BDMS / BTMS. Bearing Distance and Temperature Monitoring System. For two stroke diesel engines

Transcription

1 Bearing Distance and Temperature Monitoring System BDMS / BTMS For two stroke diesel engines Operating Instructions Design and Function Operation Trouble Shooting Technical Data DK Edition 2/2008 Dr. E. Horn GmbH Im Vogelsang 1 D Schönaich Telefon: Telefax: Internet: Dr._E._Horn_GmbH@t-online.de

2 List of contents General Information about the BDMS System overview: Indication units Indication unit display for BDMS + water in oil sensor only Indication unit for BDMS including optional main bearing sensors Indication unit for main bearing sensors type TGL only Indication unit for all possible sensors mounted inside the engine Connection boxes Transfer box Sensors Distance sensor type IW Sensor brackets Water in oil sensor type FRG Main bearing temperature sensor type TGL Switch type temperature sensor TGL01621 for big- and small end bearings (OPTION) Operation Alarm indication Alarm settings Installation Bracket and sensor mounting Sensor adjustment for engines with single sensor brackets Sensor adjustment for engines with double sensor brackets Outside mounting of connection boxes type GHG Electrical connection to and between the connection boxes Sensor connection to connection box type GHG Installation of line converter box type GHG / Installation of indication unit type MDA Installation of main bearing sensor type TGL Measuring of Offset values after retrofit installation only Speed table needed for adjustment of retrofit installations Installations in new engines on production test beds Maintenance Regular inspections Function Tests Exchange of sensors Removal/Replacement of sensor brackets Technical Data Indication unit type MDA Transfer box type GHG / Distance sensor type IW / see data sheet Main bearing temperature sensor type TGL00921 / see datasheet Water in oil sensor type FRG00032 / see data sheet Temperature switch type TGL01621 / see data sheet Technical data sheets / dimensional drawings Indication unit Line converter Connection boxes Distance sensor Water in oil sensor BDMS/BTMS E01/2008 page 2

3 10.6 Main bearing temperature sensor Temperature switch Connection diagrams Cabling Installation at the engine Sensor connection to terminal box type GHG Connection between the terminal boxes and line converter Connection table for Line Converter type GHG Connection to Line Converter type GHG Connection to the indication box type MDA312 in the ECR Torque moments for bolts BDMS/BTMS E01/2008 page 3

4 General Information about the BDMS The Bearing Distance Measuring System measures continuously the distance between the surface of the distance sensor and the cross head in the lower dead point position of the crosshead. Additionally the sensor is able to measure the temperature of the splash oil around his location. Measured values are calculated into real distance values in x.xx mm and stored in an internal memory. Also installed is water in oil sensor measuring the water content in the lube oil. This sensor is installed in the pressure line or in the near to the pressure outlet of the lube oil filter. The distance as well as the water in oil sensor transfers there measured values on request by the indication and master unit via a RS232 serial link through the connection boxes to the transfer box. The transfer box supplies all connected sensors / connection boxes with galvanic isolated power and acts as a data transfer unit changing the RS232 signal received from the sensors into a RS422 signal. This signal is delivered via a special bus cable to the indication and master unit located either in the engine room or in the engine control room. The indication and master unit presents per compartment the measured oil temperature in digital figures and 2 x bar graphs indicating the situation of the distance crosshead/sensor surface measured by the distance sensors. If the optional available main bearing analogue temperature sensors are installed those values are displayed, too. The received data are analysed and compared with the set limits in the memory. If necessary the responsible alarm relay is activated. Furthermore the indication and master unit stores the measured values in real time for the past 48hrs and than with one min/max value for every day in the internal memory. The storage capacity is min. 10 years based on 7600 engine running hours per year. The BDMS can be installed as a retrofit into engines already in service. The system is Type Approved by Germanischer Lloyd (GL). The system can be extended by optional available analogue temperature sensors type TGL00921 for the temperature surveillance of the main bearings. This sensor must be glued to the main bearing support and delivers via the serial link of the BDMS the temperature values to the indication and master unit. For engines under new production it is optional also possible to install temperature switches with contact less operation for the protection of big- and small end bearings type TGL The switches cannot be installed as retrofit due to the fact that the needed long holes do not exist in running engines. BDMS/BTMS E01/2008 page 4

5 1.0 System overview: The system contains the following components: 1. BTMS/ BDMS indication and master unit 2. Connection boxes 3. Transfer box 4. Sensors type IW with brackets (clamping type) 5. Water in oil sensor type FRG00032 Typical Setup of a Bearing Monitoring System 24VDC 24VDC PC RS232-I/O for Service Purposes Engine Transfer Box Sensors Sensor Cables Connection Boxes Power RS422-Bus RS232-Bus + Power Power Engine Control Room Engine Room Cable lengths: RS422-Bus: Length max. 200 m RS232-Bus + Power: Cable length between connection boxes 1..2 m, length from transfer box to the last connection box m Sensor cable: Length 10 m 1.1 Indication units Figure 1 General View of the system Prüfaufbau EMV.cdr B3 Figure 2: Indication unit mounted in field housing with IP66 for installation inside engine room BDMS/BTMS E01/2008 page 5

