MAN Diesel

Off-line PMI System

Pressure Analyser
Installation Guide
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Installation Guide
Off-line PMI System
Pressure Analyser
Version 2.3
About this Guide
This Installation Guide applies to MAN Diesels Off-line PMI System. It provides
installation and commissioning personnel with technical advice and instructions
on installing, adjusting and checking the system to make it ready for use by the
technical personnel responsible for the daily operation of the system.
The scope of supply of the Off-line PMI System hardware varies according to
the actual engine design specifcation and whether the system is delivered for a
new engine or a retroft project. The components of typical Off-line PMI System
confgurations are outlined in chapter 1.2 The Basic System.
For instructions on mounting and connecting a crankshaft pickup for triggering
the system, consult the separate Mounting Guide belonging to the particular
pickup which is to be used with the system.
For guidance on the use of the system for cylinder pressure measurements on
diesel engines, a common Users Guide is provided with the system.
The supply, distribution and use of the PMI System and Data media, including
System Documentation, are subject to your acceptance of the Standard Condi-
tions of Licence which are supplied in the Software Package containing the PMI
System.
Taking the PMI System in use will indicate your acceptance of these condi-
tions.
Windows is a trademark of the Microsoft Corporation, U.S.A. Trademarks
Conditions of Use
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MAN B&W Diesel A/S
Teglholmsgade 41
DK- 450 Copenhagen SV
Denmark
Telephone +45 33 85 11 00
Telefax +45 33 85 10 30
manbw@dk.manbw.com
www.mandiesel.com
Copyright MAN Diesel A/S. Reg. No. 39 66 13 14
Reproduction permitted provided source is given
Subject to modifcation in the interest of technical progress
3520-0006-00ppr May 2007
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1. Before You Begin
1.1 About this Guide ............................................................................................8
General Overview ............................................................................................8
PMI On-line Help ...........................................................................................8
Text Conventions .............................................................................................8
1.2 The Basic System ...........................................................................................9
2. Hardware Installation
2.1 General ........................................................................................................ 14
2.2 Intermediate/Freq. Divider & Junction Boxes ............................................. 16
2. Converter Box ............................................................................................. 16
2.4 Cable and Power Checks ............................................................................ 17
2.5 Engine Address & Pickup TDC Checks ...................................................... 19
3. Commissioning the System
.1 Installing the PMI Software ......................................................................... 22
.2 Checking Engine Registration .................................................................... 22
. Setting Up Communication ......................................................................... 24
.4 Trigger and TDC Test .................................................................................. 26
.5 System Reference Measurements .............................................................. 28
0-Diagram Measurements ........................................................................ 28
E-Load Measurements .............................................................................. 29
.6 Checking & Editing Reference Measurements ........................................... 0
.7 Technical Assistance ................................................................................... 4
Index
Contents
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Chapter 1
Before You Begin
Welcome to MAN Diesels, Off-line PMI System. It is designed to provide engi-
neers and service staff on board ship and at power plants with a computerised
tool for cylinder pressure measurements and analysis on MAN B&W two and
four stroke diesel engines.
It consists of a pressure transducer, a PMI Controller and a trigger system with
crankshaft pickup which can be operated using an IBM compatible PC on
which the PMI System software is installed. The system is supplied with the
necessary hardware and software, and is designed to automatically calculate,
display and log measurement results.
In this Chapter
About this Guide ................................................................................................... 8
General Overview ........................................................................................... 8
PMI On-line Help .......................................................................................... 8
Text Conventions ............................................................................................ 8
The Basic System ................................................................................................. 9
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1.1 About this Guide
1.1.1 General Overview
This Installation Guide provides information about the initial preparations and
procedures necessary for installing the hardware and software of the PMI Sys-
tem on board ship and at power plants, as well as for commissioning the sys-
tem.
The guide includes the following chapters:
Chapter 1 Before You Begin
This is the chapter which you are now reading. It provides brief details about
the contents of this Guide and how to obtain on-line help with the Application
Software of the system. In addition, a short description of the PMI System and
its main components is included, explaining what you need to know about the
system before installing it.
Chapter 2 Hardware Installation
Provides instructions and advice on how to mount, connect and adjust the
hardware of the PMI System. For information about the pickup device which is
to be used for triggering the system, consult the separate Mounting Guide for
the device.
Chapter 3 Commisioning the System
Explains how to install the PMI software on your PC and start the system. Also,
details are given about how to make reference measurements for setting up the
PMI System.
