DK02021 Installationmanual BDMS 2008-10-28
DK02021 Installationmanual BDMS 2008-10-28
DK02021 Installationmanual BDMS 2008-10-28
2008-10-20
E-Mail: [email protected]
Internet: www.dr-e-horn.de
Release:
Created by:
Kothes!
Technische Kommunikation GmbH & Co. KG
www.kothes.de
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Bearing Distance and Temperature Monitoring System BDMS/BTMS
Table of contents
1 General .................................................................................... 7
1.1 Information on this Manual ............................................ 7
1.2 Explanation of symbols .................................................. 8
1.3 Limitation of liability ........................................................ 9
1.4 Copyright........................................................................ 9
1.5 Spare parts .................................................................. 10
1.6 Warranty terms ............................................................ 10
1.7 Customer Service ........................................................ 10
2 Safety .................................................................................... 11
2.1 Customer’s responsibility ............................................. 11
2.2 Personnel requirements............................................... 12
2.2.1 Qualifications ................................................ 12
2.2.2 Unauthorized persons .................................. 13
2.3 Intended use ................................................................ 14
2.4 Personal protective equipment .................................... 15
2.5 Specific dangers .......................................................... 16
2.6 Conduct in a dangerous situation and in case of
accidents ...................................................................... 21
2.7 Environmental protection ............................................. 22
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Table of contents
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Table of contents
7 Operation .............................................................................. 92
7.1 Safety ........................................................................... 92
7.2 Operating the Indication unit ........................................ 92
7.3 Testing sensors ........................................................... 94
8 Maintenance ......................................................................... 96
8.1 Safety ........................................................................... 96
8.2 Maintenance schedule ................................................. 98
8.3 Maintenance tasks ....................................................... 99
8.3.1 Changing distance sensors .......................... 99
8.3.2 Inspecting a main bearing after production
test run........................................................ 102
8.4 Screw tightening torques ........................................... 103
8.5 Measures after maintenance ..................................... 103
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Table of contents
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General
1 General
1.1 Information on this Manual
This Manual provides important information on how to work with
the device safely and efficiently.
The Manual is part of the device, must always be kept in the
device's direct proximity and should be available for the personnel
at any time. All personnel working with the device is obliged to
have this Manual read and understood before starting any work.
Strict compliance with all specified safety notes and instructions is
a basic requirement for safety at work.
Moreover, the accident prevention guidelines and general safety
regulations applicable at the place of use of the device must also
be complied with.
For better representation of circumstances the illustrations used
are not necessarily to scale and may vary from the actual design of
the device.
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General
DANGER!
… indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
WARNING!
… indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
CAUTION!
… indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate
injury.
CAUTION!
… indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
Special safety notes The following symbols are used in connection with the safety notes
to highlight particular dangers:
… highlights hazards caused by electric current.
There is a danger of serious injury or death if the
safety notes are not complied with.
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General
1.4 Copyright
This Manual is protected by copyright law and exclusively to be
used for internal purposes.
Passing this Manual on to third parties, duplication of any kind –
even in form of excerpts – as well as the use and/or disclosure of
the contents without the written consent of the manufacturer is not
permitted, except for internal purposes.
Violations oblige to compensation. The right for further claims
remains reserved.
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General
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Safety
2 Safety
This paragraph provides an overview of all important safety
aspects for optimal protection of personnel as well as safe and
trouble-free operation.
Disregarding this Manual and safety regulations specified therein
may result in considerable danger.
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Safety
WARNING!
Danger of injury if insufficiently qualified!
Improper operation can lead to serious personal
injuries or property damage.
Therefore:
– Have all activities performed only by qualified
personnel.
The following qualifications are specified for different areas of
activity listed in the Manual.
An instructed person
has been instructed by the customer in an orientation session
on the assigned tasks and possible dangers in case of improper
behavior.
Qualified personnel
based on their professional training, know-how and experience
as well as knowledge of the applicable standards and
regulations is able to perform assigned work activities and to
detect and avoid possible dangers on their own.
A professional electrician
based on his/her professional training, know-how and
experience as well as knowledge of the applicable standards
and regulations is able to perform work on electrical systems
and to detect and avoid possible dangers on his/her own.
The professional electrician has been trained for the special
location where he/she works and knows the relevant standards
and regulations.
Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is
impaired, e.g. through drugs, alcohol or medication are not
permitted.
When selecting the personnel, the stipulations regarding age
and occupation applying at the location must be observed.
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Safety
WARNING!
Danger for unauthorized persons!
Unauthorized persons not meeting the
requirements outlined here are not aware of the
dangers in the work area.
Therefore:
– Keep unauthorized persons away from the work
area.
– If in doubt, address the persons and direct them
to leave the work area.
– Interrupt work activities as long as unauthorized
persons are present in the work area.
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Safety
WARNING!
Danger in case of unintended use!
Every use of the appliance above and/or different
from the intended use may lead to dangerous
situations.
Therefore:
– Use the appliance only in compliance with the
regulations.
– Follow all instructions contained in these
installation instructions.
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Safety
Protective clothing
are tight fitting working clothes with low tear resistance, with light
sleeves and without any sticking out parts. These clothes are
mainly a protection against being caught by moving machine parts.
Do not wear rings, chains, necklaces, and other jewellery.
Safety boots
to protect against heavy parts falling down or slipping on slippery
ground.
Personal protective equipment for When performing special tasks it is necessary to wear personal
special tasks protective equipment. This personal protective equipment will be
separately specified in the chapters of this Manual. This special
protective equipment is explained below.
Hard hat
to protect against parts and materials falling down and flying
around.
Protective gloves
to protect the hand against friction, graze, punctures or deep cuts
as well as contact with hot surfaces.