6 The indication unit is available in 2 executions, one as shown in Figure 2 built into special field housing for direct installation in the engine room or in a version to be mounted in a switchboard panel or engine control console with IP68 from the front and IP20 from the backside. If the unit is installed in the engine room directly care must be taken that the installation place can be reached safely by the crew even under alarm condition of the engine under surveillance. The field housing is equipped with EMC cable glands allowing the connection of the serial link bus cable, the 24VDC power supply, the connection of the RS232 to ships or engine PC as well as the relay outputs. The panel unit has all connections by secured connectors at the backside. For correct connection please refer to the connection diagrams in this manual. The indication unit presents data from all connected sensors within a certain priority chain. Water in oil as well as analogue main bearing temperatures can be updated with a lower rate than the distance measurement values. The measured values are verified against limits given by the engine manufacturer. Pre-alarm / load reduction / auto stop relays are available for selection by the user. All received data are stored in the unit in a special storage card allowing the view of the last 48hrs in real time. After 48hrs have gone the min/max value for each sensor is stored once per day. The storage capacity is about years, depending on the operational cycle of the engine. The customer can connect the RS232 link of the unit to an engine PC and store the data here also. For this storage as well as for special views to the behaviour of the bearing wear a programme called LagMon is available from Dr. E. Horn. If this programme is installed the crew / superintendents / classification surveyors and service specialists can easily track the wear record and load down to there data storage the values. BDMS/BTMS E01/2008 page 6

7 1.2 Indication unit display for BDMS + water in oil sensor only The BDMS indication indicates for one compartment at time the bearing wear situation + splash oil temperature delivered by the distance sensors type IW BDMS indication unit for a 6 cylinder engine with water in oil sensor The display has 2 bar graphs (left right), 2 temperature indicators and an indication which compartment is visible at the moment. By optical buttons left/right of the compartment no. it is possible to select another compartment. The two bar graphs indicating the momentary situation of the wear status detected by the sensors type IW The temperature indicators delivering the splash oil temperature around the sensors. The lower LED row of the display indicates how many distance sensors are installed and the state of the distance sensors (alarm or working or failure condition). If a water in oil sensor is installed this is indicated in the end of the LED row. 1.3 Indication unit for BDMS including optional main bearing sensors Figure 4: Display BDMS, distance-, water in oil- and main bearing sensors Lower range indicates the nos. of distance sensors installed; last two Led s indicating correct working water in oil sensor, no alarm active BDMS/BTMS E01/2008 page 7

8 This display indicates besides the under 1.2 described sensors also the temperature of main bearing sensors type TGL00921, visible under MB-Temp A + MB-Temp B. The lower LED row can indicate max. 14 compartments, but indicated by lit Led s are the amount of sensors installed only; last two indicating no alarm on water in oil sensor present. 1.4 Indication unit for main bearing sensors type TGL only Figure 5: Display for system equipped with main bearing temperature sensors only The BDMS can be delivered for the temperature surveillance of the main bearings only. For this the indication unit presents just the main bearing sensors information only. Change between compartments using the optical buttons besides the no. of compartment indication. 1.5 Indication unit for all possible sensors mounted inside the engine Figure 6: Full System, all sensors mounted, temperature switches indicated by green Led s in big- and small end bearing This display version is needed, if all possible sensors (distance, main bearing temperature, temperature switches and water in oil sensor) mounted in the engine BDMS/BTMS E01/2008 page 8

9 2. Connection boxes Figure 7: Connection box type GHG view into the open box The connection boxes type GHG is needed for the connection of the sensors to deliver the necessary galvanic isolated power received from the transfer box to the sensors and to establish the serial data link from the sensors to the transfer box. The connection box has no active electronic on the board and allows maximum the connection of 16 sensors. If more than 16 sensors are installed (engine >7cylinders) in a system a second box must be installed. A green LED on the board indicates the presence of supply power. An electronic fuse protects the box as well as the enclosed electronic units in case of a short circuit in one of the sensors. BDMS/BTMS E01/2008 page 9

10 3. Transfer box Figure 8: Transfer box closed type GHG / 5 The transfer box delivers the galvanic isolated power and receives the data from all to the system connected sensors. The RS232 data are changed in the transfer box to RS422 and transferred to the indication unit. The open box in the figure 7 has right hand space for a larger DC/DC amplifier which will become necessary if all possible sensors are connected to the unit. Figure 8a: Transfer box opened type GHG02611 Here it is important at the stage of ordering a system what power is available on or close to the engine. Normally 24V DC is present, but on some engines the 24V DC power available does not allow the connection of the BDMS due to load limitations. In such cases 115 or 230V AC are to be used which must be informed at the order to deliver ex works the correct DC/DC or AC/DC amplifiers in the transfer box. For 24VDC supply the type to be ordered is GHG ; for VAC the type GHG must be ordered. BDMS/BTMS E01/2008 page 10