Wiring diagrams and drawings of the system hardware are supplied in a sepa-
rate folder which is included with this and the other documentation provided.
For information and instructions about operation and use of the system for cyl-
inder pressure measurements, please consult the separate Users Guide which
is provided.
1.1.2 PMI On-line Help
To help you in hands on use of the PMI System, its application software in-
cludes on-line help information. This is available directly on your PC whenever
using it together with the PMI System. It is activated by pressing the function
key F1 on the keyboard.
1.1.3 Text Conventions
Settings & Values:
The values and settings shown in the displays and stated in accompanying text
throughout the guide, are included as examples only.
Menus & Menu Commands:
References to specifc commands that are given in menus and dialogue boxes
are indicated in single quotes, e.g. Open Engine in the File menu.
Commands depicted with a leader, i.e. Options ..., open a selection dialogue
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which offers a number of options to choose from, while those without a leader,
i.e. Print, immediately initiate the particular action designated.
1.2 The Basic System
A schematic of the Off-line PMI System is shown in Fig. 1-1.
Junction Box
PMI Controller Pressure Transducer
Crankshaft Angle Encoder
or Position Pickup
Power Supply
Intermediate or
Frequency Divider
Box
TwoStroke
Diesel Engine
LED
Indicator
Personal Computer
with PMI System
Application Software
Engine Control
Room
Converter Box
Fig. 1-1 Schematic of the Off-line PMI System (not to scale)
The off-line version of the system employs a high-performance piezo-electric
transducer of well proven design which is mounted on the cylinder head cover
from which the cylinder pressure is measured.
To obtain a pressure indication which accurately describes the change in cylin-
der pressure throughout each work cycle of an engine, the pressure detected
by the transducer must be synchronised with the motion of the engine. For this
purpose the PMI System is designed to be used with different types of crank-
shaft pickup, for example:
Angle Encoder: A sealed unit containing an optically encoded disc, coupled
to the crankshaft of the engine.
LE-Pickup: A pair of Light Emitting Sensors which detect the light refected
from a continuous strip of zebra tape bonded on the drive shaft of the engine.
PD-Pickup: A pair of Proximity Detectors which are based on inductive pick-
ups. They detect the rotation of a TDC marker and the individual teeth of a
gear wheel or a specially designed trigger ring at the end of the crankshaft.

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Pickup Engine Type
& Layout
Mounting Maintenance
Angle
Encoder
Main & Aux. Engines
without PTO
Engine crankshaft via
fexible coupling
Sealed unit requiring
little or no maintenance
LE-Pickup
& Zebra Tape
Main & Aux. Engines
with / or without PTO
Zebra tape bonded
to free section of en-
gine drive shaft
Zebra tape must occa-
sionally be cleaned
PD-Pickup Main & Aux. Engines
with / or without PTO
Operates from gear
wheel
Immune to most
disturbances
Table 1-1 Crankshaft Pickups for use with the PMI System
Divider Box
24V DC
PDPickup
Box
To Next Engine
Junction Box
Gear Wheel or
Trigger Ring
Intermediate
Box
Junction Box
PMI
Controller
Pressure
Transducer
LEPickup
Box
Zebra Tape
on Drive Shaft
Intermediate
Box
Junction Box
Engine
Crankshaft
Angle Encoder
plus
flexible coupling
Personal Computer
with PMI System
Application Software
Converter
Box
Engine Room
Control Room
24V DC
24V DC
Engine No. 3
Engine No. 2
Engine No. 1
Fig. 1-2 Connection of the PMI System with an Angle Encoder, Light Emitting Pickup and/or Proximity
Pickups
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All types of pickup produce a train of electrical pulses which are used to detect
the absolute position of the crankshaft. In addition, they produce a separate
pulse which is used to synchronise the PMI System with the TDC position of
Cylinder No. 1.
As indicated in Table 1-1 the choice of appropriate crankshaft pickup and its
connection with the PMI System (see Fig. 1-2), depends on the engine layout.
With the Angle Encoder a precise number of crankshaft angle/position pulses
are generated (e.g. 1024) per revolution of the crankshaft, while with the other
sensors the number of pulses depend on the diameter of the drive shaft or the
number of teeth on the turning wheel or trigger ring on the engine.
The crankshaft pickup pulses from the engine are frst fed to either an Interme-
diate Box or Frequency Divider (depends on whether engine is a two-stroke or
four-stroke type) and then on to a Junction Box. From there they are relayed to
the portable PMI Controller which is attached to the pressure transducer and
serves as the systems remote nerve centre for controlling measurements.
