now light continuously.

Deactivation of the intermediate speed function:

By actuating the yellow button “IGN ON/OFF" (5) the intermediate engine speed function is terminated.

The intermediate engine speed function is carried out in similar fashion on the emergency unit, see page 92.

Commissioning and operation

Optional External LC display of the ship-vehicle management computer (SFFR) in the cover of the engine terminal box

Alarms and their codings can be indicated via the external LC display of the ship-vehicle management com puter and communicated to our customer service organisation. If an active MMDS alarm occurs the corresponding MMDS alarm page will be indicated automatically and can be exited only after confirmation.

Flashing light , Indication of EDC, SFFR fault with high priority.

Permanent light , Indication of EDC, SFFR fault with low priority.

Flashing light Active, non-confirmed MMDS alarm

Permanent light Active, confirmed MMDS alarm

Operation of the external LC display of the ship-vehicle management computer

Operating button for calling up menu if no active, non-confirmed MMDS alarm is indic ated.

For navigating in the menu, for indicating next or previous fault.

Confirmation of selection.

Acoustic acknowledgement of all monitoring devices connected to the same CAN bus.

For visual acknowledgement of an MMDS alarm.

For sending a resetting signal to the central MMDS unit.

Commissioning and operation

CAN bus-controlled display devices:

2. CAN-Bus round instruments, rev counter with information display and buttons

D Rev counter (0-3000 rpm) with integrated LCD display for the following parameters and buttons for pa

ging:

- Engine oil pressure

- Gearbox oil pressure

- Coolant temperature

- Engine oil temperature

- Engine exhaust temperature

- Charge air temperature

- Boost pressure

- Load

- Hours of operation

- Fuel consumption

- Battery voltage

D Oil pressure engine 0-10 bar D Gearbox oil pressure 0-25 bar D Oil temperature engine 50--150°C D Coolant temperature engine 40-120°C D Exhaust temperature engine 100-900°C D Battery voltage 18-32 V

Commissioning and operation

Tachometer CAN-Master

The VDO Ocean Link Tachometer (CAN-Bus Tachometer)

The VDO Ocean Link tachometer is a multifunctional instrument for indicating engine data, and is intended for use in navigation of sports ships. The tachometer shows the actual engine speed in operation, on the analogue scale. Further values and operating aids appear in the LC display.

The instrument has a push-button on the front side, with which all the functions can be selected. Handling of the instrument is thus easy and uncomplicated.

LC‐Display Push button key

Main Functions

The main functions of the VDO Ocean Link can be called up by pressing the push-button. Each time the button is pressed, the next measured value is displayed.

- Engine oil pressure - Charge air temperature

- Gearbox oil pressure - Charge air pressure

- Coolant temperature - % Load

- Engine oil temperature - Running time

- Exhaust gas temperature b. turbine 1 - Current fuel consumption

- Exhaust gas temperature b. turbine 2 - Battery voltage

- Exhaust gas temperature after turbine

The exhaust temperature to be displayed must be set when the display messages (Screen on / off).

Commissioning and operation

Setting possibilities

Further settings can be made by pressing the button:

D Selection of illumination intensity in 8 steps D Selection of display unit in metric or English units D Selection of transmitters for the analogue inputs

Selection of illumination intensity

If you keep the push-button pressed for 4 seconds, the scroll bar for the illumination setting appears. By repeatedly pressing the key, you can change the illumination of the tachometer and the connected bus display in 8 steps. The display jumps back to the normal operating mode 8 seconds after the last time the button is pressed. The illumination setting is retained even after switching the power supply off and on again. Please note that setting of the illumination is possible only if external illumination is set to “Internal" in the settings menu, see page 32.

Basic Settings

The basic settings necessary for perfect operation can be selected in the settings. These are obtained by pressing and holding the button while switching on the power supply of the display.

Display Units: Selection of display unit Screens on / off: Selection of display Simulator Mode: activation of simulator mode Exit Setup: exits the setting menu

In order to change a value (e.g. from NO to YES) press the button briefly. In order to not change a value, keep the button pressed until the set value flashes once. Then release the button immediately. This adopts the displayed setting. If the button is not pressed, the displayed setting is automatically adopted after 10 seconds.

Selection of the display units)

The values for temperatures and pressures can be displayed alternatively in the units °C/bar (METRIC) or °F/psi (ENGLISH). Selection of the units is carried out as follows:

In the example shown the unit is changed from METRIC to ENGLISH.

DISPLAY UNITS

Press key

METRIC

DISPLAY UNITS

ENGLISH

Commissioning and operation

Setting the illumination (external illumination)

Select here whether illumination of the tachometer and the connected bus instruments are to be connected internally or externally.

EXTERNAL: The illumination is switched on and off through an input of the 14-pin plug.

Dimming of the illumination is thus not possible.

INTERNAL: The illumination is regulated in the normal operating mode by pressing and

holding the push-button key in 8 steps.

Selection of the displays (Screen on / off)

Select here which measured values are to be displayed in the normal operating mode.

YES: Here all measured values, with their ISO symbol, are displayed. By selecting

NO", the measured value can be removed from the normal operating mode. If the measured value is to be displayed again, select YES" when the ISO symbol of the measured value is displayed

NO: No change in the setting are made.

Activation of the simulation mode (simulator mode)

Select here whether the simulation mode is to be switched on.

YES: The simulation mode is switched on. The display now generates random va

lues for all measuring channels and displays these. The measured values are also transmitted to the bus instruments.

NO: The simulation mode is switched off.

Please note that the simulation mode still remains after switching off and switching on again, if it has not been switched off by selecting NO.

Setting of the number of exhaust gas temperature measured values (Charge Boost Amount)

Select here whether one or two measured values are to be displayed for the exhaust gas temperature be fore the turbine.

1: One exhaust gas temperature measured value. 2: Two exhaust gas temperature measured values. (V-engines)

Ending the settings (exit setup)

Select here whether the settings are to be exited.

YES The settings are exited, the display restarts in the normal operating mode. NO The settings are restarted.

Commissioning and operation

3. MMDS-CLC 6.5 display device (colour display)

Introduction

This document describes how the MMDS-CMS 6.5 colour display with MMDS-CLCB 6.5 remote control op erates and is used in its application as an engine display to monitor engine operation. Fitting, mounting and installation are explained in separate instructions for the unit.

The engine and gearbox data are shown on the colour display in the form of dials and digital displays. LED symbols are used to display alarms; these are complemented by a table which lists all alarms present with more detailed information.

A logo which will be displayed on all pages may be activated when installed. The shipyard can select this logo selection itself (see page 47).

Function

The colour display is automatically activated when the supply voltage is applied. It can then be switched on

and off manually using the “Power" button . The other alarm functions such as the alarm relay and the internal buzzer and the acknowledge button remain operative.

The engine speed display incorporates a damping algorithm to simulate mechanical instruments. This means that small variations do not lead to an unstable display, which could irritate the officer con trolling the ship.

Commissioning and operation

Pre-Start page

The display is activated by switching the ignition on and the following Pre-Start page is displayed.

Pre-Start page

If a button is actuated or the engine started, the display switches to the basic display.

Pre-Start page with active acknowledged alarms

Should active acknowledged alarms arise, these are indicated by a red triangle. The number corresponds to the number of alarms that have arisen.

Commissioning and operation

Pre-Start page in the warning and alarm range.

If a value represented on the Pre-Start page reaches the warning or alarm range, the colour of the picto graph changes to red. In the example shown the gearbox is not in the neutral position.

Commissioning and operation

Basic display

On starting the engine the start page is called up automatically, indicating engine speed, coolant temperat ure and oil pressure in the form of round instruments and also in digital format. The calculated fuel con sumption is represented bottom, right.

Basic display

Engine and gearbox data are represented as digital display values or bar displays on three further pages.

The pages are selected with the buttons and

Page 2

Commissioning and operation

Page 3

The exhaust gas temperature values “Exhaust gas v. Turbo", and the operating hours counter are presen ted on page 3.

Page 3

Page 4

Page 4 displays the daily fuel consumption counter “Trip".

Page 4

Commissioning and operation

Buttons

Figure: Numbering of the operating buttons

Operational functions and configuration

The operation of the system and the display adjustment is carried out with the display buttons or the re mote control MMDS-CLCB 6.5.

The following functions are incorporated:

Standard function: Call the alarms table, or browse to further alarm pages.

Additional function: If pressed longer than 5 seconds ⇒ Switches configuration menu on and off.

Standard function: Page back to the previous page

Additional dimming function: On simultaneous actuation of the buttons (4) and (3)

the brightness is reduced.

Additional function in the menu: Change parameter / reduce value.

Standard function: page up to the next page.

Additional dimming function: On simultaneous actuation of the buttons (4) and (2)

the brightness is increased.