11 4. Sensors 4.1 Distance sensor type IW Figure 9: Distance sensor type IW The distance sensor type IW with protection IP67 is a high speed intelligent sensor measuring the distance in a range of max 5 mm with a resolution of 0.01 mm. In addition the splash oil temperature in the area of the sensor is measured with a tolerance of +/- 2 C. The sensor has no thread; the fastening in the engine is arranged by clamping in the brackets. The sensor detects the crosshead within his distance range and calculates the lowest air gap in X.xx mm. The value is stored in an internal buffer and constantly at every revolution updated. On request of the indication unit which acts as a master the buffer information is delivered via the serial link (connection box > transfer box > indication unit) and analysed against limits by software. For correct installation to the serial net the sensor has a LED installed allowing the installer to identify the sensor to ensure that left or right hand sensor is connected correctly to the network. For connection to the outside through the cable glands in the engine wall the sensor is delivered with an angle connector and 10 m oil resistant PUR cable. By this connection an easy exchange is possible in case an exchange should become necessary. BDMS/BTMS E01/2008 page 11

12 4.2 Sensor brackets Figure 10: Single bracket with sensor + cable Figure 11: Double bracket for 2 sensors The sensor brackets are needed for correct, vibration free installation of the distance sensors. Two versions are available, for one and two sensors. Both versions are of clamping type avoiding threaded sensors. The single version figures 9 are mounted on both sides under the crosshead sliding plate. Therefore a mounting surface must be made about 2 mm more in diameter than the bracket to allow correct vertical/horizontal placing. In the centre a threaded hole with M10x1 is needed to fix the bracket in place with a high tensile M10 bolt with torque moment 95 Nm. This bracket can be turned to place the sensor correct under the crossheads. The double version for two sensors must be placed in the centre under the crosshead sliding plate. For this version 2x M10 or M12x1 bolts are needed. To avoid problems after removal of a double bracket with the exact placement afterwards the bracket is aligned by 2 alignment pins of 5mm. To remove the bracket 8mm thread exists. 4.3 Water in oil sensor type FRG00032 Figure 12: Water in oil sensor type FRG00032 BDMS/BTMS E01/2008 page 12

13 This sensor is designed to monitor the amount of water content of the engine lube oil. The measuring principle is the change of the dielectric value of the oil due to the water content. The capacitive design recognizes these changes and the built-in microprocessor calculates the values for pre-warning and alarm threshold. Default values are 0,3 and 0,5 percent. The value is transferred via the RS232/RS422 serial link to the indication unit. The mounting of the sensor should be made in a non turbulence area behind the filter unit inside the oil stream. Green and red Led s indicating the status: Green LED Red LED Indication permanent green dark adjusting or readjusting state flushing dark water content < 0,3 % flushing flushing 0,3 % < water content < 0,5 % flushing Permanent red water content > 0,5 % dark dark faulty operation or not connected 4.4 Main bearing temperature sensor type TGL00921 Figure 13: Analogue main bearing temperature sensor This sensor is able to measure the temperature of the main bearing. The minimized flat design allows mounting at the main bearing support close to the bearing shell. The sensor can easily be placed at the support with the help of internal magnetos. If correct in place he must be secured by oil resistant glue. The temperature data are measured within a tolerance of +/- 1.5 C and transferred via the serial links to the indication unit. The refreshment of this measured values made with a lower priority within every 1500 ms. The max operating temperature is 90 C and short time 115 C. If a bearing should be overheated above the short time tolerable value the sensor must be replaced. BDMS/BTMS E01/2008 page 13

14 4.5 Switch type temperature sensor TGL01621 for big- and small end bearings (OPTION) Figure 14: Temperature switches big- and small end bearings with transmitters Figure 15: Installation of TGL01621 at big end bearing The optional available sensor TGL01621 is built up with 3 components, the stainless steel shell that carries in the front a shock and vibration resistant temperature switch (temperature range can be chosen within steps of ~3 C) and is inserted in a hole allowing contact directly with the big end bearing shell; a transmitter to be mounted on the big end and a receiver mounted in a fix position inside the engine wall/structure. BDMS/BTMS E01/2008 page 14