All of the equipment is powered by an external 24 V DC source and except for
the pressure transducer and portable PMI Controller, are mounted as a perma-
nent fxture in situ with the engine.
For subsequent calculation, display and storage of the data using the PC, the
software supplied with the PMI System must be installed.
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Chapter 2
Hardware Installation
This chapter explains how to mount, connect and adjust the hardware of the
PMI System.
For information about mounting the crankshaft pickup which is to be used for
triggering the system, consult the separate Mounting Guide that is supplied
with the device.
In this Chapter
General ............................................................................................................... 14
Intermediate/Freq. Divider & Junction Boxes ................................................... 16
Converter Box .................................................................................................... 16
Cable and Power Checks ................................................................................... 17
Engine Address & Pickup TDC Checks ............................................................ 19
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2.1 General
The connection of the hardware used by the PMI System, including a Crank-
shaft Pickup, is illustrated in Fig. 2-1.
PMI
Controller
Pressure
Transducer
Intermediate (or
Freq. Divider)
Box
Junction Box
Crankshaft Pickup
See separate
Mounting Guide
Personal Computer
with PMI System
Application Software
Converter
Box
Control Room
24V DC
(PMI - 1)*
(PMI - 5*)
(PMI - 3*(or 9)*
(PMI - 2 (or 8)
(PMI - 6)
(PMI - 4)
* Item not included
To Junction Box
of Next Engine
(PMI - 7)*
Fig. 2-1 Connection of PMI System with an angle Encoder
To permit easy identifcation of the appropriate cables used for connecting the
equipment, the cables are numbered from PMI-1 through to PMI-1 as indicat-
ed above. A brief explanation of each of these cables is given below:
PMI1: 24V DC Power Cable to Junction Box: Item not included. Can
be made using a 1 x 2 x 0.75 mm
2
screened cable.
PMI2 / 8: Pickup Cable to Intermediate/Freq. Divider Box: 1.5 m long
fxed screened cable supplied with the pickup.
PMI3: Intermediate Box: Item not included. Can be made using a 4 x
(2+1) x 0.5 mm
2
multi screened cable.
PMI4: Converter Box Cable to PC: 1.5 m long, fxed cable supplied
with Converter. Has Sub-D9 female plug for connecting to free
Communication Port on PC.
PMI5: Converter Box Cable to Junction Box: Item not included. Can
be made using a 4 x 2 x 0.5 mm
2
screened cable. Max. overall
length of PMI-5 including PMI-7 must not exceed 1200 m for
RS422 operation.
PMI6: PMI Controller Box Cable to Junction Box: Fixed cable sup-
plied with PMI Controller. Has multipin connector for connect-
ing Junction Box. Either 8 m or 15 m long cable supplied, de-
pending on engine size.
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PMI7: Junction Box Cable: Item not included. Is used for intercon-
necting Junction Boxes in multiple engine installations. Can
be made using a 4 x 2 x 0.5 mm
2
screened cable. Max. overall
length of PMI-5 including PMI-7 must not exceed 1200 m for
RS422 operation.
PMI9: Freq. Divider Box Cable to Junction Box: Item not included.
Requires 2 x 2 x 0.5 mm
2
screened cable, but can be made us-
ing 4 x (2+1) x 0.5 mm
2
screened cable.
PMI10 / 11: Terminal/Freq. Divider Box to Pick-up: 5 m cable ftted with
connector for pickup. Supplied with the pickup.
PMI12 Terminal Box to Junction Box: Item not included. Requires 2 x
2 x 0.5 mm
2
screened cable, but can be made using 4 x (2+1) x
0.5 mm
2
screened cable.
PMI13: Junction Box A1 to Junction Box: Item not included. Requires
1 x 2 x 0.5 mm
2
screened cable as minimum
The cable connections are shown in the wiring diagrams provided with the PMI
System.
Important: To ensure reliable operation of the PMI System its communication
and power cables must not be routed directly alongside other power cables. If
PMI cables have to be routed over power cables then they should cross at 90.
Cables not included with the PMI System, can be ordered from MAN Diesel.
For specifcations and electrical data of the individual cables, please refer to
the installation drawings and wiring diagrams provided with the PMI hardware.
NOTE
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To prevent damage, wait until section 2.4 in this chapter before applying
power to the system.