Additional function in the menu: Change parameter / increase value.

Standard function: Acoustic and optical acknowledgement of all monitoring devices connected to

the same CAN-Bus.

Additional dimming function: Adjustment of the brightness on simultaneous actuation of the but

tons and .

Test function: If currently no alarm is on, or if all alarms have previously been optically acknowled ged, after an actuation for longer than 5 seconds a horn test is carried out, i.e. the internal sum mer and the horn relay are activated for the duration of the button press.

Commissioning and operation

Standard function: A reset signal is sent via the CAN bus to the engine monitoring and diagnostic system control unit (engine terminal box) or to a data station. As long as the appropriate criteria are fulfilled, the engine slow down or shutdown alarms arising are reset.

Additional function in the menu: Accept change and pass to the next parameter.

Function (Actuation for approx. 3 seconds): Switch-on and switch-off of the display (display only,

not on remote operation). Additional display function (Brief actuation): Insertion of the info. display for approx. 5 seconds

Commissioning and operation

Alarms

Definition of alarm condition

An alarm is triggered when a monitored value exceeds or fails to reach its set limit value.

Should an alarm condition occur, an alarm table is automatically displayed. This lists all advance warnings, alarms and sensor fault alarms. An internal buzzer and the horn relay are activated at the same time. The collective alarm relay issues a repeat pulse if another alarm was already active. In this way, it is pos sible to activate a visual call system for each new alarm or to send a telephone message if the ship is not

occupied. Acoustic acknowledgement with the (4) button switches the internal buzzer off and the horn relay drops out.

Alarm acknowledgements and reset signals are sent on the CAN bus to the engine monitoring and dia gnostic system Diagnostics unit and to all the monitoring devices subscribing to the same CAN bus. All the equipment thus has the same alarm status.

So long as the values are displayed in white, the values are in their “normal ranges". On reaching a prelim inary alarm the digital value flashes orange, with a main alarm red, and in the case of a sensor fault a yel

low flashing “SE" appears. On pressing the optical acknowledgement (Button (4)) all the flashing displays revert to a continuously lit condition. When the fault has been eliminated and both acoustically and

optically acknowledged (button (4)), the alarm display reverts to the “Normal condition".

Normal Advance war

Figure: Example of the display of the engine oil pressure with alarm indication

The engine monitoring and diagnostic system control unit monitors all important sensors for plausibility. If a sensor fault alarm occurs, the value is cleared from the digital displays and the pointer is removed from the dials.

In the case of alarms, which have led to the automatic stopping or speed reduction of the engine

Alarm Sensor failure

via the central MMDS unit, the button (5) must also be actuated. In the case of a stop alarm, this function is released on engine shutdown and with a reduce alarm below an engine speed of 800 1/min.

Alarm acknowledgements and reset signals are sent via the CAN bus to the engine monitoring and dia gnostic unit and to all the monitoring devices connected to the same CAN bus.

Commissioning and operation

Alarms table

This table is automatically called when an alarm condition occurs, or can be called manually by pressing

the “Alarms" button (1) It shows all existing alarm messages, i.e. those that have not been acknow ledged or reset. Each entry contains a measuring point text, the current measured value, the time when the alarm occurred, the unit of measurement and the type of alarm. The following labels are used for the type of alarm:

Text Meaning

Warning Advance warning Alarm Alarm Sensor Sensor fault alarm

A new alarm always appears in the top line. This is highlighted in flashing red until it is visually acknow ledged. Older messages are automatically displaced one line downwards. If there are more than 6 entries, further alarm pages are automatically presented for selection. In this event, pressing the “Alarms" button

(1) switches on to the next available alarm page. When the first page reappears, or if the display remains the same after pushing that key, there are no further alarms. The numbering of the displayed alarm page is shown at the bottom right of the page.

A message generally remains active until it has been acoustically and visually acknowledged (button (4)) and the fault has been rectified. Shutdown and engine slow down alarms must also be reset using the

button (5).

Note:

The alarm texts are presented in the selected display language.

Active alarm page

Commissioning and operation

Acknowledged alarm page

Figure: Alarms table

Commissioning and operation

Menu functions

The display unit provides a number of setting options. Activation of the button (1) for approx. 3 seconds activates the menu page. The page contains the following configuration points:

DSelection of the presentation in German, English, Italian, Spanish and French D Setting the time D Selection of the logo D Selection of the display in metric/non-metric units D Activation of display start status D Activation of the service page

The menu point in the respective blue marked field can be changed with the buttons (2) and

(3). Pressing the button (5) switches the marking to the next field. Pressing the button

(1) again for approx. 3 seconds causes the set values to be accepted and the menu is exited. The display switches to the alarm table.

Figure: Menu for setting the display

Commissioning and operation

Service page

The engine and gearbox data and the alarm conditions of all measuring stations are displayed in a table on

the service page. This page is accessed and exited on selecting the menu item and

changing the page via the buttons (2) and (3).

Service page

tank

ture

Water level in fuel filter 1

Engine oil pressure

Water level in fuel filter 2

0.0 mV

4.8 bar

0.0 mV

Commissioning and operation

Engine oil pressure at the oil filter

Engine oil temperature

Engine oil level

Crankcase pressure

Coolant temperature

Cool.temperature. in cool.exp.

Cool.press coolant pump

Coolant level in expansion tank

Gearbox oil pressure

?? %

78 _C

?? bar

3.8 V ?? mbar

81 _C

?? bar

0.5 bar

?? bar

Gearbox oil pressure at the filter

12.5 bar

Temp. exh. b. turbine 1

Temp. exh. a. turbine

Failure EDC

Failure SFFR

Temp. exh. b. turbine 2

510 _C

512 _C

420 _C

???? SPN

Remote slow-down

???? SPN

Override

Emergency stop

Alarm throttle control

?? mV

Safety system failure

Safety system alarm

Engine number

Engine type

12345678

D286X LE4XX

Water pre−filter 1

Water pre−filter 2

Oil press. engine

Oil press.eng.b.filtr

Service page 1/2

63 %

80 %

?? m/h

1200 1/min

Engine speed

Throttle

Load/Torque

Relative load

Oil temp. engine

Oil level engine

Crankcase press.

Coolant temp.

Cool. press. exp. t.

25.2 V

120 l/h

Fuel consumption

24.1 V

4.5 bar

4.4 bar

Fuel press. pump1

Pow. supply PIN15

Generator D+

Fuel press. pump2

Cool. press.wat. p.

Coolant level

Oil press. gearbox

Oil press.gbox.b.fil

Exhaust temp. 1

Service page 2/2

30 _C

250 mbar

100 mbar

Fuel press.handp.

Fuel press.return l.

23.5 mV 1200 rpm

Fuel temperature

Inject. pipe leak

Engine speed

Exhaust temp. 2

Exh.temp.aft.turbo

EDC−failure

SFFR−failure

Remote slow down

Override

?? %

78 _C

Oil temp. gearbox

?? _C

Oil level gearbox

Bearing temp.gear

?? bar

?? l/min

Seawater flow

Seawater press.

Emergency stop

Alarm throttle cont

Safety syst. fail

Alarm safety syst.

?? _C

58 _C

25 mbar

Charge air temp.

Seawater temp.

Air intake pressure

?? _C

2.5 bar

Boost pressure

Temp. MMDS int.

Engine number

Engine type

?? _C

30 mbar

Temp. plug X1

Exh. back press.

Engine speed

Throttle lever

Load

Relative load

Fuel consumption

Voltage, term. 15

Fuel press. pump1

Voltage, Gen. D+

Fuel press. pump2

Fuel press. handp.

Fuel temperature

Fuel press. return

Injection pipe leak

Engine speed

Gearbox oil tempera-

Oil level gearbox

Bearing temp.gearb.

Seawater flow

Seawater press.

Charge air tempera-

Seawater temp.

Boost press.

Temp. MMDS

Temp. plug X1

Exh. back press.

Commissioning and operation

The table has 3 columns for each measuring point. Each entry contains an abbreviation of the designation of the measuring point, the current measured value and the unit of measurement. The alarm status is presented via LED symbols. As long as the LED is green the value is in the normal range. If the initial alarm is reached the colour changes to orange and with a main alarm to red. A flashing LED indicates that the alarm has not yet been visually acknowledged. If there is a sensor failure, the LED goes out.

Automatic dimming

A photo element is integrated in the front plate of the display unit. This registers the brightness of the envir onment and the background lighting is automatically adapted to the circumstances. When the light condi tions get darker the brightness of the display is reduced; if there is more light it is increased.

The automatic dimming can be adjusted to one's own requirements. By simultaneously activating the but

tons (4) and (2) or (3) the darkest point of the display lighting can be set.