15 The principle of operation is as follows: Under normal, non alarm conditions the temperature switch is closed and the coil in the transmitter has a certain resistance value. This enables at every revolution and contact to the receiver that from the active coil in the receiver certain power consumption is taken indicating a closed switch. The bearing temperature is below the fixed limit of the temperature switch. If the temperature measured by the temperature switch element exceeds the fixed, non adjustable value, the element opens The opening changes immediately the resistance value of the transmitter resulting in a change of power consumption at the receiver. At the next revolution this is verified and the alarm relay in the receiver opens changing the status information in the serial link. The indication unit acts with a red LED in the display inside the graphics to identify the bearing. 5. Operation If the system is installed and works the operators should daily scroll through the compartments using the optical buttons in the display. The bar graphs should be viewed to recognise starting wear or to control the wear status. Figure 16: Display, push buttons besides compartment no. indicator illuminated If the system failure alarm relay is activated it is possible to identify a faulty sensor in the lower LED row. A green LED is OFF, indicating the faulty sensor. If you now scroll through the compartments you must find an indication in OFF position. Attention: This is not valid for a system with main bearing temperature sensors; here you must scroll through to find a non working indicator to detect the faulty sensor 5.1 Alarm indication If the Pre-Alarm or Main alarm value of the temperature, distance or water in oil content is crossed, the Pre-alarm or main-alarm relay changes from high to low impedance state or vice-versa, according the required application. In the lower row of the indication unit the sensor that activated the alarm has changed the colour from green to red. This allows an easy identification of the compartment. BDMS/BTMS E01/2008 page 15

16 In the photo the compartment C6 right hand side indicates alarm The bar graph right hand indicates min alarm; 0.5mm wear has been Reached For the main bearing analogous temperature sensors 5.2 Alarm settings The alarm values in the BDMS or BTMS are given by the engine manufacturer. Values for the IW distance measurement: Alarm at wear of >0.30mm Slow Down at wear of >0.50 mm Splash oil temperature alarm >65 C MAN B&W (>65 C Wärtsilä RT) Splash oil temperature slow down >75 C MAN B&W (>70 C Wärtsilä RT) Values for the main bearing temperature sensor type TGL00921: Alarm at 65 C MAN B&W (65 C Wärtsilä RT) Slow Down at 75 C MAN B&W (70 C Wärtsilä RT) Value for temperature switch type TGL01621: Alarm at temperature > 70 C Value for water in oil sensor type FRG00032: First alarm at water content >0.3% Second alarm at water content >0.5 % BDMS/BTMS E01/2008 page 16

17 6. Installation Installation of the sensors in the system can be done after all holes in the web plate according to the MAN Diesel AS drawings (enclosed to the delivery) are drilled and thread have been inserted. Thread size M10x Bracket and sensor mounting The tube and profile type brackets for MAN engines shown in the photo. Tube type Sensor bracket for engines profile type sensor brackets for 2 sensors with bolts and NordLock washers After mounting of both tube type brackets left/right hand side or the profile type bracket central between the crosshead slide plate the sensors can be inserted fixed in the way that an easy shifting by hand is possible. Bracket bolts to be fixed with correct torque moment. Profiled type brackets need after installation and tightening with correct torque moment the alignment by 2x 5mm alignment pins. Use hereto the 2x 5mm holes in the bracket, drill 10mm into engine wall and insert the pins. (Pins belonging to the scope of supply) Attention: Distance sensors must be installed in accordance with nos. available on each sensor. Attention: Cylinder counting for our system is lowest cylinder no. opposite from the flywheel; highest no. is always the cylinder at the flywheel side The counting from the sensor nos. to be made as follows: Cylinder no. 1 sensor no. 11 left hand side of the crosshead Cylinder no. 1 sensor no. 21 right hand side of the crosshead Cylinder no. 2 sensor no. 12 left hand side of the crosshead Cylinder no. 2 sensor no. 22 right hand side of the crosshead Following cylinders up to cylinder no. 8 are counted as 13 / 23, 14 / 24, 15 / 25, 16 / 26, 17 / 27, 18 / 28, Cylinder no. 9 sensor no. 19 left hand side of the crosshead Cylinder no. 9 sensor no. 29 right hand side of the crosshead BDMS/BTMS E01/2008 page 17

18 Now a number change is needed as follows: Cylinder no. 10 sensor no. 1A left hand side of the crosshead Cylinder no. 10 sensor no. 2A left hand side of the crosshead Cylinder no. 11 sensor no. 1B left hand side of the crosshead Cylinder no. 11 sensor no. 2B left hand side of the crosshead Cylinder no. 12 sensor no. 1C left hand side of the crosshead Cylinder no. 12 sensor no. 2C left hand side of the crosshead Cylinder no. 13 sensor no. 1D left hand side of the crosshead Cylinder no. 13 sensor no. 2D left hand side of the crosshead Cylinder no. 14 sensor no. 1E left hand side of the crosshead Cylinder no. 14 sensor no. 2E left hand side of the crosshead Sensor numbering and mounting table for 4 to 14 cylinders Sensor numbering example for 4cylinder engine BDMS/BTMS E01/2008 page 18