2.2 Intermediate/Freq. Divider & Junction Boxes
The Junction Box is to be mounted on the indicator side on the top section of
the engine with the Intermediate Box or Freq. Divider Box close by the Crank-
shaft Pickup (1.4 m max.). Make sure that the Junction Box is located not more
than 7 metres or 14 metres (depends on length of PMI Controller cable sup-
plied) away from the furthest cylinder cock, as otherwise it will be out of reach
of the Pressure Transducer.
14
14
52
6 6 238
14
14
6
52
6 113
Mounting Holes
2 x 4.8 for
M4 Screws
Mounting Holes
2 x 5 for
M4 Screws
23
35
52
42
Junction Box
Intermediate, Freq.
Divider or Converter
Box
Fig. 2-2 Location of the mounting holes in the PMI Junction Box, Intermediate Box, Freq. Divider Box
and Converter Box
The diverse boxes have two holes for bolting them to a fat, vibration-free sur-
face. The Junction Box is to be bolted on a raised support with it connectors
protruding over one side of the support (see Fig. 2-2), so as to allow room for
fastening the multipin connector of the PMI Controller.
2.3 Converter Box
After connecting the Crankshaft Pickup, Intermediate Box and Junction Box,
etc., the output of the Junction Box should be coupled to the Converter Box.
CAUTION
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The Converter Box must be mounted close to the PC which is stationed either
in the engine control room or in some other convenient location. It is supplied
with a 1.5 metre long integral cable (PMI-4) with Sub-D9 female plug which
should be fastened to one of the free communication ports on the PC.
5 - I M P e l b a C 4 - I M P e l b a C
1 2 3 4 5 6 7
To
Junction Box
To PC
Com. Port
5 V DC
1 7
Fig. 2-3 Location of the PMI Systems Converter Box. The 5 V DC power input is
on terminals 5 and 6
For connecting the Converter Box to the Junction Box, the cable PMI-5 is used.
This is shown in the wiring diagrams provided with the PMI System and can be
made up using a 4 x 2 x 0.5 mm
2
screened cable. The maximum overall length
of the cable, including the extension cables PMI - 7 if more than one Junction
Box is to be installed, must not exceed 1200 m.
2.4 Cable and Power Checks
Before applying power to the entire system the following power check and
power start up procedure should be carried out to reduce risk of damaging the
system:
Unplug all terminal blocks in the PMI boxes.
Switch on the external 24 V power supply for the system.
Measure that there is 24 V (18 to 2 V acceptable) on the terminal block for
PMI-1 and that the supply polarity on the terminals matches that shown in
the wiring diagram provided for PMI-1.
Plug the PMI-1 terminal block back into the Junction Box and check that all
three power indicator LEDs in the box are lit. See Fig. 2-4.
If one or more of the indicators fails to light, make the checks indicated in
Table 2-2 overleaf.
1.
2.
.
4.
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1 7 14 19 15 8 1 7
LED-1 LED-2 LED-3
0.8 A Fuse
Extra Fuse
J
P
3
J
P
1
J
P
2
On
Off
JP3
SW-1
Fig. 2-4 PMI Junction Box - switch and jumper setting
5. Check that the 5 V supply, communication and terminal block connections
of cable PMI-5 match the wiring diagram provided and have the correct po-
larity.
6. Plug the terminal block for PMI-5 back in the Junction Box and check that
there is 5 V on the PMI-5 terminal block in the Converter Box and that the
polarity is correct.
7. Plug the terminal block for PMI-5 back in the Converter Box and check the
status of the power indicator LEDs in the Junction Box.
If one or more of the LEDs no longer lights, immediately unplug the PMI-5
terminal block and make the checks indicated in Table 2-1.
8. Check that the 24 V supply, communication and terminal block connections
of cable PMI- (or 9) match the wiring diagram provided and have the cor-
rect polarity.
Junction Box LED No.
Comments
24V
1
15V
2
5V
3
Off Off Off Unscrew and check that the 0.8 A fuse in the Junction
Box is intact. An extra fuse is included in the box for
replacement.
Also check that the 24 V DC power input cable PMI - 1
is connected correctly, as indicated on the print board
in the box
On Off On/Off 15 V power regulation is defective. Replace Junction
Box
On On Off 5 V power regulation is defective. Replace Junction
Box.
On On On System is OK.
Table 2-1 Junction Box Supply and Cable Checks
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9. Plug the PMI- (or 9) terminal block back in the Junction Box and check
that there is 24 V on the PMI- (or 9) terminal block in the Intermediate/Freq.
Divider Box and that the polarity is correct.
