Allan Juul Larsen, MDT LEO9 Prime Serv Piraeus MAN Diesel & Turbo Allan Juul Larsen Examining HCU Events

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1 Examining HCU Events HCU events from a-z Allan Juul Larsen, MDT LEO9 Prime Serv Piraeus < 1 >

2 Content to cover Basics What is a HCU event (data stored and saved in case of fault, thus including data before failure) When is a HCU event stored (manual vs. automatic). Amount of data and marker line FIVA Basic understanding FIVA Internal parts. FIVA Flow diagram. Examining using LDE plot Signals Which signals are stored Alarms Explanation of most common alarms Don t waste time on bad data (jitter profile, engine not running) < 2 >

3 HCU Events - Basics What is a HCU event Hydraulic Control Unit Event Tells us what is going on in the FIVA control loop VERY important for troubleshooting Fuel and Exhaust valve problems! Many names: HCU Event HCU Dump Log Dump Burst Log Electrical signals related to exhaust valve and fuel booster Continuously sampled by each CCU In case of an critical alarm the data is send to the MOP and stored Both data before and after alarm is stored Stores a few seconds of data sampled at 2 khz (2000 times pr. sec.). FIVA Setpoint, position, Fuel plunger and exhaust valve position Data size: 124 kb each. (~50 kb zipped) < 3 >

4 HCU Events - Basics What is a HCU event HCU Event retrieved from the MOP GUI one by one Select one and export to USB If more dumps are needed they may be copied using explorer: D:\MANDiesel\MAD < 4 >

5 HCU Events - Basics When is a HCU event stored HCU events are store either manually or triggered by a specific alarm. Information about the reason is stored in the HCU event. Header is composed of: MPC type. Date and time for event Trigger reason, actual alarm or manual dump. Make manual dumps from all cylinders for reference. The specific list of alarms triggering alarms is shown later. < 5 >

6 HCU Events - FIVA Internal part MDB FIVA < 7 >

7 HCU Events - FIVA Internal part MDB FIVA Control signal CH70 Feedback signal Pilot spool A T P Solenoid Actuator CH30 Main spool P CFI TFI CVA TVA = Hydraulic high pressure supply = Fuel booster = Fuel booster to tank = Exhaust actuator = Exhaust actuator to tank T FI C FI P C VA T VA < 8 >

8 HCU Events - FIVA FIVA main spool Feedback signal CH30 Main spool T FI C FI P C VA T VA P CFI TFI CVA TVA = Hydraulic high pressure supply = Fuel booster = Fuel booster to tank = Exhaust actuator = Exhaust actuator to tank < 9 >

9 HCU Events - FIVA Flow diagram x-axis position [mm] y-axis flow area [mm 2 ] -6mm 30 mm 2 Pressure port to exhaust valve actuator -6mm 600mm 2 Fuel plunger to tank < 10 >

10 HCU Events - Basics FIVA Set Point For ME-C engine one engine revolution Fuel injection Preparation return plunger and close exhaust valve Levels found in Flow diagram for valve type. Red area dangerous only allowed here near TDC! Y-axis Position mm. Exhaust valve opening < 11 >

11 HCU Events - Basics How are axis scaled X-axis shows time in ms. Resolution is in 500µs (½ms) Resolution locked to MPC CPU clock of 2 khz. Y-axis is scaled according to the signals being displayed: The resolution is 1 and the span is ±32767 (16 bit values). FIVA Set Point / Feedback are shown in mm * 1000 Electrical current is shown in A/D Counts Electrical voltage is shown in A/D Counts Exhaust valve position in mm but must be scaled according to parameter Tacho angle is shown in deg. < 12 >

12 HCU Events - Basics Amount of data stored Time stored dependents on the number of signals. Number of signals depend on engine type: ME-C 6 signals = sec. ME-B DOT3 5 signals = sec. ME-B 4 signals = sec. ME-B (2 cyl. pr. MPC) 7 signals = sec. In total samples are stored. Marker line indicated the time where the HCU event was triggered. ECS Parameters determine the time before and after Marker line. < 13 >