19 The sensors must be mounted in accordance with the numbering information indicated before. (Cylinder 1 left hand side no. 11, right hand side no. 21) 6.2 Sensor adjustment for engines with single sensor brackets Turn down left hand side crosshead to lower dead point. If crosshead is not fully covering sensor tip loose the bracket fixing bolt and turn bracket until the sensor tip is fully covered by the crosshead. Insert now the 4mm plastic sheet out of the delivery between crosshead and sensor tip and tighten bracket bolt again (75Nm) and clamp the sensor with 6Nm. Continue this operation until all sensors are correctly installed. Sensor fixed in the bracket, air gap 4mm between sensor tip and crosshead; crosshead fully covering sensor tip Sensor brackets mounted, sensors clamped, cable connectors fixed Inside the engine the sensor cables fixed by cable binders and the cable laid into the cable trays according to the MAN B&W drawings for the relevant engine type. 6.3 Sensor adjustment for engines with double sensor brackets Here the crossheads must also be positioned at lower dead point. By loosening the clamp bolt on one side the relevant sensor can be attached using the 4mm plastic plate correctly under the surface. If 4mm is set fix clamp screw hand tight. Now open the other side adjust the sensor to 4mm and tighten the clamp screw with 6Nm. Tighten than the other side also correctly with 6Nm. Sensor bracket for 2 sensors type IW000184; sensors connected BDMS/BTMS E01/2008 page 19

20 6.4 Outside mounting of connection boxes type GHG After installation of all sensors and cable glands the place for the connection boxes must be chosen on site. Attention: One connection box can take max. 16 sensors therefore the boxes should be mounted in a way that distance sensors of 3 cylinders can be connected. Schematic drawing for connection box/line converter mounting from 4 to 7 cylinder Schematic drawing for connection box/line converter mounting from 8 to 14 cylinder BDMS/BTMS E01/2008 page 20

21 Schematic of connection boxes and line converter on 8 to 14 cylinder engines The connection box and line converter are mounted on the engine surface on the manoeuvre side. The boxes can be attached to the engine block by bolts or by electrical welding. Between the boxes cable rails should be placed if needed to guide and secure the sensor cables as well as the cabling needed between the boxes. Attention: Obey the maximum allowed cable length! 6.5 Electrical connection to and between the connection boxes Having mounted the boxes the connection to and between those must be made in accordance with the in the Annex enclosed electrical wiring diagram. The cable type to be used is our article no. LT2004F0 BDMS/BTMS E01/2008 page 21

22 Between the connection boxes and the line converter a single cable for data and power bus must be connected; our article no. LT2004F0 Connection to be made to the 4-pole connectors X15/1 to X15/4 on both sides of the boxes as follows. Power supply: connection X15/1 connection X15/2 Data bus: connection X15/3 connection X15/4 6.6 Sensor connection to connection box type GHG The relevant sensor connections can be made to the existing connection points in the boxes. The connections to be made according to the following table: BDMS/BTMS E01/2008 page 22

23 6.7 Installation of line converter box type GHG / -5 The line converter box must be installed close to this connection box where the power and data bus must connect (end of the line) mostly at cylinder no. 1. The transfer box is equipped with optional available Z-brackets; those can be connected to the engine wall either by bolts or by electric welding. Data transfer box type GHG02611 mounted at the free end (cylinder 1) of the engine The electrical installation must be made according to the enclosed sketch A B C D A B C D a. Main power supply line 24 V DC or 115/230 V AC / 2 A (A) b. RS422 data line - connection to indication unit, colour violet (B) c. RS232 sensor data bus to the connection boxes (C) d. 24 V DC Power supply bus to the connection boxes (D) BDMS/BTMS E01/2008 page 23

24 The bus cable supplied by us is our article no. LT2004D0 Bus cable to be used between line converter and indication unit Cable is part of the delivery and has our article no. LT2004D0 A protection fuse (glass type with dimension 5 x 20) is placed on the PCB and has the value 6, 3 A. 2x green Led s near the terminal blocks indicating correct power. 6.8 Installation of indication unit type MDA312 The indication unit type MDA312 is available in 2 executions, inside of the optional available field housing for mounting in the engine room with IP66 and as an open unit with front IP66 back IP20. MDA321 in field housing for engine room Mounting (Option) MDA312 without field housing for cabinet or panel mounting BDMS/BTMS E01/2008 page 24

25 Based on installation connections are made via cable glands or directly to connectors Connection to the indication box type MDA312 in the ECR X V DC X12/1 - Relay 2 / bearing wear slow down** / N.O. X13/1 TxD br. X11/2 0V DC X12/2 + Relay 2 / bearing wear slow down ** / N.O. X13/2 TxB\ wh X11/3 - H2O >0.3% pre-alarm */ N.O X11/4 + H2O >0.3% pre-alarm * / N.O. X12/3 - Relay 3 Main bearing temperature alarm * / N.O. X12/4 + Relay 3 Main bearing temperature alarm * / N.O. X13/3 RxD gn X13/4 RxD\ ye X11/5 - Ready Relay / N.C. X12/5 - Relay 4 Main bearing temperature slow down ** / N.O. X11/6 + Ready Relay / N.C. X12/6 + Relay 4 Main bearing temperature slow down ** / N.O. X13/5 GND X13/6 PE X11/7 - Relay 1/ bearing wear alarm */ N.O. X11/8 + Relay 1/ bearing wear alarm */ N.O. X12/7 - Relay 5 / H2O >0.5% alarm * / N.O. X13/7 not connected X12/8 + Relay 5 / H2O >0.5% alarm */ N.O. X13/8 not connected * connection to alarm system **connection to safety system The indication unit delivers the potential free alarm contacts. Those contacts can be connected using the 12 lead cables out of the scope of supply. The bus cable (colour violet) between the transfer box and the indication unit must be laid on the best way in the vessel on existing cable rails. Please avoid parallel running with power cables and to close distance to generator sets. BDMS/BTMS E01/2008 page 25