10. Plug the terminal block for PMI- (or 9) back in the Intermediate/Freq. Divider
Box and check the status of the power indicator LEDs in the Junction Box.
If one or more of the LEDs no longer lights, immediately unplug the terminal
block and make the checks indicated in Table 2-1.
11. Check that the 24 V supply, communication and terminal block connections
for the Crankshaft Pickup Cable PMI-2 (or 8) in the Intermediate/Freq. Di-
vider Box match the wiring diagram provided and have the correct polarity.
12. Plug the PMI-2 (or 8) terminal block back in the Intermediate/Freq. Divider
Box and check the status of the power indicator LEDs in the Junction Box.
If one or more of the LEDs no longer lights, immediately unplug the terminal
block and check it again, as it is likely that one or more of the connections
is incorrect.
With multi engine plants, repeat the above procedure for each set of PMI
boxes in the system.
2.5 Engine Address & Pickup TDC Checks
Open the Junction Box(es) and set the address switch and jumpers as indi-
cated in Fig. 2-4 and Table 2-2.
Whereas JP must always be set to On, the setting of JP 1 and JP 2 de-
pends on the address switch setting given to the engine.
2. Apply power to the Junction Box and engage the turning gear of the engine
until cylinder No. 1 is at TDC.
. Check that the green indicator light is lit on the Intermediate Box. If not lit,
it is likely that the crankshaft pickup needs readjustment. See Mounting
Guide for the particular pickup.
Junction
Box
Single
Engine
Plant
Multi Engine Plant
1st. Main
Engine
2nd. Main or 1st.
Aux. Engine
Subsequent
Engines
Last
Engine
Address Switch 0 0* 1 2,, 4, etc. X
Jumper JP 1 & 2 On Off Off Off On
Jumper JP 3 On On On On On
Table 2-3 Junction Box Address switch and Jumper settings
With multi engine plants, repeat the above pro cedure to set the appropriate ad-
dress and synchronise the PMI System with the TDC of Cylinder No. 1 of each
of the other engines.
1.
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Chapter
Commissioning the System
In this chapter it is explained how to install the PMI software on your PC, start
the entire system and check the engine registration, communication and trig-
gering with the PMI Controller and Crankshaft Pickup. Also, details are given
about how to make reference measurements.
In this Chapter
Installing the PMI Software ................................................................................ 22
Checking Engine Registration ............................................................................ 22
Setting Up Communication ................................................................................ 24
Trigger and TDC Test.......................................................................................... 26
System Reference Measurements ..................................................................... 28
0-Diagram Measurements ......................................................................... 28
E-Load Measurements ............................................................................... 29
Checking & Editing Reference Measurements ................................................. 0
Technical Assistance .......................................................................................... 4
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3.1 Installing the PMI Software
The PMI software is normally supplied on a CD, containing both the PMI appli-
cation program and engine specifc data concerning your diesel engine plant.
To install the PMI program and its data:
Insert the CD in your CD-ROM drive.
Open the Start menu in the bottom left corner of the display and choose
Run.
Type d:\setup.exe. (If your CD-ROM Drive is not letter D, type the appropri-
ate letter instead.)
Select OK.
Follow the instructions on screen.
With WIN NT .5.1, WIN95 or later, the installation software will automatically
install a PMI System icon on the windows desktop for opening the program. In
addition, it will be listed in the programs menu and sub folder contained in the
Start menu.
3.2 Checking Engine Registration
Fig. 3-1 The primary elements of the PMI Systems main window
Click on the PMI System icon on the windows desktop or on the corre-
sponding program listed in the Program menu on your PC.
1.
2.
.
4.
5.
1.
PMI System
Title bar
Menu bar
Toolbar
Status Line
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The main window of the PMI System should now appear as indicated in Fig.
-1 overleaf.
2. Select Open Engine contained in the File menu on the far left of the dis-
play.
The Open Engine dialogue shown in Fig. -2 will now appear which lists
the individual names and types of engine in your plant that are registered
for use with the PMI System.
If the name of the engine to be checked is not listed, then select an engine
type that matches the particular engine. Later the name of the engine can
be edited.
Fig.3-2 The Open Engine dialogue
Fig. 3-3 The Edit Engine Data Torsion dialogue
. Click on the name of the engine or type of engine on which communication
is to be checked and activate the Edit tool button at the top of the dia-
logue. Alternatively, right-click anywhere in the dialogue to open the quick-
access menu, and then select Edit.