Selection of the logo

Commissioning and operation

Configuration

The logo to be blended in is selected on the logo page. This is displayed at the centre of all pages of the

display. This page is opened or closed on selection of the menu item and changing the

page via the buttons and .

After selection of the menu item by actuating the button an available logo can

be selected via the buttons and . After activation of the button for approx. 3 seconds,

the selection is accepted and the menu is closed.

LED displays

There are two LEDs beneath the display. A green Power" LED is activated by applying the supply voltage. The red error" LED flashes when there is no communication on the CAN data bus. The displays of the en gine and gearbox data then all show the value 0".

Commissioning and operation

4. MMDS-CLC 6.5 ship's alarm display, operation

Introduction

This document describes how the MMDS-CLC 6.5 colour display with MMDS-CLCB 6.5 remote control op erates and is used as a ship's alarm display. Fitting, mounting and installation are explained in separate in structions for the unit.

The data monitored on the ship is visualised by the corresponding symbols and displays on the colour dis play. LED symbols and a table that lists all active alarms with detailed information indicate states of alarm.

For commissioning and service, there is a service page where all the measured values as well as alarm states of all sensors can be viewed at a glance.

To optimise adjustment to the user's requirements, five languages and display of the data in either metric or non-metric units can be selected.

Buttons

MMDS-CLC 6.5 ship's alarm display

Operational functions and configuration

The operation of the system and the display adjustment is carried out with the display buttons or the re mote control MMDS-CLCB 6.5.

The following functions are implemented:

Standard function: Call the alarms table, or browse to further alarm pages.

Additional function: If pressed longer than 5 seconds ⇒ Switches configuration menu on and off.

Standard function: Page back to the previous page

Additional dimming function: On simultaneous actuation of the buttons (4) and (3)

the brightness is reduced.

Additional function in the menu: Change parameter / reduce value.

Commissioning and operation

Standard function: page up to the next page.

Additional dimming function: On simultaneous actuation of the buttons (4) and (2)

the brightness is increased.

Additional function in the menu: Change parameter / increase value.

Standard function: Acoustic and optical acknowledgement of all monitoring devices connected to

the same CAN-Bus.

Additional dimming function: Adjustment of the brightness on simultaneous actuation of the but

tons and .

Additional function in the menu: Accept change and pass to the next parameter.

Actuate the function (approx. 3 seconds): Switch-on and switch-off of the display (display only,

not on remote operation). Display additional function (long actuation): Info. display appears for approx. 5 seconds

Function

The colour display is automatically activated when the supply voltage is applied. It can then be switched on

and off manually using the “Power" button (6). The other alarm functions such as the alarm relay and the internal buzzer and the acknowledge button remain operative. There are two screen pages for dis playing the most important engine and gearbox data. Alarms are displayed in an alarm table.

Graphical display of measured values data

When the device is switched on, page 1 is shown automatically.

Normally, the following is displayed:

Figure: start page with fuel tank levels, bilge status and door monitoring

Commissioning and operation

a) Fuel tank: (configuration depending on boat type and tank shape)

D Fill level display and digital value D with approx. 10% of the tank content, an alarm is issued (dependent on customer wish)

b) Water tank: (configuration depending on boat type and tank shape)

D Fill level display and digital value D with approx. 10% of the tank content, an alarm is issued (dependent on customer wish)

c) Time: can be set on menu page

d) Illustration of the boat type: adapted at the request of the customer to specification.

e) Bilge alarms: with high fill level, an alarm is triggered. (rear, engine room, front end, others are possible)

f) Miscellaneous, e.g. lower bathing ladders, rear gate open (depending on boat type and configuration)

The sensors for the tank and water level as well as the switches for the bilge fill levels and miscellaneous others are to be connected to the serial substation (e.g. IO 12 ). There must be harmonisation here with re gard to configuration (tank curves) and possible signal inputs.

Page 2:

Normally, the following is displayed:

Figure: page 2 with digital display elements and bar displays

g) Trim flap position:

here is an instrument in the middle of the display that indicates the trim flap position of the port and star board trim flaps. For each speed, the trim flap position is suggested by means of a green rectangle. This proposal is generated from a trim curve integrated in the software that is recorded during the commis sioning journey. The trim flap sensors are read in at the serial substation.

h) Rudder position:

The rudder position is displayed in the upper area. The sensors for the rudder position are read in at the serial substation.

i) GPS speed:

The speed recorded by the GPS is displayed at the right-hand edge of the screen. The GPS is connected to the serial interface on the back of the CLC ship display.

j) Current fuel consumption:

The fuel consumption is shown at the bottom right. The value is transferred from the MMDS-CLC 6.5 engine display per data line. The fuel consumption can only be shown on ships with electronically controlled engines.

Commissioning and operation

k) Range:

The range of the ship is displayed on the right. This is a value calculated from the current fuel consumption, GPS speed and current fuel tank content. The range can be displayed in nautical or standard miles, which can be selected in the menu.

Furthermore, the fuel consumption and e.g. the position of the bathing ladders are often displayed on page 2.

The (2) and (3) keys can be used to switch back and forth between the two graphical pages. If the alarm table is activated, the last displayed page is opened.

All sensors and switch inputs connected to the serial substation must be provided by the shipyard and tested for proper function as well as conformity with the serial substation. Furthermore, the serial substation must have been configured. The same applies to the GPS system that is connected directly to the CLC ship.

Alarms

occupied. Acoustic acknowledgement with the (4) Alarm acknowledgements and reset signals are sent on the CAN bus to the engine monitoring and diagnostic unit and to all the monitoring devices connec ted to the same CAN bus. All the equipment thus has the same alarm status.

Alarm display on the graphics pages

On reaching an alarm condition, e.g. full bilge, the associated red LED flashes. By actuating the optical ac

knowledgement button (button (4)) all the flashing displays revert to a continuously lit condition.

When the fault has been eliminated and both acoustically and optically acknowledged (Button (4)), the alarm display reverts to the “Normal condition".

Sensor failure

All the important sensors are monitored for plausibility. If a sensor error alarm occurs, then the measured value on the corresponding instrument disappears.

Commissioning and operation

Alarms table

This table is automatically called when an alarm condition occurs, or can be called manually by pressing

the button (1) It shows all existing alarm messages, i.e. those that have not been acknowledged or reset. Each entry contains a measuring point text, the current measured value, the time when the alarm oc curred, the unit of measurement and the type of alarm. The following labels are used for the type of alarm:

Text Meaning

Warning Advance warning Alarm Alarm Sensor Sensor fault alarm

A new alarm always appears in the top line. This is highlighted in flashing red until it is visually acknow ledged. Older messages are automatically displaced one line downwards. If there are more than 10 entries, further alarm pages are automatically presented for selection. In this event, pressing the “Alarms" button

(1) causes paging on to the next available alarm page. If the first page appears again, or if the dis play remains unchanged on pressing the button, then no further alarms are present. The numbering of the alarm pages presented is displayed on the page, lower right. In general a message remains active until it

has been acoustically and optically acknowledged (Button (4)) and the fault has been eliminated.

Figure: Alarms table

Commissioning and operation

Menu functions

The display unit provides a number of setting options. Activation of the button (1) for approx. 3 seconds activates the menu page. The page contains the following configuration points:

D Setting the time D Selection of the presentation in German, English, Italian, Spanish and French D Selection of the display in metric/non-metric units D Activation of the service page

The menu point in the respective red marked field can be changed with the buttons (2) and

(3). Pressing the button (5) switches the marking to the next field. Pressing the button

(1) for approx. 3 seconds results in the set values being accepted and the menu is closed. The display switches to the alarm table. The selection of the language has no influence on the menu and the service page. These pages are always displayed in English.

Figure: Menu for setting the display

Selection of the logo

Commissioning and operation

Configuration

The logo to be blended in is selected on the logo page. This is displayed at the centre of all pages of the

display. This page is opened or closed on selection of the menu item and changing the

page via the buttons and .

After selection of the menu item by actuating the button an available logo can

be selected via the buttons and . After activation of the button for approx. 3 seconds,

the selection is accepted and the menu is closed.

LED displays

There are two LEDs beneath the display. A green “Power" LED is activated by applying the supply voltage. The red “error" LED flashes when there is no communication on the CAN data bus. The displays of the ship data then all show the value “0".

Commissioning and operation

5. MMDS-CMS display device

The visualisation of engine operating data, general ship's messages and alarms is an important part of modern alarm and safety systems on ships. The amount of information is steadily increasing and must be registered and evaluated quickly. Alarms and / or warnings are to be recorded and reported quickly and precisely. Clear and user-friendly displays are a precondition for safe operation of any ship.

The MAN Monitoring System represents a new component of the proven alarm, safety and diagnostic sys tem MMDS, which offers a variety of new functions and display formats. The PC-based system is used to display operating data of several engines and general ship messages.