26 6.9 Installation of main bearing sensor type TGL00921 The analogous main bearing sensor must be mounted at the bearing shell support. To reach the best position the sensor has magnetos inside allowing the correct placement at the support. After correct position is reached please secure the sensor as well as the thin sensor cable by appropriate glue to the engine. On right hand side the thin cable glued to the engine wall is visible, no view to sensor possible The sensor cables must be taken out from the engine through cable glands placed in a suitable position in the oil pan. Place in- + outside of the passage one cable gland to protect the cables from damage by sharp edges. From the glands take the cables to the connection box which has been fitted at an easy reachable place. Open connection and data transfer box welded to a ships hull frame close to the engine BDMS/BTMS E01/2008 page 26

27 Indication unit mounted into engine room console 7.0 Measuring of Offset values after retrofit installation only After a retrofit of system into an engine in service it is necessary to carry out a speed run at given revolutions. This run is needed because the crossheads with increasing speed by the moment of inertia closing more down to the sensors which needs compensation and values must therefore be stored in the memory. Sample of a speed run table: 7.1 Speed table needed for adjustment of retrofit installations Start revolutions Constant time Increase to next speed step during minutes 30 rpm 20 minutes Increase to 40rpm 30rpm 40rpm within 5 to 10 minutes 40rpm 20 minutes Increase to 60rpm 40rpm 60rpm within 5 to 10 minutes 60rpm 15 minutes Increase to 80rpm 60rpm 80rpm within 5 to 10 minutes 80 rpm 10 minutes Increase to 100rpm 80rpm 100rpm within 5 to 10 minutes 100rpm 10 minutes Increase to n max 100rpm n max. within 5 to 10 minutes * n max 6 minutes End of trial period BDMS/BTMS E01/2008 page 27

28 Only if engine can run above 100rpm! Remember: This speed run is necessary only for engines already in service where the system has been retrofitted! 7.2 Installations in new engines on production test beds If the system is mounted into an engine during the engine manufacturing process no speed run as for retrofit systems is needed. The system has a self learning function which starts with the first revolutions on the engine production test bed. According to the test run program automatically measuring values are taken and continuously based on the amount of already received values the alarm limits are automatically adapted. This self learning function is continuously in progress until 500 operation hours have been logged up into the system. With the measured and calculated values after 500 hours of operation the alarm limits are recalculated and kept from this moment on according to the requirements of the engine manufacturer. Note: Engines equipped with the system during production need no attendance on the production test bed or at the shipyard during sea trial! 8. Maintenance 8.1 Regular inspections At every opening of the crankcase doors please check as follows: The installed distance sensors type IW including the cabling should be visual inspected. Led s must be lit. If main bearing sensors are mounted please check the glued cabling. Check the Led s on the water in oil sensor (if installed) and the condition of the connector and related cabling. Once a year cabling to be checked, damaged cables to be repaired or replaced. 8.2 Function Tests The distance sensors type IW can be tested at open compartment as follows: Set indication unit to a compartment no and let a person view the bar graphs Enter compartment, use a metal sheet of ~2 mm and place this on top of one distance sensors and remove the sheet. The alarm relay must be activated. Old original value will be visible again after engine has been turned and sensor has detected the cross-head again. The water in oil sensor may be removed. Attention: Make sure the oil pipe is not under pressure! If sensor has been removed connect again to the plug. Press hidden button in sensor alarm should come up within next 10 minutes in the indication unit as well as on the sensor cap. BDMS/BTMS E01/2008 page 28

29 The temperature sensors type TGL00921 of the main bearings can be viewed after engine start and increasing load. The temperature value must rise up close to or above the lube oil temperature. If you scroll through the compartments you can view all relevant sensors. 8.3 Exchange of sensors If the ready relay is activated check the indication unit. If you find in the lower row of Led s one off you have found the reason for the ready relay activation. Compartment C3 right hand side sensor out of order; LED is off According to the photo the distance sensor C3 right hand side is out of order. You have to change this sensor at the next possibility. According to the ID no. 23 of the sensor (see hereto 6.1 brackets and sensor mounting) order a new one from Dr. E. Horn. ID no. not needed. To avoid complications please use the tool sensor change which is part of the hardware delivery during the exchange. Tool for tube type sensor brackets Tool for profile sensor brackets Change as follows: Turn engine that crosshead is away from defective sensor and working is possible under the sensor Place the tool over the existing sensor bracket (tube or profile type) and slide it down until it has contact with the sensor tip BDMS/BTMS E01/2008 page 29