13 HCU Events - Signals Overview Now with this FIVA basics settled lets look at the signals: FIVA Set Point Ordered main spool position FIVA Feedback Main spool position FIVA Control Control signal to pilot spool Exhaust valve position (only ME-C) Exhaust valve pos. Plunger position (only ME-C) Fuel Plunger position Tacho Angle Cyl. 1 Other cylinders must compensate ME-V Feedback (only ME-B DOT3) ON/OFF timing unit feedback Naming differs a little on ME-C vs. ME-B and ME-B DOT3 I will not distinguish between ELFI, ELFIA, or FIVA in the following but call it FIVA. < 14 >

14 HCU Events - Signals FIVA Set Point Set point signal very important. Shows us what is ordered by ECS. Not a physical signal! Not possible to measure anywhere. Calculated set point from the control loop. Where do we want the main spool to be! Set point is specified in parameters. Designed by performance measurements. Fuel profile. Exhaust valve open slope Exhaust valve close slope < 15 >

15 HCU Events - Signals Fuel injection ME-C and ME-B < 16 >

16 HCU Events - Signals FIVA Feedback CH30 Setpoint Feedback follows set point nicely. Small time delay seen at fast changes. < 17 >

17 HCU Events - Signals FIVA Feedback CH30 Fuel profile Nice step at prep. Prepare for fuel injection Fuel profile No overshoot Offset is a few ms. < 18 >

18 HCU Events - Signals Flow diagram Fuel injection Flow towards fuel injection start between -0.5 and 0.75 mm Lets just say 0 mm < 19 >

19 HCU Events - Signals Plunger position CH31 Fuel profile start Flow to plunger Mechanical system with some reaction time Start of fuel profile Feedback passes 0.0 mm < 20 >

20 HCU Events - Signals Plunger position CH31 Fuel profile shape Start of fuel profile Profile shape determines plunger acceleration < 21 >

21 HCU Events - Signals Plunger position CH31 Fuel profile end Flow to plunger stops After small time delay plunger is stationary Top dead point of fuel plunger movement. Feedback passes 0.0 mm < 22 >

22 HCU Events - Signals Plunger position CH31 Fuel plunger return Flow from plunger to tank means plunger will return. Final position Increases tank flow and plunger return speed Fuel plunger return movement. Main spool in negative position More negative position. < 23 >

23 HCU Events - Signals Plunger position CH31 Different loads Engine running 10% load < 24 >

24 HCU Events - Signals Plunger position CH31 Different loads Engine running 25% load < 25 >

25 HCU Events - Signals Plunger position CH31 Different loads Engine running 40% load < 26 >

26 HCU Events - Signals Plunger position CH31 Different loads Engine running 50% load < 27 >

27 HCU Events - Signals Plunger position CH31 Different loads Engine running 75% load < 28 >

28 HCU Events - Signals Plunger position CH31 Different loads Engine running 90% load < 29 >

29 HCU Events - Signals Plunger position CH31 Different loads Engine running 100% load < 30 >

30 HCU Events - Signals Exhaust valve ME-C < 31 >

31 HCU Events - Signals Flow diagram Exhaust valve opening Flow towards exhaust valve opening start between -4 and -6 mm Lets just say -5 mm < 32 >

32 HCU Events - Signals Exhaust valve Position CH34 Exhaust valve opening Flow to Exhaust valve actuator Feedback passes -5.0 mm < 33 >

33 HCU Events - Signals Exhaust valve Position CH34 Exhaust valve Opening speed determined by constant flow rate. Constant main spool position < 34 >

34 HCU Events - Signals Exhaust valve Position CH34 Exhaust valve close Exh.v. closing will start. Speed determined by flow rate to tank Feedback passes -5.0 mm < 35 >

35 HCU Events - Signals Exhaust valve Position CH34 Exhaust valve damp Final close speed is controlled by exh.v. damper step one and step two. < 36 >

36 HCU Events - Signals Exhaust valve Position CH34 High force Exhaust valve Dampened opening Good ability to stay open Step 1 damper Step 2 damper Highforce exhaust valve Different opening profile with overshoot < 37 >

37 HCU Events - Signals Exhaust valve Position CH34 High force Exhaust valve Slow open and close slopes Highforce exhaust valve Different opening profile with overshoot < 38 >

38 HCU Events - Signals Exhaust valve Position CH34 Low force Exhaust valve Fast open and close slopes Lowforce exhaust valve Different opening profile with overshoot < 39 >