The 10" / 15" MMDS-CMS 10 / 15 TFT monitor is part of the system. Data that has previously been pro cessed by the corresponding software is shown on the display. The software is controlled using integrated function keys that are located on the left of the display. The assigned functions are shown on the left edge of the display. There is a choice of various forms of display. These can be pages with digital displays, ana logue instruments, visual engine graphics and tabular displays. There are also two keys at the bottom right for visual and acoustic alarm acknowledgement. The keys above these are for setting the display by means of an “on screen display" menu.

Commissioning and operation

Function and operation

Display functions

The display is switched on and off using the Power button (top right). Underneath this, there are four sys tem keys for adjustment of the display illumination and for maintenance of the display. Usually, only the ar row keys are important. The “Menu" and “Store" keys are for controlling the OSD menu.

Function: Switching the display on and off.

Functions: Activation and deactivation of the OSD menu and switching to the next

higher menu level.

Standard func tion:

Functions: Selecting menu items and saving parameter values.

Software operation

The MMDS-CMS 10/15 monitor serves to display and control visualisation software that is installed on the PC. This software is adapted to the overall system and is explained in a system description. Ten function keys are arranged on the left of the display for operation of the software. The assigned functions are shown at the edge of the display.

For the control of software functions, there are also two keys at the bottom right for visual and acoustic alarm acknowledgement.

Decrease display brightness. Additional functions if the OSD menu is shown: shifting the selection field

for the menu items upwards and increasing parameter values. Increasing display brightness

Additional functions if the OSD menu is shown: shifting selection field for the menu items downwards and decreasing parameters.

Example of a function key with the assigned function to call up analogue display.

Standard function: Additional function:

Standard function:

Additional function:

Acoustic acknowledgement of all monitoring devices contained in the system.

If a Windows communication box appears, this key (TAB) enables selection control.

Visual acknowledgement, which means that all flashing alarms switch to continuous light if they have previously been acknowledged acoustically. All other monitoring devices contained in the system are acknowledged as well.

If a Windows communication box appears, this key (ENTER) enables acknowledgement.

Commissioning and operation

Software description

Introduction

Processing engine data, general ship data and alarms is an important part of modern alarm and safety sys tems on ships. The amount of information is steadily increasing and must be registered and evaluated quickly.

The MAN Monitoring System MMDS-CMS belongs to the Alarm, Safety and Diagnostic Unit MMDS. It offers a variety of functions and types of display, which are mainly defined by the visualisation software. It is fully installed and configured on the compact PC MMDS-CMS S which is part of the system.

Measured values and alarms are displayed in different forms on the monitoring system. Alongside a preset page with displays of analogue or digital instruments, there is a page that can be freely configured by the user. In addition, the engines are represented graphically. In the event of a fault, the source of the problem can be recognised easily. A further special feature is the dynamic display of speed-dependent variables. The limit value changes directly with the speed so that the distance between an actual value and the cor responding alarm limit value is easily recognisable at any time. All alarm and measuring point lists are avail able in tabular form. The displays are operated using the integrated function keys or by means of an ex ternal mouse or trackball.

This documentation is intended to make the user acquainted with the operation of the software and to provide an overview of the system at a glance. Please note that this description is a minimum configuration of the monitoring system. Extension options are documented separately. The devices belonging to the sys tem are also documented extensively in the individual device descriptions.

Commissioning and operation

Scope of services

The monitoring system registers, evaluates and displays engine and gearbox data of MAN ship's diesel en gines. The measured values are registered via the MMDS diagnostic units, one of which is placed each of the engine terminal boxes. Data interchange between the devices takes place via the separate CAN bus lines, CAN Engine 1 and CAN Engine 2. The compact PC, which is part of every display, processes the data and makes it available on a CMS 15" / 10" display with the help of visualisation software.

Display

The data is shown on the 10"/15" display MMDS-CMS 10" or the smaller MMDS-CMS 15". Ten function keys are integrated in each of the monitors. This enables functions such as page selection or scrolling. On connection of mouse and keyboard, one of the pages can be freely configured. On the Custom page, the selection of data and its displays can be adapted to the user's needs by means of a few mouse-clicks.

Extension options

The MMDS-CMS alarm system can be extended to form a comprehensive ship and engine alarm system. A large number of analogue and binary sensors can be integrated on connection of one or more data sta tions (e.g. MMDS IO12) in order to, e.g., monitor the filling levels of fuel tanks or the condition of position lanterns. Further route-specific information can be calculated by connecting a GPS receiver that uses sensor data, for example the range resulting from the current fuel consumption and speed.

Operation

Commissioning and operation

2 3 4 5 6 7

2 3 4 5

8 9

The displays are activated automatically when the power supply is switched on. They can be switched on and off individually by pressing “Power" button Ê.

The computers can be switched on and off when the power supply is switched on. The startup procedure of the operating system Windows XP, as well as of the visualisation software, takes approx. one minute and is visible on the displays.

6 7

Control with the function keys

The (1) - (10) function keys to the left of the display are used to control the software. Operation is dynamic, i.e., the assigned functions change depending on the page displayed. The currently possible functions are explained in a specifically assigned section of the display located to the right of each key. Insofar as a field is empty, the assigned key does not have any function.

Menu functions are selected using the function keys or per mouse-click on the menu text. The following list shows all the functions available in the program. They can be used to select a specific page, to scroll within tables or perform other functions.

Function: opens the start page, which exclusively shows digital displays (see page 62, Main Menu).

Function: opens a page which displays data as analogue instruments (see page 64, Analogue display).

Function: opens a page which displays data digitally (see page 65, Digital display).

Function: opens a page on which the user can customise the display interface ac cording to his / her own wishes (see page 67, User-defined display).

Commissioning and operation

Function: opens a page which shows visual representations of the engines with the corresponding measured values (see page 69, Visual engine display).

Function: opens the alarm screen. Here, the acknowledged and unacknowledged alarms are displayed in tabular form (see page 73, Tabular display of alarms).

Function: opens the measuring point lists. Here, all measuring points are shown in tabular form (see page 70, Measuring point list).

Function: opens the settings page. Here, the clock, the unit system and other options can be set.

Function (only available in the measuring point list, alarm table or settings page): swit ches over to the last visualisation mode shown.

Function (only available on settings page): selects the next adjustable element.

Function (only available on settings page): selects the previous adjustable element.

Function (only available on settings page): increases value of the selected element.

Function (only available on settings page): decreases value of the selected element.

Function: (only available in the alarm table): scrolls up in the alarm table.

Function: (only available in the alarm table): scrolls down in the alarm table.

Function: (only available in the measuring point list): opens the measuring point list for the port engine.

Function: (only available in the measuring point list): opens the measuring point list for the starboard engine.

Function: (only available in the measuring point list): scrolls up in the measuring point list.

Function: (only available in the measuring point list): scrolls down in the measuring point list.

Commissioning and operation

Function: (only available in the measuring point list or in the alarm table): shows / hi des legend with explanations for the table column “Kind of alarm".

Function: opens the instrument selection menu. An instrument selected here is dele ted, if present. (only available on the “Custom" page. The button can only be selected using the mouse).

Function: opens the instrument selection menu. An instrument selected here is in serted or the form of display is changed (only available on the “Custom" page. the but ton can only be selected using the mouse).

Function: scrolls up in the table of unacknowledged alarms.

Function: scrolls down in the table of unacknowledged alarms.

OSD menu

The Ë - Î keys to the right of the display have general functions for setting the display (on-screen menu).

Brightness adjustment

The backlighting of the display can be dimmed. On operation of the Ì or Í keys, a bar display appears which indicates the current brightness in %. It is controlled by holding down the keys. The brightness is re duced using the Ì key and increased using the Í key.

Acknowledgement

The Ï + Ð keys on the bottom right are for acknowledgement of alarms. Pressing the Ï key acoustically acknowledges all monitoring devices contained in the system.

The Ð keys visually acknowledges all alarms that were previously acknowledged acoustically, i.e. flashing alarms change to a permanent signal. All other monitoring devices within the system are also acknow ledged in this way.

Windows communication box

The Ï + Ð keys also have additional functions for Windows control. Should a Windows communication box appear, the Ï key enables selection control. The function corresponds to the “Tab" key of a PC keyboard. The Ð key is used for confirmation and corresponds to the “Return" key.

Data display

The data is visualised on 5 different graphical pages, a page with tabular measuring point lists and an alarm table.

An engine has a total of 35 measuring points. Six measuring points per engine can be enabled on commis sioning.

Commissioning and operation

Main menu (start page)

After switching on the system, the start page is shown first of all. The start page can be called up via the “MAIN MENU" function from any other page. The most important measured values of both engines are summarised here and displayed in large digits. The unacknowledged alarms, as well as the date and time, can be found in the lower section.