Safety belt
to protect against falling, if there is a higher risk of falling.
This risk is imminent if certain differences in height are exceeded
and the working area is not protected by a banister.
Wear the safety belt so that the safety rope is attached to the belt
and to a fixed anchoring point. If necessary use a fall damper.
Safety belts must be used only by persons who have been
specially trained for this purpose.
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Safety
Ear defenders
to protect against hearing damage.
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Safety
Engine WARNING!
Danger to life caused by engine in progress!
Starting the engine while working on or inside of it
may cause very serious injury or even lead to
death.
Therefore:
– Switch off the engine before performing any
work and make sure that it cannot be switched
on accidentally.
Pneumatics WARNING!
Danger of injury caused by pneumatic
energies!
Pneumatic energies can cause severe injuries.
Pneumatically driven parts may start to move
unexpectedly.
In the event of damage to individual components,
air can escape under high pressure and e.g.
damage the eyes.
Therefore:
– Have work on the pneumatic system carried out
only by trained expert personnel.
– Before starting work on the pneumatic system,
shut down the system and relieve the pressure.
Be careful of pressure accumulators. Relieve
also the pressure in accumulators.
– Do not change pressures to values higher than
the specified maximum values.
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Safety
Vibrations WARNING!
Health hazard caused by strong vibrations!
Exposure to strong vibrations over a long time can
cause considerable damage to health.
The source of vibration is to be isolated from the
environment by means of vibration dampers.
Therefore:
– Do not adversely affect the function of the
vibration dampers.
– Do not remain inside the danger zone during
operation.
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Safety
Adhesive WARNING!
Danger of poisoning through solvents!
Adhesives contain toxic solvents. The contact with
adhesives may cause serious injuries such as
poisoning, allergies or skin irritations.
Therefore:
– Obey safety data sheets of manufacturer!
– Never take in or swallow adhesives. When
taken unintentionally, visit a physician
immediately. Show package to physician.
– Avoid skin contact. Wear protective gloves. In
case of skin contact, rinse immediately under
running water.
– Do not eat or drink while working.
– Wash hands before breaks and after work
completion.
Noise WARNING!
Hearing damage caused by noise!
The noise level in the working area can cause
severe hearing damage.
Therefore:
– Wear ear defenders when prescribed.
– Stay inside the danger zone only as long as
absolutely necessary.
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Safety
CAUTION!
Danger of poisoning through engine oil and
fuel!
Contact with engine oil and fuel may lead to
serious health problems.
Therefore:
– Avoid skin contact with engine oil.
– Get splashes from engine oil and fuel off the
skin immediately.
– Do not inhale steams of engine oil and fuel.
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Safety
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Safety
Lubricants Lubricants like greases and oils contain toxic substances. These
must not be released into the environment. They must be disposed
of by a special waste disposal company.
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Technical data
3 Technical data
3.1 Indication unit
3.1.1 Type MDA312…
Specification Value Unit
Weight 2,100 kg
Length 230 mm
Width 164 mm
Height 82 mm
Supply voltage 24 V DC
IP20 back
Load voltage 60 V DC
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Technical data
Weight 6,250 kg
Length 300 mm
Width 268 mm
Height 180 mm
Supply voltage 24 V DC
Protection IP66
Load voltage 60 V DC
Length 400 mm
Width 268 mm
Height 180 mm
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Technical data
Supply voltage 24 V DC
Protection IP66
Length 400 mm
Width 268 mm
Height 180 mm
Protection IP66
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Technical data
Weight 4,000 kg
Length 300 mm
Width 190 mm
Height 128 mm
Supply voltage 24 V DC
Weight 0,120 kg
Length 132 mm
Diameter 19 mm
Protection IP67
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Technical data
Weight 0,328 kg
Length 184 mm
Diameter, maximal 60 mm
Supply voltage 24 V DC
Protection IP65
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Technical data
Weight 0,200 kg
Length 50 mm
Width 22 mm
Height 6 mm
Supply voltage 24 V DC
Current consumption 50 mA
Protection IP67
3.7 Emissions
There are no emissions expected.
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The distance sensor type IW000184 (Fig. 2/1) with protection IP67
is a high speed intelligent sensor measuring the distance between
the surface of the sensor itself and the bottom dead centre point
position of the crosshead. It is able to measure the distance in a
range of maximum 4 mm with a resolution of 0.01 mm. Additionally
it measures the splash oil temperature in the area around the
sensor with a tolerance of +/- 2 °C.
The sensor detects the crosshead within his distance range and
calculates the lowest air gap in mm. The value is stored in an
internal buffer and updated constantly at every revolution.
Fig. 2: Distance sensor On request of the Indication unit which acts as a master the buffer
information is delivered via the serial link (Terminal box > Line
Converter box > Indication unit) and compared against limits by
software.
The sensor has no thread; the fastening in the engine is arranged
by clamping in the brackets. For correct installation to the serial net
the sensor is marked with a special ID allowing the installer to
identify the sensor to ensure that left or right hand sensor is
connected correctly to the network. Additionally the sensor has a
LED under the connection point indicating correct power supply.
For connection to the outside through the cable glands in the
engine wall the sensor is delivered with an angle connector and
15 m oil resistant PUR cable. By this connection an easy exchange
is possible in case an exchange should become necessary.
Measured values are transferred as a RS232 signal via the
Terminal box to the Line Converter box.
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NOTE!
A table indicating the different types of motor and
the respective sensor brackets is given in the
chapter "Mounting the sensor brackets".
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The single sensor bracket for one sensor is placed under the
crosshead of the first (HAG003x-L, Fig. 6) and the last cylinder
(HAG003x-R, Fig. 7) because there only one distance sensor has
to be mounted.
The single sensor brackets are mounted by two M8 or M10 bolts.