39 HCU Events - Signals Exhaust valve Position CH34 Low force Exhaust valve Overshoot at open stroke Slowly closes due to leakage Lowforce exhaust valve Different opening profile with overshoot < 40 >

40 HCU Events - Signals Exhaust valve ME-B ME-V timing unit < 41 >

41 HCU Events - Signals ME-V feedback. 1 Digital position signal The up wards flank is preparing the ME-V Timing is not critical. Return flank is critical. Time is adusted to get accurate timing of exh.v. close Activation is not time critical, and will change with load. Return stroke timing is important. Will control Pcomp/Pscav ratio < 42 >

42 HCU Events - Signals Tacho Angle < 43 >

43 HCU Events - Signals Tacho Angle Cyl. 1 How to use Zoom the area that is interesting. Zoom wide and low to get best view Tacho angle values are small compared to other signals and thus not readable Want to know angle for exh.v. start open? Angle is difficult to read. Due to other signals scaling. < 44 >

44 HCU Events - Signals Tacho Angle Cyl. 1 Zoom on event and note time Use cursor to read exact time ms. < 45 >

45 HCU Events - Signals Tacho Angle Cyl. 1 Zoom on tacho at exact time Angle is in steps of 1 deg. 121 deg. Or use cursor to read values In the same way zoom on tacho signal around that time. 920 to 930ms. Again zoom low to get good resolution in y-axis time ms. < 46 >

46 HCU Events - Basics Examining using LDE plot Windows application to examine HCU Events at office. Intuitive user interface and proper screen resolution. Sort multiple events based on: Dump cause. CCU number. Data / Time. Change colors and line width. Export and print to improve documentation. Show short DEMO < 47 >

47 HCU Events Break time? < 48 >

48 HCU events from service Things NOT to look at. Use your time well - on the real problems Many HCU events are triggered by unimportant events. Remove / apply connections Electrical noise Follow alarms to other alarms (Find first alarm and start here) Start / stop Some examples. < 49 >

49 HCU events from service Know what is NOT important look at This HCU event should not give raise to much concern? < 50 >

50 HCU events from service Know what is NOT important look at Zooming in on Tacho signal. Engine is not running. May be interesting but not related to engine running. Connector on/off < 51 >

51 HCU events from service Know what is NOT important look at Burst and Prep Sync missed!! Tacho? < 52 >

52 HCU events from service Know what is NOT important look at After TDC it will jump to 0 deg. normal Migth setup exh.v. open and then this is missed due to the tacho suddenly jumping to a new position. Tacho is jumping Indicates that the engine direction have just changed! Tacho angle is always counting positive. New angle = 360-old < 53 >

53 HCU events from service Know what is NOT important look at What is wrong? Electrical noise is on channel not in HCU event. No information in this event besides engine running fine. < 54 >

54 HCU events from service Know what is NOT important look at HPS pressure drops. Connector removed. Engine not running. < 55 >

55 HCU events from service Dither function Zoomed to show feedback One sine One square Avoid that FIVA is sticking May give a idea about the FIVA condition. < 56 >

56 HCU events from service Dither function Situation 1 All OK < 57 >

57 HCU events from service Dither function Situation 2 Feedback is dead Control signal is running Missing hydraulic pressure. < 58 >

58 HCU events from service Dither function Situation 3 Set point is running No control signal? No feedback? FIVA in safe position, Control signal forced to exh.v. open < 59 >

59 HCU events from service Things to look at. Selected HCU events found for this occasion. < 60 >

60 HCU events from service Exhaust valve stroke low. Exhaust valve stroke is reduced for each revolution. At the marker the fuel is stopped. Exhaust valve activation continoues. < 61 >

61 HCU events from service Exhaust valve stroke low. Reason: SW related? Exh.v. Mech? Hydraulic? Sensor? < 62 >

62 HCU events from service Manual dump - Feed back not following well. Manual dump troubleshoot. Fuel plunger OK Exh.v. OK < 63 >

63 HCU events from service Feed back not following well. Closer look at feedback. Unable to follow set point. Large Control signal amplitude. Reason: Worn out FIVA. < 64 >

64 HCU events from service Illegal FIVA Position Exhaust valve open to avoid Cover lifting. Feedback cross zero when prep. Is made! Control signal is set to safe. Note that set point keeps going only intern signal. < 65 >