30 Use a torch light and make sure that tool is placed correct on the sensor tip Fix now the tool using the clamp, check again that the contact plate of the sensor is still in contact with the sensor tip Tools for tube type brackets (left) and profile type brackets for sensor exchange; here shown with clamped tool already placed and fixed by the clamp on tip of the to be exchanged sensor Remove damage sensor and insert new sensor. Before tightening the clamping bolt check if the connector can be placed correctly! Place the new sensor so that sensor tip is in contact with the contact plate of the tool and check this position with again using a torch light; fasten the clamp bolt with 6Nm and connect the cable Remove the tool and turn the engine and the system should indicate now the replaced sensor bar graph. Other adjustments are not needed. 8.4 Removal/Replacement of sensor brackets Our recommendation: If a larger operation in a compartment is needed please remove the bracket before starting the job to avoid damage to sensors (s) and bracket (s). If due to main bearing exchange a removal of the complete sensor bracket becomes necessary please act as follows: Mark bracket with compartment no. XX Disconnect the sensor cables but do not loosen sensor clamping bolts! and secure on site; once again do not remove or loosen sensor clamping bolts! Remove the 2 inner hexagon bolts with the 2 NordLock rings Insert a 8mm bolt thread length 15mm into the thread hole in the bracket and press bracket of seating area; deposit at secured area Leave alignment pins at place BDMS/BTMS E01/2008 page 30

31 Clean seat area before replacing bracket and place careful using alignment pins as positioning tools Use new NordLock washers and tighten bolts with correct torque moment Connect sensors again Adjustments for sensors are not needed. 9. Technical Data 9.1 Indication unit type MDA312 Supply voltage 24 V DC +/- 15% Supply current max. 1 A Nos of relays 6 (5x alarm + 1x ready for operation) Relay data: Relay type contact less photomos Load voltage max. 60 V DC Load current max 250 ma SCP Principle schematic display unit + 24 V DC ship control unit load Data output : RS232 ( 9600 Baud, 8 bit, 1 Stop bit, none parity ) Data format : < time > ; < date > ; < sensor ID > ; < sensor check *) > ; < temperature o C > ; < raw value > *) 0.00 if sensor is working / 9.99 if sensor is missing 9.2 Transfer box type GHG / -5 Supply voltage: Supply current: 24 V DC +/- 15% type GHG or alternatively 115/265 V AC type GHG to be announced at order Max. 5A (depending on numbers of sensors connected) BDMS/BTMS E01/2008 page 31

32 9.3 Distance sensor type IW / see data sheet 9.4 Main bearing temperature sensor type TGL00921 / see datasheet 9.5 Water in oil sensor type FRG00032 / see data sheet 9.6 Temperature switch type TGL01621 / see data sheet 10.0 Technical data sheets / dimensional drawings 10.1 Indication unit MDA312 indication unit built-in field housing for installation inside engine room protection class IP66 BDMS/BTMS E01/2008 page 32

33 10.2 Line converter 10.3 Connection boxes Connection box type GHG BDMS/BTMS E01/2008 page 33

34 10.4 Distance sensor Distance sensor type IW BDMS/BTMS E01/2008 page 34

35 10.5 Water in oil sensor BDMS/BTMS E01/2008 page 35

36 Drawings ANG00661 and ANG00821 indicating mounting area and Positioning of the water in oil sensor 10.6 Main bearing temperature sensor Main bearing temperature sensor type TGL00921 BDMS/BTMS E01/2008 page 36

37 Mounting area for main bearing temperature sensor TGL00921; here RT96 Wärtsilä 10.7 Temperature switch Temperature switch type TGL01621 BDMS/BTMS E01/2008 page 37

38 11. Connection diagrams 11.1 Cabling Installation at the engine If the sensors are placed correctly inside the engine (distance and main bearing temperature sensors) the cables must be placed and fixed inside the engine and taken out from the engine through the already installed cable glands. After cables are correct positioned inside the engine and passed through the inner cable gland please tight the inner gland. After tightening please use cables binders to tight the 3 cables (except compartment no. 1 and 7 respectively no. 1 and 10) together. Outside engine use the existing cable rail and move the cable to the terminal boxes. Not needed cable length can either be cut away or rolled up before entering the terminal boxes through the cable glands. Note: Inside the terminal boxes the sensor cables can be placed without following a routine or connection plan. Due to the ID nos. given to each sensor a routine in the connection is not necessary. Once again: Sensor ID nos. sees drawing ANG00783! 11.2 Sensor connection to terminal box type GHG Sensors can be connected to any available connection point inside the terminal box. There is no routine for placement; make connections according to best placement during installation. This is valid for all to be connected sensors Connection between the terminal boxes and line converter Connection with cable art. no. LT2004F0 out of scope of supply must be made. Left side terminal box GHG at X18 / at X3 line converter GHG Right side terminal box GHG at X17 / at X4 line converter GHG (see drawing no. ANG or 785) BDMS/BTMS E01/2008 page 38