NOTE
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4. Select the Torsion tab of the Edit Engine dialogue which is opened (see
Fig. -) and check that the address number indicated near the top right-
hand corner of the dialogue matches the SW1 address switch setting of the
particular engine. See section 2.5 for recommended settings.
If they do not match, change the dialogues address number accordingly.
Only entries which are not dimmed may edited.
5. Set the Trigger System section of the dialogue to correspond with the lo-
cation (i.e. Fore or Aft) of the Crankshaft Pickup on the engine.
If an LE-Pickup is installed at the drive end (normally aft) of the crankshaft,
then the following additional data must be keyed in:
The diameter of the drive shaft. Units: metre.
The distance of the triggering system to the turning wheel. Units: metre.
When another type of pickup is used, both the Diameter ... and
Distance .... should normally be left blank or set to 0.
6. Click the OK button to store the settings chosen and return to the Open
Engine dialogue.
7. For multi engine plants, repeat steps to 6 for the other engines listed in
the Open Engine dialogue and then close the dialogue by clicking on the
Cancel button.
8. Select Exit in the File menu and then switch off the PC and the 24 V sup-
ply to the PMI System.
9. Next, fasten the standard plug of the Converter Box to a free communica-
tion port on the back of the PC and then switch the 24 V supply and the PC
back on again to make the system ready for the remainder of the setup pro-
cedure given below.
3.3 Setting Up Communication
Check that all hardware has been mounted, connected and adjusted as de-
scribed in the previous sections of this and the preceding chapter.
Connect the Pressure Transducer to the PMI Controller Box. See Fig. -4.
Fasten the multipole plug of the PMI Controller to the Junction Box on the
engine to be checked.
Always connect the Transducer to the PMI Controller before connecting the
Controller to the Junction Box. Connecting the Transducer while powering
the Controller can damage the Controller.
4. Start the PMI Program on the PC and check that the name of the engine is
shown in the title bar of the main window.

1.
2.
.
PMI System
CAUTION
NOTE
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If the name of another engine is shown instead, select Open Engine in the
File menu and choose the correct engine in the Open Engine dialogue.
Power
'On'
Start
Ready
Cancel
Error
PMl
Transducer
Green
lndicator
Green
Button
Red
Button
Fig. 3-4 The top panel of the PMI Controller box
Fig. 3-5 The Tools menu Options dialogue
5. Select Options in the Tools menu.
This opens the dialogue shown in Fig. -5, which should be set as follows:
Communication Port: 1, 2, or 4, depending on which port of the
PC is coupled to the Converter Box of the
PMI System.
Calibration Factors: Transducer Value The transducer sensitiv-
ity at 20 - 2 C and 250 bar, as specifed on
the calibration chart supplied with the trans-
ducer.
System Value A fxed value of 0.95 match-
ing the system amplifcation of the Off-line
PMI System.
Measuring Settings: Averaging Period Sets the number of work
cycles over which the measurement is aver-
aged. Should normally be set for averaging
over 10 work cycles.
Single Trig. Normal setting for triggering
with an Angle Encoder.
Double Trig. Normal setting for other pick-
ups.
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Click the OK button at the bottom of the dialogue to save the settings cho-
sen and exit the dialogue.
6. Select Communication - On in the Tools menu.
After a short wait the PMI System will respond by opening the Trigger and
TDC Test dialogue explained in section .4 below.
If a No connection ........ status message is fagged instead, then it will be
necessary to check the communication port setting or the cable connec-
tions to the Junction Box. See section . and 2. respectively.
Similarly, if the status message Missing trigger pulses is obtained and the
engine is running, check the cable connections to the Crankshaft Pickup
and Intermediate or Freq. Divider Box. See section 2.2.
3.4 Trigger and TDC Test
When communication is achieved for the frst time, the PMI System will display
the Trigger and TDC Test dialogue shown in Fig. -6.
Fig. 3-6 The Triger and TDC Test dialogue
The use of the Trigger and TDC Test dialogue is as follows:
No. of pulses detected: This provides an actual count of the number of crank
angle pulses detected per work cycle.
When triggering is stable only one count will be displayed. To store the
count for future trigger tests, click the Save button. You can then proceed
with the reference measurements described in section .5.
If triggering is unstable, then the latest fve counts will be listed. See below
to help determine the cause.
No. of pulses stored for engine: The crank angle pulse count. Zero is indicated
for the frst test.
Pulse deviation (min./max): Gives the minimum and maximum percentage de-
viation of the crank angle pulses relative to their mean repetition time.