65 HCU events from service Illegal FIVA Position zommed A bit closer FIVA is reacting and following control signal safe position < 66 >

66 HCU events from service Illegal FIVA Position zoomed more.. Even closer! At first sample crossing zero control signal is set to safe. < 67 >

67 HCU events from service Illegal FIVA Position Using DOT s to see each sample First feedback >0.0mm Next sample is set to safe position. In some cases using DOT s help to see exact timing of events. < 68 >

68 HCU events from service Exhaust valve closed position changed Large control signal tells that FIVA is not reacting! < 69 >

69 HCU events from service Exhaust valve closed position changed compare revolutions Note the short fuel injection FIVA Pilot spool is stuck at exh.v. open position. Unable to control FIVA. < 70 >

70 HCU events from service Exhaust valve closed position changed- The good After fuel injection control signal settels as FIVA stoppes at desired position. < 71 >

71 HCU events from service Exhaust valve closed position changed and the bad Control signal keeps going positive to stop FIVA movement. FIVA is NOT following control signal. May be caused by particle in oil. < 72 >

72 HCU events from service Exhaust valve stroke low OR what is going on? Something is very wrong here. But what? electrical signal error CH30? CH70? < 73 >

73 HCU events from service Exhaust valve stroke low OR what is going on? Electrical fault! Fault on MPC output: CH70 or FIVA input Which signal? Is Feedback correct CH30? < 74 >

74 HCU events from service Exhaust close position change OR what is going on? Look like previous situation. < 75 >

75 HCU events from service Exhaust close position change OR what is going on? Dependent on other alarms and conditions the controller might be active and try to control the error. Could also be CH70 error. < 76 >

76 HCU events from service Exhaust close position change OR what is going on? Rev. time 3 sec. But Why is the control signal active NOW? = 20 RPM =? Load =? Pscav Below 0.9 bar!! < 77 >

77 HCU events from service ME-V feedback looking weird. ME-B 60 bore First ME-B DOT3 Incorrect design of piston. 3 groves like alpha lubricator! < 78 >

78 HCU events from service ME-V feedback looking weird. From Troubleshooting guide Typical example of noise due to loose connection or defective cable. < 79 >

79 HCU events from service ME-V feedback looking weird. From Troubleshooting guide Piston difficult moving. Partly stuck in bottom. < 80 >

80 HCU events from service ME-B Timing unit not operating Looks like normal timing unit problem at deactivation. But occur at High load. And sounded BAD! < 81 >

81 HCU events from service ME-B Timing unit not operating Incorrect ME-V parameters. Note different set point between two revolutions. ME-V return Missing < 82 >

82 HCU events from service ME-B Timing unit not operating Timing unit piston is returned at Fuel injection prep step. Exh.v. close DURING fuel injection!! < 83 >

83 HCU events from service MPC failure MPC failure but which channel? < 84 >

84 HCU events from service MPC failure CH30 matches exhaust valve and plunger. Fault is on CH70 CH30 is not changing abrupt (one sample to the next) < 85 >

85 HCU events from service MPC failure Same ship different MPC. Which signal? < 86 >

86 HCU events from service MPC failure CH30 changes ~14mm in ONE sample. This is not possible. Electrical fault on CH30 signal < 87 >

87 HCU events from service MPC failure SAME SHIP!! MPC replaced and fault removed! Which signal? < 88 >

88 HCU events from service MPC failure Fault seen on 3 signals AT ONCE exh.v. pos Fuel plng. Pos FIVA feedback Almost same value. Common electrical fault on MPC affecting all analogue inputs. < 89 >

89 HCU events from service ELFI Fluctuation G95 < 90 >

90 HCU events from service ELFI Fluctuation G95 < 91 >

91 HCU events from service SOMETHING CLEVER I hope this lecture have given you a : Practical ways to look at HCU Events. Better understanding of the signals presented in HCU Events Understanding that not all HCU Event contain important information Gained some idea of the complexity of looking at HCU Events If you have funny looking HCU Events or get some. Let me know and I will comment on them. Question.. < 92 >

92 Disclaimer All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions. < 93 >

93 Do you have any more questions? Allan Juul Larsen Manager EEO9 Control and Electronics Operation < 94 >

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