39 Connection to Terminal box type GHG GHG X18/1 (24V) WH to GHG X3/1 (24V) WH Left side X18/2 (0V) BN to X3/2 (0V) BN X18/3 (Rx/D) GN to X3/3 (Rx/D)GN X18/4 (Tx/D) YE to X3/4 (Tx/D) YE GHG X17/1 (24V) WH to GHG X4/1 (24V) WH Right side X17/2 (0V) BN to X4/2 (0V) BN X17/3 (Rx/D)GN to X4/3 (Rx/D)GN X17/4 (Tx/D) YE to X4/4 (Tx/D) YE 11.4 Connection table for Line Converter type GHG X1/1 (24V) connection from ship net X1/2 (0V) connection from ship net Connection to Line converter GHG X2/1 TxD X2/2 TxD\ bus cable type LT2004D0 out of scope of supply for connection from X2/3 RxD engine to indication box type MDA312 in ECR. X2/4 RxD\ BDMS/BTMS E01/2008 page 39

40 11.5 Connection to Line Converter type GHG This version of the Line Converter is foreseen for AC supply out of the ships net and needs therefore AC power supply between VAC. The internal wiring of 24VDC has already been made in the factory. BDMS/BTMS E01/2008 page 40

41 11.6 Connection to the indication box type MDA312 in the ECR X V DC X12/1 - Relay 2 / bearing wear slow down** / N.O. X13/1 TxD br. X11/2 0V DC X12/2 + Relay 2 / bearing wear slow down ** / N.O. X13/2 TxB\ wh X11/3 - H2O >0.3% pre-alarm */ N.O X11/4 + H2O >0.3% pre-alarm * / N.O. X12/3 - Relay 3 Main bearing temperature alarm * / N.O. X12/4 + Relay 3 Main bearing temperature alarm * / N.O. X13/3 RxD gn X13/4 RxD\ ye X11/5 - Ready Relay / N.C. X12/5 - Relay 4 Main bearing temperature slow down ** / N.O. X11/6 + Ready Relay / N.C. X12/6 + Relay 4 Main bearing temperature slow down ** / N.O. X13/5 GND X13/6 PE X11/7 - Relay 1/ bearing wear alarm */ N.O. X11/8 + Relay 1/ bearing wear alarm */ N.O. X12/7 - Relay 5 / H2O >0.5% alarm * / N.O. X13/7 not connected X12/8 + Relay 5 / H2O >0.5% alarm */ N.O. X13/8 not connected * connection to alarm system **connection to safety system The indication unit delivers the potential free alarm contacts. Those contacts can be connected using the 12 lead cables out of the scope of supply. Power supply 24VDC X11/1 Power supply 0 VDC X11/2 Connections to alarm system: H2O >0.3% X11/3 (-) H2O >0.3% X11/4 (+) Ready alarm X11/5 (-) Ready alarm X11/6 (+) Bearing wear alarm >0.3mm X11/7 (-) Bearing wear alarm >0.3mm X11/8 (+) Main bearing / splash oil temperature alarm >65 C X12/3 (-) Main bearing / splash oil temperature alarm >65 C X12/4 (+) H2O >0.5% X12/7 (-) H2O >0.5% X12/8 (+) Connections to safety system: Bearing wear alarm >0.5mm X12/1 (-) Bearing wear alarm >0.5mm X12/2 (+) Main bearing / splash oil temperature alarm >65 C X12/5 (-) Main bearing / splash oil temperature alarm >65 C X12/6 (+) BDMS/BTMS E01/2008 page 41

42 Connections to / from Line Converter GHG (-5) X2/1 TxD X2/2 TxD\ (bus cable type LT2004D0 out of scope of supply for connection from X2/3 RxD engine to indication box type MDA312 in ECR) X2/4 RxD\ ATTENTION: Valid for all Terminal boxes, Line Converters and Indication unit Besides the fixing bolts the PE connection to GND must be arranged, too. Here the copper mesh band from the housing of all units must be connected to the engine with a 6mm hexagon bolt. Attention: Ensure that all existing paint under the connection has been removed! Connection to be done on metallic clean surfaces! 12. Torque moments for bolts The following torque moments are required for the bolts used in the system Sensor brackets: Single sensor bracket (tube type) bolt M10 Single sensor bracket (tube type) bolt M12 Double bracket (profiled type) bolt M8 Double bracket (profiled type) bolt M10 Double bracket (profiled type) bolt M12 Sensor clamping screw in all brackets M6 Bolts for GHG02611 and GHG02621 M8 = 95N = 120N = 50N = 50N = 80N = 30N = 16N GND screw M6 = 6N BDMS/BTMS E01/2008 page 42