Fig. 6: Single profile type sensor bracket
type HAG00321-L After the sensor bracket has been installed correctly with the two
bolts, two drillings for the alignment pins have to inserted. These
pins which are part of delivery ensure a correct placing of the
sensor bracket.
1 Bolt
2 NordLock® disc
3 Alignment pin
4 Sensor bracket
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The double sensor bracket for two sensors (Fig. 8) must be placed
in the centre under the crosshead sliding plate. Therefore two M8
or M10 bolts are needed.
The double profile type sensor brackets also have to be fixed with
two alignment pins according to the single profile type sensor
Fig. 8: Double profile type sensor bracket
type HAG00321
brackets.
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The Line Converter box (Fig. 11) delivers the galvanic isolated
power and receives the data from all sensors connected to the
system. The RS232 data from the sensors are changed into
RS422 in the Line Converter box and transferred to the Indication
unit.
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1 Display
2 Connections with cable glands
The Indication unit to be installed inside the engine room has cable
Fig. 14: Indication unit with field housing glands (Fig. 14/2) allowing the connection of:
serial link bus cable
24 V power supply
connection of the RS232 to ship or engine PC (not part of
delivery from Dr. E. Horn)
relay outputs
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4.4 Connections
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NOTE!
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within
the applicable complaints periods.
5.3 Transport
Transport of packages by crane Packages with lifting eyes can be transported by crane under the
following conditions:
Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
The operator must have authorization for operating the crane.
Hooking up:
1. Fasten ropes, belts or multi-point tackle as shown in Fig. 24.
2. Make sure that the package is hanging straight, if necessary
observe an eccentric centre of gravity.
Fig. 24
3. Start transport.
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Transport of pallets by crane Packages on pallets can be transported by crane under the
following conditions:
Crane and lifting tackle must be sufficiently dimensioned for the
weight of the package.
The operator must have authorization for operating the crane.
Fastening lifting tackle:
1. Fasten ropes, belts or multi-point tackle on the pallet as
shown in Fig. 25.
2. Make sure that the package will not be damaged by the lifting
tackle. If necessary use other lifting tackle.
3. Start transport.
Fig. 25
Transport of pallets by forklift truck Packages on pallets can be transported by forklift truck under the
following conditions:
The forklift truck must match the weight of the transport units.
The operator must have authorization for operating the forklift
truck.
Picking up:
1. Insert the forks of the forklift truck between or under the pallet
beams.
2. Insert the forks until they appear on the opposite side.
3. Make sure that pallets with eccentric centre of gravity will not
tip over.
Fig. 26
4. Lift the package and start transport.
5.4 Packing
Concerning packing The individual packages have been packed to match the transport
conditions that can be expected. Only environmentally friendly
materials were used for packing.
The packing has the function of protecting the individual
components against damage, corrosion, etc., until they are finally
assembled. The packing material must therefore not be damaged
and should only be removed just before assembly takes place.
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Handling packing materials If there is no returns agreement for the packing, separate materials
according to type and size and direct to further use or recycling.
CAUTION!
Environmental damage caused by incorrect
waste disposal!
Packing materials are valuable raw materials and
can continue to be used in many cases or sensibly
reconditioned and recycled.
Therefore:
– Dispose of packing materials environmentally.
– Follow the locally valid waste disposal
regulations. If necessary employ a special
waste disposal company to dispose of packing
material.
5.5 Storage
Storage of packages Store packages under the following conditions:
Do not store outdoors.
Store in a dry and dust-free environment.
Do not subject to aggressive media.
Protect against direct sunlight.
Avoid mechanical vibrations.
Storage temperature: 15 to 60 °C.
Relative air humidity: max. 60 %.
For storage periods longer than 3 months check the general
condition of all parts and packaging regularly. If necessary
refresh or renew the conservation.
NOTE!
Packages may be marked with notes for storage,
which may exceed the requirements mentioned
here. These must be adhered to.
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Personal protective equipment Wear the following personal protective equipment at all installation
and commissioning work:
Protective clothing
Safety boots
Hard hat
Wear the following personal protective equipment when entering
the engine room:
Protective gloves
Safety belt if it is necessary to bridge big heights
NOTE!
Other personal protective equipment that has to be
worn at particular work will be mentioned in the
warning notices in this chapter.
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Engine WARNING!
Danger to life caused by engine in progress!
Starting the engine while working on or inside of it
may cause very serious injury or even lead to
death.
Therefore:
– Switch off the engine before performing any
installation work and make sure that it cannot
be switched on accidentally.
WARNING!
Danger of injury due to improper installation
and commissioning!
Improper installation and commissioning can result
in severe personal injury or material damage.
Therefore:
– Prior to beginning installation, ensure that there
is sufficient space to work.
– Handle open sharp-edged components with
care.
– Make sure that the assembly location is clean
and well organized. Components that are
loosely stacked or lying around can cause
accidents.
– Assemble components properly. Comply with
specified screw tightening torques.
– Secure components so that they cannot fall or
tip over.
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6.2 Preparations
Cable glands CAUTION!
Damages to cables caused by sharp hole
edges!
The cables might get damaged by sharp edges
when they are guided through the holes.
Therefore:
– Insert two cable glands one inside and one
outside the engine crankcase.
– Have defective cable glands repaired
immediately.
NOTE!
There are two different kinds of cable glands. Type
“A” has only one cable pass with a diameter of 6
mm (new engines, M20x1.5). Type “B” has one,
two or more of them (retrofit, M25x1.5).
In new engines under construction each sensor has its own cable
gland. Therefore only cable glands of type “A” are used.
1. Insert the cable glands type “A” (Fig. 27, M20x1.5) into the
drillings from the first to the last cylinder. One cable gland
inside and one cable gland outside of the engine wall!
NOTE!