Description of function keys for software operation

Area for depiction of port en gine measuring points

Area for depiction of starboard engine measuring points

Date Table of all unacknowledged alarms Time

Figure: start menu

Commissioning and operation

Settings page (Adjustments)

The time and units (metric or imperial system) are set on the settings page. The display of the mouse pointer, as well as the commissioning sensors, can be enabled and disabled here.

This page is only accessible from the “Main Menu" page. Pushing the F7 key opens the settings page.

Values are set using the F5 and F6 function keys. Pushing the F5 (+) key increases the selected value by one; pushing the F6 key (-) reduces the value accordingly. The appropriate key can also be held down to accelerate setting of the time.

The value to be set next is activated with the “NEXT ELEMENT" (F2) button. The “PREV ELEMENT" (F3) button is used to move back one value. The currently selected value is framed in red. Switching back to the main menu page is possible by means of the “BACK" button after completion of the settings. The set val ues are automatically adopted and stored.

Setting the date and time

Mouse indicatorvis ible / not visible

Showing / hiding com missioning sensors

Figure: settings page

Changing the unit system

Commissioning and operation

Analogue display

This page is opened using the “ANALOGUE" function. The most important engine and gearbox data is visualised as instrument dials in this display. The battery voltage and current fuel consumption are shown digitally. The unacknowledged alarms, as well as the date and time, can be found in the lower section.

Description of function keys for software oper ation

Area for depiction of port en gine measuring points

Area for depiction of star board engine measuring points

Table of all unacknowledged alarms

Figure: Analogue display

Commissioning and operation

Digital display

This page is opened using the “DIGITAL" function. Important engine and gearbox data is shown here as bar displays. This form of representation enables easy evaluation of the registered data, including how far they are away from limit values, as well as their relationship to other values.

Battery voltage, current fuel consumption and total operating hours for both engines are displayed digitally. In a similar way to the other graphical pages, the table with the unacknowledged alarms is located in the lower area.

Description of function keys for software oper ation

Area for depiction of port en gine measuring points

Area for depiction of star board engine measuring points

Table of all unac knowledged alarms

Battery voltage Rel load Fuel consumption Total engine op erating hours

Figure: Digital display

Commissioning and operation

User-defined display

The user can configure the instrument range as desired in the user-defined display. All instruments can be defined as regards their size and type of representation. Important measuring points can thereby be high lighted visually. The instruments are available in different forms of display. For example, exhaust gas tem peratures can be represented as thermometers or instrument dials; the speed can be shown as an instru ment dial or meter.

Binary engine alarms are not available in this display. Alarms are, however, listed in the table of unacknow ledged alarms, as on all other pages.

Description of function keys for software operation

Configurable area

Table of all unacknowledged alarms

Figure: user-defined display (example)

Commissioning and operation

Configuration of user-defined display

A mouse or trackball and a keyboard must be connected to the MMDS-CMS S compact PC in order to con figure this display. To insert or delete an instrument, click on the softkeys to open the selection menu on the softkeys (the F7 and F8 keys are disabled here, as a mouse or another pointer devices is required).

Various instruments are available in this menu for the individual measuring points. Selecting an instrument adds or deletes it.

Figure: opening the selection menu

A mouse click on the point is used to configure an instrument.

Figure: click points of the individual instruments

Commissioning and operation

To shift an instrument, click to select it and drag with the mouse button pressed (drag and drop).

Figure: shifting an instrument

The following configuration window appears on clicking an instrument while holding down the [Shift] key. The size of an instrument can be adjusted here between 250 and 400 pixels. To do this, the orange indic ator on the scale is dragged with the mouse or the value is entered directly into the adjacent field. The changes are accepted and the configuration window is closed by clicking the “DONE" button.

Figure: the configuration window

Commissioning and operation

Visual engine display

In the graphical display, the exhaust gas temperatures are shown at the relevant installation positions of the sensors. Other measuring points and binary alarms are located in the lower half of the page shown. The instrument area is divided into two halves. The measuring points for the starboard are arranged in the right half; those for the port are shown in the left half.

As on all pages, the unacknowledged alarms are shown in the lower part.

Selection area for other pages

Display area of starboard engine

Display area of port engine

Figure: Visual engine display

Commissioning and operation

Display of all measuring points

List of measuring points

This display shows tables of all the measuring points available in the system. The “ENGINE PORT" and “ENGINE STBD" keys are used to select the list for the respective engine. This view can be opened from all other pages by pressing the “MEASURING POINTS" key. The complete list can be viewed by pressing the “TABLE UP" or “TABLE DOWN" keys. Selection of the “BACK" key opens the last activated view. A le gend that explains of the abbreviations can be hidden or shown using “SHOW LEGEND" button.

As on all pages, the unacknowledged alarms are shown in the lower part.

Figure: table with all measuring points and legend shown

Commissioning and operation

Structure of the table

The columns “Measuring point“, “Unit", “Value" and “Kind of Alarm" in the tabular display mean:

Measuring point Contains the designation of the measuring point Unit Contains the unit of the measurement variable Value Contains the current measured value Min / Max Identification of the type of monitoring of the limit value Kind of Alarm The three alarm stages: “Sensor failure", “Warning" or “Main alarm"

List of all measuring points

Each of the two engines has analogue and binary sensors. The measured values are monitored and evalu ated by the MMDS diagnostic unit. The data is made available to the PC system via CAN BUS.

Identification of alarm monitoring

The following identifiers are distinguished at “Min / Max":

D NORM Normal state D XAExternal alarm D FAULT Failure alarm D TIAH Temperature limit value exceeded D TIAL Temperature limit value undershot D DTIAH Positive temperature deviation D DTIAL Negative temperature deviation D TAH Temperature too high (binary alarm) D TAL Temperature too low (binary alarm) D PIAH Pressure limit value exceeded D PIAL Pressure limit value undershot D DPIAH Positive pressure deviation D DPIAL Negative pressure deviation D PAH Pressure too high (binary alarm) D PAL Pressure too low (binary alarm) D LIAH Level limit value exceeded D LIAL Level limit value undershot D LAH Level too high (binary alarm) D LAL Level too low (binary alarm) D IND Display (analogue input, no limit value control, but failure display) D BLC Blocked alarm (measuring point blocked by another measuring point)

Commissioning and operation

Alarm and limit value display

Dynamic limit value display

Limit values depending on the speed are represented dynamically by the monitoring system. In the follow ing illustration, the speed was changed at constant oil pressure. The rise in the limit value can be recog nised with increasing speed.

Figure: dynamic limit value display on the oil pressure gauge

Graphical alarm display and alarm acknowledgement

When a state of alarm has been reached, the corresponding instrument starts flashing. In the event of an alarm, the instrument flashes until the alarm state is acknowledged. Two keys to the right of the display are used for the acknowledgement.

Function: acoustic acknowledgement or deactivation of the internal horn. All monitoring devi ces within the system are acknowledged on operation.

Function: Visual acknowledgement, which means that all flashing alarms switch to conti nuous light if they have previously been acknowledged acoustically. All monitoring devices within the system are acknowledged on operation.

Figure: various versions of the “Coolant temperature" instrument flashing in the event of an alarm

Commissioning and operation

Tabular alarm display

There is a graphical alarm display in parallel to a tabular display. There is an “Alarms" table in the display that contains all alarms and the “Unacknowledged alarms" table with all unacknowledged alarms. Both can be seen in the alarm table. This view is opened from any other page using the “ALARMS" key. An excerpt from the table with the unacknowledged alarms is also found on all other pages.

Figure: active alarm table

Structure of the table

The columns “Measuring point", “Unit", “Value", “Time", “Date" and “Kind of alarm" in the tabular display mean:

Measuring point Contains the designation of the measuring point Value Contains the measured value at the time of the alarm Unit Contains the unit of the measurement variable Time Contains the time the alarm occurred Date Contains the date the alarm occurred Min / Max Identification of the type of monitoring of the limit value (see chapter

“Identification of alarm monitoring" on page 71)

Kind of Alarm The three alarm stages: “Sensor failure", “Warning" or “Main alarm"

The control options on the alarm table page are identical to those on the measuring point list.

Commissioning and operation

Alarm table and alarm acknowledgement

Each new alarm flashes initially in the top line. Existing alarms move down one line. On acknowledgement, the flashing display of all alarms turns into constant light. If there are more alarms than can be represented, the user can use the “ALARM TABLE UP" and “ALARM TABLE DOWN" keys to scroll up and down. When the source of an alarm has been removed and the alarm has been acknowledged, it is deleted from the alarm table. Two keys to the right of the display are used for the acknowledgement.

Function: acoustic acknowledgement or deactivation of the internal horn. All monitoring devi ces within the system are acknowledged on operation.