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Large deviations indicate irregular rotation or defective operation of the
pickup.
To obtain a graphic view of the trigger pulse deviation, click on the Display
button in the dialogue. See Fig. -7.
Fig. 3-7 The Triger Deviation dialogue
TDC Pulse
Crank Angle Pulses
A
Fig. 3-8 The Timing of the TDC and Crank Angle Pulses
TDC pulse relative to trigger pulse: Indicates relative position of the leading
edge of the TDC pulse with respect to the start and end of the crank pulse
period. For correct synchronisation the leading edge must be positioned
between 15 and 85% of the crank pulse period.
If either of the readings is less than 15 % or greater than 85 %, then the
pickup is not correctly adjusted or is defective.
Repeating the Test:
To repeat the Trigger Test, click on the Repeat button in the dialogue.

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Storing Test Count:
When a stable trigger pulse count is displayed, click on the Save button in the
dialogue. This will store the pulse count for use in subsequent trigger tests.
After storing a count, click on the Close button to return to the main window.
For multi engine plants, repeat section . and .4 to check communication and
triggering with the other engines.
3.5 System Reference Measurements
3.5.1 0-Diagram Measurements
0-Diagram measurements are used to correct pressure measurements so that
they refect the actual TDC of each of the respective cylinders of an engine. In
order to do this, a set of 0-Diagram measurements must be made at the time
of installing the PMI System on an engine.
For main engines, reference measurements are to be made in calm weather
conditions and deep water. No rudder movements or change of ships course
are to be made during measurements.
The procedure for making 0-Diagram measurements is as follows:
Run the engine at 50 to 75% load.
Start the PMI Program on the PC and check that the name of the engine is
shown in the title bar of the main window.
If not, open the appropriate engine by selecting Open Engine in the File
menu and select it in the dialogue which is opened.
. Select Communication On in the Tools menu.
The PMI Program will now check communication. At frst the status line
will fag a red marker which shortly after should change to a green marker
showing that the system is ready.
If the program continues to show a red marker, then it is likely that the PMI
Controller and Transducer have yet to be connected to the engine. See next
step.
4. If not already connected, connect the Pressure Transducer to the PMI Con-
troller and the multipole plug of the PMI Controller to the Junction Box. See
Fig. 2-1 and -4.
Always connect the Pressure Transducer to the PMI Controller before con-
necting the Controller to the Junction Box. Connecting the Transducer while
powering the Controller can damage the Controller.
5. Set the fuel pump index to zero (or lift the fuel pump roller guide, depending
on the type of engine) to shut off the fuel oil to the particular cylinder to be
measured.
1.
2.
CAUTION
NOTE
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6. Mount the Pressure Transducer on the indicator cock of Cylinder No. 1 and
open the indicator cock.
The system is ready for measurements when the green light on the PMI
Controller begins to repeatedly fash. However, make sure that at least 2
minutes have elapsed between changing the fuel pump index and starting
the measurement. This is necessary to obtain stable operation with clean
compression.
7. Press the green Start button on the PMI Controller to start the measure-
ment.
The green light will then be extinguished for a period and then light again
when the measurement has been completed.
8. Immediately close the indicator cock when the measurement has been
completed and return the fuel pump index to its original setting (or lower the
fuel pump roller, depending on the type of engine).
9. Remove the Pressure Transducer from the indicator cock and mount it on
the indicator cock of the next cylinder to be measured.
Always check that the indicator cock is closed before removing the trans-
ducer. Failure to do this can result in release of extremely hot combustion
gasses which can severely injure personnel.
10. Repeat steps 5 to 9 until you have completed measurements on all cylin-
ders.
11. Return to the PC and stop measurements by pressing the Esc. key on the
keyboard or by selecting End Measurement in the Tools menu.
Alternatively, you can stop measurements by unscrewing the multipole plug
of the PMI Controller from the Junction Box. This is useful if you want to
make another set of measurements before returning to the PC. To be able
to do this it is important that you unscrew the plug only when the green
Start button is lit and that you wait at least 10 seconds before reconnect-
ing the plug.
Stopping measurements automatically stores them in the PMI Systems
database.
The 0-Diagram measurement fle must be renamed and specifcally selected
as default as described in section .6.
3.5.2 E-Load Measurements
Immediately after having prepared a set of 0-Diagram measurements another
set of reference measurements must be made using the same procedure and
load conditions as stated in section .5.1, but this time without altering the fuel
pump index of the cylinders.