The number of cylinders depends on the type of
motor. Therefore the number of cable glands that
have to be mounted may differ.
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Drillings The respective holes have to be drilled into the engine wall before
the cable glands are inserted.
1. Drill the holes with the core-hole drill (23.5 mm) into the
engine wall according to the drawings.
2. Use the thread drill to insert the thread M25x1.5 into the
holes.
3. Insert the cable glands type “B” (Fig. 28, M25x1.5) into the
drillings at all cylinders; one cable gland inside and one
outside the crankcase.
NOTE!
The number of cylinders depends on the type of
motor. Therefore the number of cable glands that
Fig. 28: Cable gland type B have to be mounted may differ.
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6.3 Installation
6.3.1 Preface
The following sections describe general aspects which are
significant for the correct installation of the device.
Preparing cables Cables have to be prepared before they can be assembled in the
system.
NOTE!
It is also possible to remove only a small ring of the
outer sheath at that point where the spring is in its
final position in the cable gland.
Fig. 29: Screen of a cable But it is necessary that the spring is in full contact
with the screen. The screen itself can be led into
the box.
CAUTION!
Danger of short-circuit due to improperly
connected cables!
Conductors that contact each other may short-
circuit. This may cause damages to the device.
Therefore:
– Connect each conductor of a cable to its
connector with cable lugs.
– Make sure the wires of the conductor do not
contact each other.
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3. Put each conductor into a suitable cable lug (Fig. 31/1) and
squeeze it.
NOTE!
The spring of the cable gland (Fig. 32/1) has to lie
on the naked screen of the cable.
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Bearing Distance and Temperature Monitoring System BDMS/BTMS
Types of sensor brackets Depending on the type of motor two different types of sensor
brackets may have to be installed:
Tube type sensor brackets
Profile type sensor brackets two sensors
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2. Tighten the tube type sensor bracket (Fig. 34/2) with the bolt
M10 or M12 (Fig. 34/1) in the web plate on left (first cylinder)
or right (last cylinder) hand side of the crosshead.
z M10: 95 Nm
z M12: 120 Nm
NOTE!
Both NordLock® discs are fitted with glue and must
not be separated.
Do not use Loctite® or any other screw locking for
mounting the tube type sensor brackets.
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1 Bolt
2 NordLock® disc
3 Alignment pin
4 Sensor bracket
1. Attach two NordLock® discs (Fig. 35/2) on every bolt M8, M10
or M12 (Fig. 35/1).
NOTE!
Fig. 35: Profile type sensor bracket Both NordLock® discs are fitted with glue and must
not be separated.
Do not use Loctite® or any other screw locking for
mounting the tube type sensor brackets.
2. Tighten the profile type sensor bracket (Fig. 36/1) for two
sensors with the bolts M8, M10 or M12 (Fig. 36/2) centrally
between the crosshead web plate.
z M8: 50 Nm
z M10: 50 Nm
1 Bolt
2 NordLock® disc
3 Alignment pin
4 Sensor bracket
3. Tighten the profile type sensor bracket (Fig. 37/4) for one
sensor (here bracket for cylinder no. 1 left hand side) with the
bolts M8 or M10 (Fig. 37/1) and NordLock® discs (Fig. 37/2)
under the crossheads of the first and the last cylinder.
z M8: 50 Nm
Fig. 37: Single profile type sensor bracket z M10: 50 Nm
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NOTE!
See Appendix for installation schemas on how to
mount sensor brackets in dependency of the
number of cylinders.
4. Drill two holes through the existing drill holes (Fig. 38/1+2) of
each sensor bracket with a depth of 10 mm into the engine
material by using the 5 mm drill.
5. Insert the alignment pins (Fig. 37/3) into these holes by using
the hammer.
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Disfunction CAUTION!
Danger of malfunction through wrongly
installed distance sensors!
The BDMS/BTMS will not work if sensors are
installed incorrectly.
Therefore:
– Install the distance sensors in the sequence
given in Fig. 39.
– Use the right connector for the respective
sensor.
NOTE!
The cylinder with the highest number is that one at
the flywheel side. Opposite from the flywheel there
is the cylinder with the lowest number.This is valid
for MAN B&W engines; Wärtsilä Sulzer engines
have opposite counting therefore verify the sensor
positions against the drawings valid for the specific
engine!!
Cylinder and sensor counting It is important that the sensors are installed in the right sequence
(Fig. 39). Therefore consider the following figure:
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Note: Cylinder counting is different between MAN B&W engines and Wärtsilä Sulzer engines; cylinder no. 1
at MAN B&W is opposite flywheel side whereas Wärtsilä Sulzer cylinder no. 1 is at flywheel side!!
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Example:
Sensors 11 and 21 have to be mounted in the brackets of
cylinder 1
Sensors 12 and 22 have to be mounted in the brackets of
cylinder 2 and so on
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Mounting a sensor in a tube type 1. Turn the motor so that the crosshead of the respective
sensor bracket into the engine compartment is in the bottom dead center (Ö see operating
instructions of the engine manufacturer).
6. If the crosshead is not fully covering the sensor tip loosen the
bracket fixing bolt (Fig. 44/2) and the turn the bracket
(Fig. 44/1), until the crosshead is fully covering the sensor tip
(Fig. 44/arrow).
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NOTE!
The illustrations in Fig. 45 and Fig. 46 show a
profile type sensor bracket. The procedure is the
same as for adjusting the tube type sensor
brackets.
NOTE!
Repeat these steps with every sensor to be
mounted.
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Mounting a sensor in a profile type 1. Turn the motor so that the crosshead of the respective
sensor bracket into the engine compartment is in the bottom dead centre
(Ö see operating instructions of the engine manufacturer).