Table of unacknowledged alarms

The first alarm that occurs is shown in the top line. All following alarms initially appear in the second line and move one line down as other alarms follow. The first alarm can always be found in line 1, simplifying the evaluation of the cause of further alarms. If there are more alarms than can be displayed, the complete list of unacknowledged alarms can be called up using the F9 and F10 keys. The display remains active until the alarms have been acknowledged. All alarms in the table are deleted on acknowledgement. The “Visual ackn" and “Acoustic ackn" keys are used for acknowledgement.

Commissioning and operation

6. Drive lever control Marine Power Control (MPC)

Danger:

For safety reasons a separate, functioning red emergency-stop button for each engine must be in stalled at every bridge (the engine must stop immediately when the button is pressed once).

At the request of the shipyard or customer, it is possible to purchase from MAN an electronic drive lever control system made by Bosch-Rexroth, model Marine Power Control.

This control system has plug connections specially configured for MAN.

Command master

Danger:

Incorrect function due to damaged control head! Humidity may ingress into the damaged control head. The vessel can then no longer be controlled correctly. Inspect the control head for visible damage before every operation of the vessel. Do not set out with a damaged control head.

Caution:

Danger! Do not secure or lean on the lever. Undesired engine speed change and breakage of the lever is possible. Never use the control head or the lever as a hand hold. Do not lean against the control head.

Caution:

Damage can result from pointed objects! Destruction of the covering film is possible. Dampness can then ingress and lead to control fault functions. Do not use pointed objects to operate the control buttons. Do not cover the control head in use with a protective hood.

Commissioning and operation

The control head is used to control engine speed and the gearbox. The operation takes place via the control lever and four buttons. On twin engine installations the left control lever operates the port engine and gearbox and the right lever the starboard engine and gearbox. On single engine installations the handle on the control lever is the universal control.

Function

Infinitely variable speed adjustment

Max. speed

Control panel

Gearbox ahead (lock)

Ahead range

Neutral

(lock)

Gearbox astern (lock)

Astern range

Infinitely variable speed adjustment

Max. speed

Acoustic signalling device

“Neutral" (lock) position (1) In this position, the gearbox clutch is disengaged and the power unit is idling. Each time the “Neutral-posi

tion" is reached, the control system indicates this acoustically by means of a short “beep-tone".

Commissioning and operation

“Gearbox forwards / reverse" (lock) position (2)

In this lever position, two different functions are possible.

1. Standard function:

The gearbox clutch is engaged to Forwards" or Reverse"; the power unit is idling.

2. “Increase engine speed" function

The Increase engine speed" function is set. The engine speed of the power unit is raised prior to enga ging the clutch and after disengaging the clutch it is lowered again to idling speed. Between the clutch engaging operations, individual delays (waiting periods BEFORE and AFTER clutch engaging) can be set.

“Maximum engine speed" position (3) Position (3) shows the maximum engine speed" for the “Forward and Reverse Range". Between positions

(2) and (3) the engine speed can be set variably. The gearbox clutch is engaged to “Forward" or “Reverse".

Control panel - Control head for twin engine installations

(1) Button COM

(2) Button SYN

(3) Button TRL

(4) Button S&G

(5) Brightness sensor

(7) LED WARM UP

(8) LED SYNCHRO

(9) LED TROLLING

(10) LED SLIP & GRIP

(11) LED ALARM

(6) LED COMMAND

Commissioning and operation

Description of buttons

Button Function see

Request command “Activate control console", see page 79 Accept command

Engine warm up “Engine Warm Up", see page 81 Acknowledge alarm “Acknowledge alarm", see page 86 Adjust brightness of LEDs “Adjust brightness" see page 85

“Change control console", see page 80

Automatic synchronisation of the en gine speeds for twin engine layouts

Switch on and off the “Slip & Grip" ope rating function

Switch on and off the “Trolling" opera ting function

Description of LEDs

LED Function

Flashes slowly: Command requested, Handover not possible

Flashes rapidly: Command requested, Handover possible

Continuously lit: Command active

Continuously lit: Engine speed adjustment possible Gearbox “Neutral"

Flashes: Speed synchronisation is in stand-bymode

Continuously lit: Speed synchronisation active

“Synchronise engine speed", see page 81

Switch “Slip & Grip on and off", see page 85

Switch “Trolling on and off", see page 84

Separate display for port and starboard

engine

yes

Continuously lit: Trolling active

Continuously lit: Slip & Grip active

Continuously lit: Alarm

yes

Commissioning and operation

Description of acoustic signal transmitter

Warnings and alarms can be reproduced via the acoustic signal transmitter..

Interval signal tone

fast actuation of the button Handover of the control console possible

slow

Continuous tone Fault alarm of the connected control Alarm

Activate control console

If the control is switched on via the master switch, first all control consoles are initialised. This is indicated by a slow flashing LED on each control console.

D D and an unbroken acoustic signal.

During the initialisation

D the control consoles are inactive and D the vessel cannot be controlled from any control console.

Event Meaning

Initialisation of the connected control Handover of the control console is requested

actuation of the button Handover of the control console not possible

Select control head

Select the control head by actuating the button.

TheLEDs and signal tone stop on all other control consoles.

If the levers are not in the “Neutral“ position, the LEDs continue to flash and the sig nal tone remains the same.

If necessary, place the lever in the “Neutral" position.

The LEDs now flash quickly and the signal tone is faster.

Extinguish the LEDs by pressing the button again . The control console is active and the engine can be started.

Commissioning and operation

Change control console

Note:

The control console can only be changed, when no directional change is taking place in the gear box.

Current control console Control console to accept control

"Ahead range" “Ahead" range or “Neutral" “Neutral" range Neutral Astern range “Astern" range or “Neutral"

In order to activate a passive control console, the control head must be selected and then the selection confirmed. The active command remains with the active control console, until the selection is confirmed.

Select the control head by actuating the button.

If the levers are not in the “Neutral position, the LEDs flash slowly and the signal tone is likewise slow.

Adjust the lever of the control head according to the table.

The LEDs flash quickly and the signal tone is likewise fast.

Confirm the control head by pressing the button again.

The LEDs go out and the signal tone stops.

The requested control console now has active command, the previously active control console is passive.

If the button to confirm the change of command is not pressed within 15 seconds, the change of control console terminates.

Note:

If the “COM" button to confirm the change of command is not activated within 15 seconds, the change of control console terminates.

Commissioning and operation

Engine Warm Up

Caution:

Do not exceed the permissible highest engine speed.

Note:

On vessels with twin engine drive the port and starboard engines can be warmed up independ ently.

Start the “Warm Up" function

1. Set the respective control head in the “Neutral“ detent.

2. Press and hold the button.

3. Set the respective control head lever in the “Ahead" or “Astern" position.

4. Release the button.

The “Warm Up" function is activated. The respective LED lights permanently.

The engine speed corresponds to the lever setting, the gearbox remains disengaged.

Exit the “Warm Up" function

The “Warm Up" function is stopped by moving the lever to “Neutral".

Synchronise engine speeds

On twin engine layouts the option exists to synchronise the speeds of the propulsion engines.

The “Synchro" can be used

D to control all engines at the same engine speed, D or to set the engine speed of all engines using one lever (Master)

In this instance the master system takes over the control of the slave system.

Note:

The engine speeds can also be synchronised in the “WARM UP“ mode. This is useful, for ex ample, when it is required to apply identical control of the engines with reference to the tachomet ers.

Commissioning and operation

Control engines at the same engine speed

1. Set both levers in the range between “Ahead" and “Full ahead" (max. deviation of the levers from each other 10%).

2. Press button.

Both engines are regulated to the same engine speed. The LEDs light.

Note:

If the levers are moved out of synch. with each other by more than 10%, then the “SYNCHRO" mode reverts to Stand-by mode. As soon as the levers are again positioned less than 10% away from each other, the synchronisation becomes effective again.

Adjust engine speeds with a single lever

1. Position the lever in the “Ahead" detent.

2. Press button.

The LEDs light. Both engines are engaged at idle.

Increase speed of all engines:

3. Push the lever of the master system forward.

The LED of the master system remains lit, the LED of the slave system goes out.

Note:

If the speed of the slave system is increased, the “SYNCHRO" function reverts to the Stand-by mode. As soon as the levers are again positioned less than 10% away from each other, the syn chronisation becomes effective again.

and

1. Set both levers in the range between “Ahead" and “Full ahead" (max. deviation of the levers from each other 10%).

2. Press button.

The LEDs light. Both engines are engaged.

3. Move the lever of the slave system quickly to the “Ahead" detent.

The LED of the master system remains lit, the LED of the slave system goes out.

If the slave system lever is moved too slowly, then the “SYNCHRO" function reverts to the Stand-by mode.