4. Loosen the sensor clamp (Fig. 48/3) of one sensor and place
the calibration tool (Fig. 48/2) correctly under the surface
(Fig. 48/1).
5. Bear this sensor against the plastic sheet until it rests on the
calibration tool (Fig. 49/1) which has to be in contact with the
machined crosshead surface.
6. Turn the sensor in a way that the sensor cable connector
shows towards the other sensor.
7. Tighten the respective clamp screw (Fig. 49/2) hand tight.
8. Remove the calibration tool.
ª Between sensor and surface there is a gap of 4 mm.
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Bearing Distance and Temperature Monitoring System BDMS/BTMS
11. Fix both cables (Fig. 51/2) with a cable tie (Fig. 51/1) and lead
them towards the cable channels.
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Mounting a water-in-oil sensor The water-in-oil sensor has to be installed into the pressure line
previous to the engine (Fig. 52).
1 Water-in-oil sensor
2 Cylinder
3 Engine
4 Area where the water-in-oil sensor should be mounted
5 Pressure line
WARNING!
Danger of injury caused by oil under pressure!
In case of defective lines or machine parts oil may
escape under pressure. This can cause severe
injuries.
Therefore:
– Do not open pipelines under pressure.
– Depressurize pipelines before starting any work.
– Have defective parts repaired.
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Bearing Distance and Temperature Monitoring System BDMS/BTMS
1 Bolt
2 Connector of sensor cable
3 Water-in-oil sensor
NOTE!
We recommend mounting the sensor in a position
range of 45° (Fig. 56/1).
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CAUTION!
Damage to cables caused by improper laying!
Cables might get damaged if they are laid
improperly.
Therefore:
– Follow the instructions in this Manual
corresponding to the placement of cables.
– Avoid placing cables around sharp corners.
– Make sure cables are not buckled.
– Lead cables only through the respective cable
glands.
6.3.4.1 Placing and fixing of cables inside new engines under construction
Cables of the sensors inside the engine have to be placed
according to MAN Diesel drawings.
1. Lead the cables (Fig. 57/3) from the sensor bracket (Fig. 57/1)
through the fastening clamp (Fig. 57/2) on the bed plate.
2. Lead cables from the bed (Fig. 58/1) plate into the provided
cable trays (Fig. 58/2–4) to the manoeuvre side of the engine.
3. Fix cables by cable ties wherever possible.
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4. Lead cables through cable glands (Fig. 59/1) from the inside
to the outside of the engine.
NOTE!
In new engines under construction there are cable
glands with one outlet for one cable only
(M20x1.5).
NOTE!
The number of cables that have to be led through
the cable glands depends on the type of engine
and whether there is a main bearing temperature
sensor installed or not.
Cable glands in new engines Cable gland with… With main bearing Without main
temperature bearing
sensor temperature
sensor
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Fig. 60: Schematic for placing the magnetic clips inside the engine
1 Loctite®
2 Cable
3 Loctite® (Engine)
4 Cable (Engine wall)
5 Gripmagnet
6 Loctite®
1. Clean the foreseen area of the bedplate with a suitable
cleaner.
2. Lead cables (Fig. 61/1) from the sensor bracket behind the
steel plate of the magnetic clip.
3. Fix the magnetic clips (Fig. 61/2) as well as the cables using
the provided glue (part of delivery).
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5. Lead cables (Fig. 63/1) through cable glands (Fig. 63/2) from
the inside to the outside of the engine.
6. Tighten the cable glands inside the engine.
7. Tighten the cable glands outside the engine after all sensors
have been mounted.
NOTE!
The number of cables that have to be led through
the cable glands depends on the type of engine
and whether there is a main bearing temperature
sensor installed or not.
Cable glands in retrofit engines Cable gland with… With main bearing Without main
temperature bearing
sensor temperature
sensor
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NOTE!
One Terminal box can take up to 16 sensors max.
In case of a BDMS/BTMS with a 7-cylinder engine
14 distance sensors and one water-in-oil sensor
can be connected to one Terminal box.
If more than 16 sensors should be installed (8
cylinders or more) a second Terminal box is
needed.
4-7 8-14 1
8-14 15-28 2
Mounting NOTE!
The distance between the Terminal box(es) and
the Line Converter box must not exceed a distance
of 5 m to avoid malfunctions.
NOTE!
The Terminal box(es) should be mounted near the
cable glands on the manoeuvre side of the engine.
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NOTE!
Fig. 64: Connection box The Terminal box in Fig. 64 is different from this
one in the scope of today's supply.
CAUTION!
Damage to cables in case of improper leading!
The cables of the sensors might get damaged if
they are not led through the cable trays.
Therefore:
– Always use the provided cable trays to lead
cables.
– Mount additional cable trays if necessary.
NOTE!
Cables that are too long may be shortened or
coiled up and fastened on the cable tray or
Fig. 65: Cable trays on engine block Terminal box.
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Leading cables into the box 2. Prepare all cables according to the description
3. Loosen the screws on the Terminal box (Fig. 66/1) and open
it.
7. Make sure all cables (Fig. 68/1) are placed correctly and the
spring (Fig. 68/2) is in contact with the naked screen
(Fig. 68/3).
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NOTE!
Inside the Terminal box the distance sensors can
be connected to any available connector without
following a routine.
Distance sensors, water-in-oil sensor and main
bearing temperature sensor get connected
similarly.
1 +ub brown
2 RxD white
3 TxD black
Fig. 70: Connecting a sensor
4 GND blue
The Terminal box has two connectors for a bus cable. They are
identified as X17 (Fig. 71/1) and X18 (Fig. 71/2).
1. Choose a connector taking into account the position of the
Line Converter box.
z X17: Line Converter box left of Terminal box
z X18: Line Converter box right of Terminal box
1 +ub_BUS green
2 RxD_BUS brown
3 TxD_BUS yellow
4 GND_BUS white
Fig. 72: Connecting the bus cable
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NOTE!
The distance between the Terminal box(es) and
the Line Converter box must not exceed a distance
of 5 m to avoid malfunctions.
The Line Converter box may optionally have Z-profiles (Fig. 73/1)
with vibration dampers (Fig. 73/2).
1. Attach the Line Converter box to the engine block by six bolts
(Fig. 74/1).
The cable glands should be on the bottom side of the box
(Fig. 74/2).
z Bolts M8 and NordLock® discs are included in delivery.
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CAUTION!
Damage to cables in case of improper leading!
The cables might get damaged if they are not led
through the cable trays.
Therefore:
– Always use the provided cable trays to lead
cables.
– Mount additional cable trays if necessary.
The Line Converter box has four cable glands, one for each cable
(Fig. 77/1). The bus cables from the Terminal boxes are thinner
than the others. So they have to be led through both the right cable
glands.
NOTE!
If only one Terminal box is installed it has to be
connected to connector X3.
Fig. 77: Cable glands
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NOTE!
Cables that are too long may be shortened or
coiled up and fastened on the cable tray or Line
Fig. 78: Cable trays on engine block Converter box.
Leading cables into the box 2. Prepare all cables according to the description in "Preface".
3. Loosen the screws on the Line Converter box (Fig. 79/1) and
open it.
7. Make sure all cables (Fig. 81/1) are placed correctly and the
spring (Fig. 81/2) is in full contact with the naked screen
(Fig. 81/3).
8. Tighten the pressure screw (Fig. 80/1) of each cable gland so
that the cable is fixed.
9. Connect the conductors to the respective connector according
to chapters 6.3.8.1 till 6.3.8.3.
10. Close the Line Converter box and tighten the screws.
Fig. 81: Spring on naked screen
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1 Connector X3
2 Connector X4
1 +ub green
2 RxD brown
4 GND white
All cabling inside the Line Converter Box except the bus
connections at X2, X3 and X4 are factory-made.
So the board power supply at X1 looks as shown in Fig. 84.
1 +24 V red
2 0V blue
Fig. 84: Board power supply
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The centralized supply from the ship is carried out via the power
switch (Fig. 85/1). It can be closed to switch on and opened to
switch off the power supply from the ship.
1 – blue
2 + red
1 – blue
2 + black
3 GND yellow/green
Fig. 87: Connection with 115/265 V AC
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1 RxD\ white
2 RxD brown
3 TxD\ yellow
Fig. 88: Connecting the bus cable
4 TxD green
NOTE!
The Indication unit may be mounted in a distance
up to 1000 m to the Line Converter box.
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CAUTION!
Damage to cables in case of improper leading!
The cables might get damaged if they are not led
through the cable trays.
Therefore:
– Always use the provided cable trays to lead
cables.
– Mount additional cable trays if necessary.
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NOTE!
Cables that are too long may be shortened or
coiled up and fastened on the cable tray or the
Fig. 92: Cable trays on engine block Indication unit.
The violet cable from the Line Converter Box has to
be laid on the best way in the vessel on existing
cable rails.
Avoid parallel running with power cables and too
close distances to generator sets.
Leading cables into Indication unit When using the Indication unit type MDA 321… it is necessary to
MDA321… lead the cables into the unit via cable glands.
2. Prepare all cables according to the description in "Preface".
3. Loosen the screws on the Indication unit (Fig. 93/1) and open
it.
4. Loosen the pressure screw of the cable glands.
5. Guide the cables through the cables glands (Fig. 93/2) into
the Indication unit.
6. Make sure all cables (Fig. 94/1) are placed correctly and the
spring (Fig. 94/2) is in contact with the naked screen
(Fig. 94/3).
7. Tighten the pressure screw of each cable gland with the
special wrench (Art. no. WG000120) so that the cable is fixed.
8. Connect the conductors to the respective connector according
to chapters 6.3.10.1 to 6.3.10.2.
9. Close the Indication unit and tighten the screws (Fig. 93/1).
Fig. 94: Spring on naked screen
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2 0V depends on yard
connection
Fig. 95: Connecting power supply
6.3.10.2 Connecting the bus cable from the Line Converter box
Type of cable: LT2004D0 (cable data sheet enclosed in
Appendix)
1 TxD brown
2 TxD\ white
3 RxD green
Fig. 96: Connecting bus cable
4 RxD\ yellow
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6.4 Checks
There are a few checks that have to be carried out before
commissioning.
Checking connections Make sure that all sensors are connected correctly inside the
engine in line with the ID numbers for 4 to 14 cylinder engines
mentioned in the Annex.
Recheck all power connections between Terminal box(es) and
Line Converter box for correct connection. Obey the colour
code.
Recheck the bus connections between Terminal box(es) and
Line Converter box for correct connection. Obey the colour
code.
Recheck the bus connections between Line Converter box and
Indication unit in the engine control room for correct connection.
Obey the colour code.
Check if all GND connections at Terminal box(es), Line
Converter box and Indication unit are mounted with the copper
mash bands to the units.
Measure the voltage foreseen to be used to make sure that 24
V DC are not mixed up with 115/265 V AC or vice versa.
Recheck polarity.
Checking function 1. Open the Line Converter box and switch on power supply by
closing the power switch.
2. Open the Terminal box(es) and check if the green LED is lit at
all busy connectors.
Preparing transport of an When an engine is delivered in parts and not as a whole to the
incomplete delivered engine shipyard, the following works have to be carried out:
1. Open the Line Converter box and switch off the power supply.
2. Mark the sensor cable allowing a clear identification at
reassembling which cable belongs to which sensor, left or
right hand side.
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NOTICE!