Both LEDs light, because the port and starboard sides are not synchronised. As soon as the levers are again positioned within 10% of each other, the process is repeated.

Commissioning and operation

Switch offsynchronisation

Danger:

On switching off the synchronisation, the speeds of both engines revert to the speeds set by the respective levers. The direction of travel of the vessel changes if the lever settings are not identical.

Press button. The synchronisation is deactivated.

Note:

The synchronisation also switches off, if at the active control console one lever is set to “Neutral" or “Astern".

Commissioning and operation

Switchtrolling on and off

Control of the propellor slip of a trolling transmission can be specified with the “Trolling" function. Thus the propulsion of the vessel can be reduced when manoeuvring.

Prerequisite: The vessel must be equipped with a trolling transmission.

Danger:

On activating the trolling function a reduction in engine speed may result. On deactivating the trolling function an increase in engine speed may occur.

Switch on trolling

1. Set the levers at the active control console to the “Neutral" detent. The gearboxes are now disengaged.

2. Press button.

The LEDs light. The “TROLLING" transmission function is activated.

Navigate with trolling

When the lever is at the “Ahead" or “Astern" detent,

D the slip in the trolling transmission is a maximum, D the propulsion of the vessel is almost non-existent.

When the lever is at the “Ahead" or “Astern" detent,

D the slip in the trolling transmission is minimal, D the propulsion of the vessel is of a similar order of magnitude as in normal operation at idle.

Switch off trolling

1. Set the levers at the active control console to the “Neutral" detent. The gearboxes are now disengaged.

2. Press button.

The LEDs go out. The “TROLLING" transmission function is deactivated.

Commissioning and operation

Switch SLIP & GRIP on and off

Prerequisite: The vessel must be equipped with a trolling transmission.

The transmission function “SLIP & GRIP“ is a combination of trolling in the lower lever range and normal operation in the upper lever range. This enables a more precise control of vessel speed at slower speeds. However, maximum speed can be selected at any time.

Danger:

On switching off the “SLIP & GRIP“ the vessel can undergo moderate accelerations.

Switch on Slip & Grip

1. Set the lever on the active control console in the “Neutral" detent.

2. Press button.

The LEDs light.

Switch off Slip & Grip

The “SLIP & GRIP" transmission function can be switched off at any lever position.

1. Press button.

The LEDs go out.

Adjust display brightness

Switch over between day and night mode

Hold button pressed and press briefly.

A repeated brief press of the button always switches between the day and night mode.

Commissioning and operation

Continuously adjust display brightness

Hold button pressed and wait until the brightness of the display changes.

- When the display becomes brighter, you can adjust the display brightness up to maximum bright

ness.

- When the display becomes darker, the brightness first reaches the minimum brightness and then be

comes brighter again. The display brightness can then be adjusted up to maximum brightness.

Reverse dimming direction

Hold button pressed and press in order to continuously adjust the display brightness.

Release button briefly and then press again. The dimming direction reverses.

Acknowledge alarm

Alarm messages are optically displayed to all control consoles simultaneously, irrespective of whether the control console is active or passive. The acoustic signal is only output at the active control console.

Switch off acoustic signal

1. Press the button at the active control console.

2. Eliminate the cause of the fault message.

Danger:

Under certain circumstances the vessel is no longer manoeuvrable in the event of an alarm mes sage!

On vessels with twin engine drive the port and starboard engine alarm messages are displayed independ ently of each other.

Commissioning and operation

The following alarm messages can occur:

Message Meaning

Warning

Alarm lamp without signal tone

Alarm lamp and continuous si gnal tone

Fault table

Fault Possible cause Remedy

Uncontrolled behaviour of the ve ssel

The “WARM UP" function will not start.

The “TROLLING" function will not activate.

The “SLIP & GRIP" function will not activate.

Control head does not react to le ver movements.

Remote control fault, which does not have a direct effect on the con trollability of the drive system, e.g. control head of another control con sole damaged.

Alarm Control of the vessel is restricted or is even no longer possible, e.g.

active control head damaged.

Surface visibly damaged, water has penetrated the unit.

Lever does not remain in the “Neutral" detent.

Command head potentiometer is defective.

Control head is not activated. “Change control console",

No internal system voltage. Check and restore Internal sys

Replace device.

“Warm Up" chapter, see page 81.

“Switch trolling on and off" chap ter, see page 84.

“Switch SLIP & GRIP on and off" chapter, see page 85.

Replace device.

see page 80.

tem voltage.

Commissioning and operation

6.1. Mobile navigating console

The mobile control console serves to extend freedom of movement. The control signals are transferred to the MPC via a cable.

The two command master levers are used to set the engine speed and the gearbox position (forwards, neutral, reverse).

full ahead

1. Detenta ahead

Neutral

1. Detent astern

full astern

As an additional user interface the following operating elements are provided:

safety stop push-button

Command master lever Port

Anchor winch Down button

bow thruster Port

stern thruster Port

full astern

full ahead

1. Detent ahead

Neutral

1. Detent astern

Command master lever

Starboard

Anchor winch Up button

bow thruster Starboard button

stern thruster Starboard button

starboard alarm LE

portside alarm LED

portside command LED

starboard command LED

command push-button

trolling LED

trolling push-button

dead man's switch

Buzzer

Commissioning and operation

Description of the operating elements:

General:

After switching on the supply voltage for the Mini-Marex system and the entire system of the mobile navig ating console, all correctly functioning command masters are in the state 'lamp test' (all LEDs and buzzers on). The lamp test is terminated automatically after a short time and the standard takeover procedure be gins. At each navigating console, pressing the Command button once requests the command. Pressing the Command button again takes over the command.

Command push-button:

Pressing the button requests the command takeover for the mobile navigating console. This state is indicated by the two Command LEDs flashing and the buzzer sounding.

D The two LEDs and the buzzer will be flashing respectively bleeping fast if com

mand transfer is possible. The command may be transferred by pressing the

Fast bleeping l

slowly bleeping

Steady lighting of the two command LEDs signal the transfer of command. In this mode of operation the buzzer is turned off. The hand-held remote control is now active and can give commands.

Special function “Warming Up"

The “Warming Up" function can be used to set a specified speed without shifting the gearbox. This function is required to warm up the engines.

To enable the “Warming Up" function, press the button and simultaneously place the lever in For

wards or Reverse. The button can then be released. To switch off, return the lever to Neutral. The button must not be pressed here. If the function “Warming Up" is active, the command LED will be flashing.

push-button once again.

D The two LEDs flash and the buzzer beeps slowly when no command takeover

is possible. An error cause can be that the command master levers are not located in the same range of the active navigating console.

. Warm-up function can be switched on and off independently for each side. The command LEDs are as

signed to the corresponding levers.

Commissioning and operation

Trolling push-button:

The button can only be pressed in neutral position of the command master levers. The function is ac

tivated by pressing the

Pressing the the trolling function..

Synchronising:

The command can also be adopted by the mobile navigating console when the active navigating console is in the synchronisation mode. Here, the synchronisation mode is retained at the mobile navigating console and the LED on the Trolling button flashes. A neutral position of one of the two command master levers switches off the synchronisa tion. The synchronisation cannot be switched on at the mobile navigating console; it can only be taken over from the active navigating console.

button again (the command master levers must also be in neutral position) switches off

button and is indicated by the Trolling LED lighting up.

Commissioning and operation

Dead man's switch:

The supporting loop of the dead man's switch at the hand-held remote control is to be looped around the user's wrist during operation of the hand-held remote control. In case of loss of the hand-held remote con trol the pin fixed at the supporting loop will be torn out off the hand-held remote control so that the vessel's propulsion will be turned off. In this way an uncontrolled manoeuvring of the vessel is avoided.

The dead man's switch has a function in active as well as passive mode of the hand-held remote control!

By tearing off the dead man's switch the engines are set down to idle speed and the gears are shifted into neutral position. This state will be signalled by lighting up of the two alarm LEDs and bleeping of the buzzer.

activeop

erating

mode

passiveop

erating

mode

Bow and stern thruster push-buttons:

Pressing a thruster button switches on the corresponding thruster. Releasing the button terminates the function.

. All relay outputs are available at the same time.If, for example, the push-buttons for starboard and port

side bow thrusterare activated at the same time, accordingly both contacts will be closed.

In order to re-obtain command the following steps have to be carried out: 1 Acknowledge error message by means of command push-button (consequence: buzzer

off). 2 Plug dead man's switch back into the designated bushing. 3 Move both control head levers to neutral position.

Subsequently, the alarm LEDs will cease to be lighted and the hand-held remote control has command again.

When requesting command without a dead man's switch being provided the following error messages will occur: 1 Both alarm LEDs will be lighted.

2. The buzzer sounds. 3 The two command LEDs will be slowly flashing.

Only after plugging the dead man's switch back into the designated bushing command can be taken over.