Malfunction through dirty sensors!
When a cable is displaced from a sensor it might
get polluted by dirt and particles.
Therefore:
– Always place the foreseen cap onto the sensor
cable and the sensor itself.
3. Loosen the sensor cable from the sensor and place a cap on
the sensor cable (Fig. 98/2) as well as another one on the
sensor (Fig. 98/1) itself.
NOTE!
The caps are part of Dr. E. Horn's delivery.
4. Coil up the sensor cables and secure them in the engine bed
plate.
After transport of an incomplete 1. Remove the caps from sensor and sensor cable and connect
delivered engine them according to the marking.
2. Check the sensor brackets for damages. Replace them if
necessary.
3. Open the Terminal box(es) and the Line Converter box.
4. When all sensors are connected switch on the power supply
at the power switch.
5. Open the crankcase doors.
6. Check all LED in Terminal and Line Converter box for lighting.
7. If all LED are on close the crankcase door, the Terminal
box(es) and the Line Converter box.
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6.5 Commissioning
6.5.1 Prior to commissioning of retrofit installations
If the system is installed as a retrofit into engines already in service
it is necessary to carry out a speedrun with given revolutions.
The crossheads are closing down nearer to the distance sensors at
the moment of inertia with increasing speed. This has to be
compensated by differed values that have to be stored in the
system.
The following table shows the speed needed for compensation:
6.5.3 Commissioning
The system is in operation from the first revolution on. There are
no special tasks that have to be performed for commissioning.
When the system is installed completely and connected to the
ship's net it is ready for operation. All alarms are active.
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Operation
7 Operation
7.1 Safety
Personal protective equipment During operation no special protective equipment has to be worn.
1. Use the optical buttons "Up" (Fig. 99/2) and "Down" (Fig. 99/4)
to scroll through the different compartments.
2. Check all values with regard to what is expected.
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Operation
Oil temperature The splash oil temperature is measured by the distance sensors as
well. The respective temperature is presented as absolute value for
each side of a compartment (Fig. 99/1 and Fig. 99/5).
NOTE!
The temperature of the splash oil near a distance
sensor is measured with a tolerance of ± 2 °C.
Main bearing temperature The temperature of the main bearings (Fig. 99/7 and Fig. 99/10)
will be displayed when the engine has been started and the load
increases.
NOTE!
When operating normally the temperature has to
rise up close to or above the lube oil temperature.
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Operation
Personal protective equipment Wear the following personal protective equipment when entering
the compartment:
Protective clothing
Safety boots
Safety gloves
Hard hat
Safety belt if it is necessary to bridge big heights
Testing a distance sensor The distance sensor can be tested at open compartment.
1. Shut off the engine and secure it against accidental restart (Ö
see Operating Instructions of the engine manufacturer).
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Operation
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Maintenance
8 Maintenance
8.1 Safety
Personnel The maintenance work described here cannot be executed by
the operator unless otherwise indicated.
Some maintenance tasks can only be executed by trained
qualified personnel, or only by the manufacturer. In these cases
this is separately indicated in the description of the specific
maintenance tasks.
All work on the electrical equipment should only be executed by
a qualified electrician.
Personal protective equipment Wear the following personal protective equipment at all
maintenance work:
Protective clothing
Safety boots
Hard hat
Safety belt if it is necessary to bridge big heights
NOTE!
Other personal protective equipment that has to be
worn at particular work will be mentioned in the
warning notices in this chapter.
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Maintenance
Engine WARNING!
Danger to life caused by engine in progress!
Starting the engine while working on or inside of it
may cause very serious injury or even lead to
death.
Therefore:
– Switch off the engine before performing any
maintenance work and make sure that it cannot
be switched on accidentally.
WARNING!
Injury hazard posed by improperly executed
maintenance work!
Improper maintenance can cause severe injury or
property damage.
Therefore:
– Prior to starting work ensure that there is
sufficient assembly space.
– Ensure order and cleanliness at the assembly
site! Loose parts and tools, parts and tools
placed on top of each other are hazard sources.
– If components have been removed, ensure that
they are properly mounted; re-install all
mounting elements and comply with all screw
tightening torque specifications.
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Maintenance
At every opening of Visually check the distance sensors and the cabling for Qualified personnel
the crankcase door damages. The LED must be lit.
Visually check the main bearing sensors (if installed) Qualified personnel
and the cabling concerning being glued.
Visually check the water-in-oil sensor (if installed). LED Qualified personnel
must be lit.
Annually Check all the cabling being laid for damages. Have Professional electrician
them repaired or replaced immediately.
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Maintenance
NOTE!
When a distance sensor is defective, the respective
LED on the Indication unit will not be lit anymore.
Distance sensors cannot be repaired, they have to
be changed.
The LED C3 (Fig. 104/1) in the lower range of the Indication unit is
off. The respective sensor is defective and has to be changed.
1. Order a new sensor from Dr. E. Horn.
NOTE!
We recommend taking our special tools for
changing sensors (Fig. 105/1 and Fig. 106/1) to
have fewer complications with the exchange. The
Fig. 104: Indicating a defective sensor
tools will be part of the hardware delivery.
Required tools:
z Special tools for changing defective sensors:
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Maintenance
Changing a sensor in a tube type 1. Shut off the engine and secure it against accidental restart
sensor bracket (Ö see Operating Instructions of the engine manufacturer).
2. Turn engine, so that the crosshead is away from the defective
sensor and working under the crosshead is possible
(Ö see Operating Instructions of the engine manufacturer).
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Maintenance
Changing a sensor in a profile type 1. Shut off the engine and secure it against accidental restart
sensor bracket (Ö see Operating Instructions of the engine manufacturer).
2. Turn engine, so that the crosshead is away from the defective
sensor and working under the crosshead is possible
(Ö see Operating Instructions of the engine manufacturer).
NOTE!
Further adjustments are not necessary.
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Maintenance
NOTE!
When the clamping bolts get opened the sensors
have to be arranged anew.
Fig. 109: Sensor bracket with sensors
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Maintenance
M12 120 Nm
M10 40 Nm
Ground screw M6 6 Nm
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Troubleshooting
9 Troubleshooting
The following chapter describes possible causes of faults and the
steps required to eliminate them.
In the event of frequent faults, reduce the maintenance intervals to
correspond to the actual working load.
In the event of faults that cannot be eliminated through the
following instructions, please contact the manufacturer (service
address on page 2).
9.1 Safety
Personnel All troubleshooting work on the electrical system must be
performed by a qualified electrician.
Personal protective equipment Wear the following personal protective equipment at all
troubleshooting work:
Protective clothing
Safety boots
Protective gloves
Hard hat
Safety belt if it is necessary to bridge big heights
NOTE!
Other personal protective equipment that has to be
worn at particular work will be mentioned in the
warning notices in this chapter.
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Troubleshooting
Engine WARNING!
Danger to life caused by engine in progress!
Starting the engine while working on or inside of it
may cause very serious injury or even lead to
death.
Therefore:
– Switch off the engine before performing any
maintenance work and make sure that it cannot
be switched on accidentally.
WARNING!
Unauthorized troubleshooting procedures can
result in injury!
Improper troubleshooting procedures can result in
severe personal injury or material damage.
Therefore:
– Prior to beginning installation, ensure that there
is sufficient space to work.
– Make sure that the assembly location is clean
and well organized. Components that are
loosely stacked or lying around can cause
accidents.
– If components have been removed, ensure
proper assembly, install all mounting elements
and comply with screw tightening torques.
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Troubleshooting
NOTE!
The chapter "Troubleshooting" below provides
information on who is authorised to eliminate the
fault.
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Troubleshooting
Indication unit is connected but No electrical connection Check the status of the 9.3.1
not illuminated. existing. LED on the back.
Indication unit is illuminated but Bus cable is not Check the bus cable. 9.3.2
no indication in the bar graphs or connected.
temperature windows.
Power switch in the Line Close power switch in the 9.3.2
Converter box is open. Line Converter box.
Distance sensor in the lower row Distance sensor is not Check connection of the 9.3.3
of the display is missing. connected. sensor in Terminal box.
Main bearing temperature for Main bearing Check connection of the 9.3.4
one sensor is missing when temperature sensor is sensor in Terminal box.
scrolling through the not connected.
compartments.
A water-in-oil sensor is not Water-in-oil sensor is not Check connection of the 9.3.5
indicated in the display. connected. sensor in Terminal box.
No function of the Terminal box. Terminal box is not Check if Terminal box is 9.3.6
connected. connected.
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Troubleshooting
9.3 Troubleshooting
9.3.1 Checking the electrical connection of the Indication unit
Execution only by a qualified electrician.
1. Check if the LED (Fig. 110/1) on the back of the Indication unit
is lighting.
2. If the LED is off measure the voltage at the connectors X11
(Fig. 110/3) and X12 (Fig. 110/4).
NOTE!
A voltage of 24 V DC is required.
9.3.2 Checking the bus cables of the Indication unit and power supply
Execution only by a qualified electrician.
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Troubleshooting
4. If the LED are off check the voltage at the power switch. It
must be 24 V DC.
If there is still no power (green LED in Fig. 113 off) and there is no
Fig. 114: Fuse
voltage measurable at the main supply inlet:
7. Check the main supply the BDMS/BTMS system in the ship
supply distribution system.
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Troubleshooting
2. Open the Terminal box and check all connected terminals for
the respective LED (Fig. 117/1) being on.
3. If an LED is off remove the respective connector (Fig. 117/2).
4. Replace the connector after 30 seconds.
ª The LED (Fig. 117/1) must be on.
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Troubleshooting
1. Note the number of the cylinder (Fig. 118/1) and the position
A (Fig. 118/3) and B (Fig. 118/2) respectively.
2. Open the Terminal box and check all connected terminals for
the respective LED (Fig. 119/1) being on.
3. If an LED is off remove the respective connector (Fig. 119/2).
4. Replace the connector after 30 seconds.
ª The LED (Fig. 119/1) must be on.
If the LED just shortly lights up the cabling or the main bearing
temperature sensor itself is defective.
Fig. 119: Terminal box 5. Have the cabling repaired or the sensor changed.
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Troubleshooting
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Troubleshooting
If no LED is on:
3. Check X17 (Fig. 123/1) and X18 (Fig. 123/2) respectively for
correct cabling and insertion of the leads.
4. Measure the voltage at the connectors X17/1, X17/4 and
X18/1, X18/4 respectively.
ª The voltage is 24 V DC.
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Troubleshooting
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Appendix
10 Appendix
10.1 Installation schemata for the distance sensors
The following drawings show the installation schematics of
distance sensors for engines with
4 cylinders (ANG00742-4)
5 cylinders (ANG00742-5)
6 cylinders (ANG00742-6)
7 cylinders (ANG00742-7)
8 cylinders (ANG00742-8)
9 cylinders (ANG00742-9)
10 cylinders (ANG00742-10)
11 cylinders (ANG00742-11)
12 cylinders (ANG00742-12)
14 cylinders (ANG00742-14)
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Index
11 Index
A Connecting ..................................................... 84
Brackets ............................................................. 34 L
Preparation ..................................................... 90 M
D Maintenance....................................................... 95
E Noise .................................................................. 19
F Operation ........................................................... 91
H P
134 2008-10-20
Bearing Distance and Temperature Monitoring System BDMS/BTMS
Index
2008-10-20 135