Anchor winch push-buttons:

The anchor winch buttons are used to raise and lower the anchor. The operation is terminated when the button is released.

. All relay outputs are available at the same time. If, for example, the push-buttons for anchor winch up

wards and downwards are operated at the same time, accordingly both contacts will be closed.

Safety stop push-button:

Caution:

The safety stop push-button is also effective in case of an inactive hand-held remote control!

A safety stop button is available for both the port and starboard sides (see Chapter 1, page 26). The engine is stopped immediately by actuating the safety stop button.

Commissioning and operation

7. Emergency operation unit::

The emergency operation control system - Em - is conceived as a simple engine speed and gearbox control system which enables safe continuation of a trip in the event of a failure in the electrical con trol lever system.

The operation unit for emergency running control is preferably integrated next to the throttle lever in the bridge console. For safe marine operation, the front buttons must be easily accessible. When the ignition is on, emergency running can be activated by way of appropriate function buttons. A green LED indicates operational readiness.

Operation is effected by way of six front buttons, which light up when a requested status is achieved and thus indicate the relevant operating or actual status.

Key Activate emergency operation

Key Shift gearbox to neutral position

Key Shift gearbox to forwards position

Key Shift gearbox to reverse position

Key Increase engine speed

Key Decrease engine speed

LED Power On indicates the presence of supply voltage when the ignition is on

LED System Failure indicates failure status by flashing or with continuous light

Commissioning and operation

Operating the emergency operation unit

Requirements for operation / activation / deactivation: D The emergency running control system should be only activated while the engine is running.

Otherwise the “System Failure" LED flashes to indicate there is no engine speed signal

D The engine should be shut down via the ignition lock

When the emergency stop button is pressed, the “System Failure" LED on the Em-C operation unit lights up when the ignition is simultaneously on as the active systems EDC engine control and emergency run ning unit are shut down by the emergency stop. The “System Failure" LED goes out after the emergency stop button has been released.

Operation / function of emergency operation unit in operation:

Enabling emergency operation unit

The system is ready for operation once the ignition has been turned on. This is indicated by the green “Power-On" The red LED (Failure) must not light up. The emergency running system can now be activated

by pressing the button twice:

Pressing the button for the first time requests emergency running mode. The button flashes cycli cally for approx. 6 seconds and an acoustic signal is issued. During this time, the request must be acknowledged by pressing the button for a second time. The button lights up permanently once the changeover to emergency running mode has taken place.

If there is no acknowledgement by pressing the button for a second time, the system returns to the initial setting (operational readiness).

Note:

Once the emergency running system has been activated, it is only possible to switch back to nor mal throttle lever mode by shutting down the engine (ignition “OFF" for at least 3 seconds)!

Commissioning and operation

Gearbox control

When emergency running mode is active, the gearbox is engaged in the neutral, forwards or astern posi tions by means of 3 button functions:

Key Shift gearbox to neutral position

Key Shift gearbox to forwards position

Key Shift gearbox to reverse position

Gearbox reversal will only take place when the engine speed is in the idle range. It is advisable always to engage the gearbox in neutral first prior to a reversal operation. If however the operator requests a reversal e.g. from forwards directly to astern (or vice versa) and the en gine is at a higher speed, the engine is automatically set to idle speed prior to each active reversal opera tion. The relevant pressed button flashes until the desired status is reached. It goes out when another control command is given or lights up permanently to indicate that gearbox re versal has taken place (indication of actual status).

Engine speed control

Once the gearbox is engaged in the forwards or reverse position, the current engine speed can be in creased or reduced by means of 2 button functions:

Key Increase engine speed

Key Decrease engine speed

As long as the + or - keys are pressed (“insert button symbol"), there is a continuous change in the engine speed. The increase or alteration rate is 50 revolutions / seconds. Each individual short pressing of a button brings about a speed change of 10 engine revolutions. The engine speed is restricted downwards to the idling speed and upwards to the maximum permitted en gine speed.

Commissioning and operation

Deactivating emergency running mode

Emergency running mode is always deactivated only after the engine has been shut down, it is necessary for the ignition to have been turned off for at least 3 seconds. When the ignition is turned on again, normal throttle lever mode is always activated first, i.e. the emergency running system must be reactivated as required.

Fault messages

Two LEDs on the Em-C operation unit (green “Power On" LED and red “Failure" LED) are used to differen tiate between various failure states:

Green LED off and red LED off

Ignition off or no supply voltage (emergency running mode not possible)

Green LED on, red LED flashes without another operator button also flashing

Drop-out of internal speed signal (function with delayed reversal times nevertheless still possible)

Green LED on, red LED flashes together with forwards button

Failure after gearbox reversal into forwards direction (this propulsion direction can no longer be activ ated)

Green LED on, red LED flashes together with astern button

Failure after gearbox reversal into astern direction (this propulsion direction can no longer be activ ated)

Green LED and red LED permanently on

System failure or no communication between Em-C and Em-R. (emergency operation not possible) Em-R is the receiver component in the terminal box.

Failure states which are indicated by flashing on the Em-C operation unit must be cancelled with the key

after the fault has been rectified. The failure indications continues to flash until it is cancelled.

Commissioning and operation

7.1. Override button

The Override button with LED is available as an option and is installed as an external button in the area of the navigating consoles. A separate Override button is required for each engine. Pressing the Override button after an alarm has reduced the engine speed recovers the original power out put of the engine. The Override button may be used in emergencies exclusively to protect the health and lives of the crew.

Function: If the engine output has been reduced due to an alarm, there is the possibility to press the Override button once (LED on) and recover the original power output of the engine. If there is another reason for power output reduction on the engine, this does not trigger a power output reduction of the engine. The function remains active until the Override button is pressed again (LED off) or the engine is shut down via the ignition (off position).

Urgent recommendation: Determine the cause of the drop in power output (alarm)!

If pressing the Override button leads to engine damage, this is not covered within the framework of MAN' li ability for defects.

Override button

Commissioning and operation

Main fuses for voltage supply + / - to the en gine

Two main fuses with 50 A are fitted at the engine; these trip in the event of overcurrent or short cir cuit. If a fuse as blown, the engine can no longer be started. The fuses can be reset by the operator using the keys fitted.

Main fuse on the control unit carrier EDC

A further 3 main fuses (arrow) are installed on the control unit carrier.

These fuses blow in the event of overcurrent or short circuit.

The fuses can be reset by the operator using the keys fitted.

Commissioning and operation

Shutting down

Do not switch off engine immediately operation at high loads, but let it idle for about 5 minutes to achieve a temperature equalisation.

Set the deck switch to “Neutral" and switch off the engine by means of the ignition key or Ignition button.

Remove key from starting lock.

Danger:

Ensure that the engine cannot be started by unauthorised persons.

Maintenance and care

Lubrication system

Ensure utmost cleanliness when handling fuels, lubricants and coolants.

Caution:

Use only approved fuels, lubricants etc. (see brochure Fuels, lubricants etc."). Otherwise the liab ility for defects will become null and void!

Refilling with oil

Danger:

The oil is hot-risk of scalding. Do not touch the oil drain plug with bare fingers. Oil is an environmental hazard. Handle it with care!

With the engine at operating temperature, remove the oil drain plug on the oil sump and the oil filter bowl and allow the old oil to drain off completely. Use a vessel of sufficient size to ensure that the oil does not overflow.

Note:

Change the oil filter elements every time the engine oil is changed.

Loosen oil filter cover (1) and unscrew it from the oil module by 2-3 thread turns. The engine oil now runs from the oil module into the oil pan.

Caution:

Allow the engine oil to run out without residue, or otherwise engine oil can flow from the unfiltered area into the filtered area.

Maintenance and care

Unscrew the oil filter cover (1) and remove it, to gether with the oil filter insert (3). Remove the oil filter insert (3) from the oil filter cover. Remove the sealing ring (2) from the oil fil ter cover.

Fit new sealing ring (2) to the filter cover (1). Insert the new oil filter insert (3) into the oil filter cover (1). Insert the oil filter cover (1) in the oil module and tighten to a torque of 40 Nm.

Changing the second oil filter insert takes place by analogy.

100

Man D2868 LE433, D2862 LE453, D2862 LE433, D2862 LE423, D2862 LE463 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Information and Copyright

Contents

Declaration

Nameplates

Safety regulations

Commissioning and operation

Engine views V8-1200 (D2868 LE433)

Engine views V12-1800 (D2862 LE433) / V12-1650 (D2862 LE453)

Engine views V12-1550 (D2862 LE423) / V12-1400 (D2862 LE443) / D2862 LE463)

First commissioning

Commissioning

Starting

Operation monitoring system

Shutting down

Maintenance and care

Lubrication system