With these reference measurements, all cylinders are employed to drive the
engine and therefore play an equal role in powering the engine and share ap-
WARNING
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proximately the same load. In this case the measurements are termed E-Load
measurements and are used to automatically compensate for torsional defec-
tions in the crankshaft.
3.6 Checking & Editing Reference Measurements
To ensure that the O-Diagram and E-Load measurements are used for cor-
recting future pressure measurements on your engine, they must be renamed
and selected as default.
To do this proceed as follows:
Select Open Measurement in the File menu and locate the set of 0-Dia-
gram measurements in the dialogue which is opened.
New measurements are listed with the letter m, followed by the date and
time of storage, e.g. m990124_10407. See Fig. -9.
Fig. 3-9 The Open Measurement dialogue as viewed with the List function
Fig. 3-10 The Edit Cylinder Observations dialogue. The curve indicated is typical
of what can be expected for a 0-Diagram observation
1.
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2. Select the measurement and then activate the Observations button in the
toolbar of the dialogue or right-click in the dialogue.
The Observations... command opens the dialogue shown in Fig. -10.
By clicking on the +/- symbol at the start of each cylinder heading you can
expand or contract a heading.
To examine an observation, click on its heading. Its pressure curve is then
displayed on the right-hand side of the dialogue.
. Check that one observation is present for each cylinder and that their pres-
sure curves have the approximate shape and form as indicated in Fig. -10
(or Fig. -11 for E-Load measurements).
If no observations are listed for a cylinder or their curves appear to be very
distorted, then the measurement must be repeated.
If more than one observation is available per cylinder, then delete those
which are not needed by selecting each of them in turn and pressing the
Delete button at the bottom of the Edit Cylinder Observations dialogue.
Be careful when deleting observations as there is no Undo function.
4. When all curves look correct, click the Close button to return to the Open
Measurement dialogue and then open the measurement by clicking the
Open button.
Fig. 3-11 The Edit Cylinder Observations dialogue. The curve indicated is typical
of what can be expected for an E-Load observation
5. Next select Calculated Values in the View menu and check that the mean
indicated pressure pi for each cylinder is negative. See Fig. -12.
Negative values signify that there is no combustion of fuel oil as is required
for O-Diagram measurements. You can proceed with step 6.
If the values are positive, then the most likely reasons are:
NOTE
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The fuel pump index has not been set to zero.
The index has been set to zero, but not enough time has elapsed before
the measurement was started, i.e. some fuel oil is still present in the cylin-
der and has not had time to fully combust.
The index has been set to zero, but leaking fuel valves result in combus-
tion or heating of fuel oil in the cylinder.
In each case the measurement must be repeated after correcting the most
likely cause of the problem.
Fig. 3-12 A Calculated Values scheme for a 0-Diagram reference measure-
ment on a four cylinder engine
Fig. 3-13 The Edit Measurement dialogue
6. Return to the Open Measurement dialogue and then activate the Edit
command in the toolbar of the dialogue.

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This opens the Edit Measurement dialogue shown in Fig. -1.
7. Click in the measurement feld of the Edit Measurement dialogue and
rename the measurement to signify that it is a 0-Diagram reference mea-
surement.
e.g. 0DIAG_70_990124_104
where the frst fve characters indicate the type of fle, the next characters
indicate the engine load, the next seven characters indicate the date and
the last fve characters indicate the time that the measurement was stored.
8. Open the list-boxes immediately below the measurement feld and reset
them so that they appear empty and do not refer to earlier 0-Diagram and
E-Load reference fles.
9. Key in the appropriate value for the scavenge air pressure of the engine in
the p(scav): data feld and press the OK button to close the Edit dia-
logue and save your changes to the reference measurements.
If no scavenge air pressure reading is available, then the program itself will
automatically estimate it. To force estimation the p(scav): data feld must
be set to 0 or 0.00.
10. Inspect the E-Load reference measurements and check and edit them as
outlined in steps 1 to 9.
The check in step 5 concerns 0-Diagram measurements only, and for E-
Load measurements should be ignored.
In this case it is suggested that E-Load measurements be renamed as fol-
lows:
ELOAD_70_990124_1055
Fig. 3-14 The Edit Engine Data General dialogue
NOTE
NOTE
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11. Press OK to close the Edit dialogue and save your changes to the refer-
ence measurements.
12. Select Open Engine in the File menu and activate the Edit function in the
toolbar of the dialogue.
This opens the Edit Engine Data dialogue shown in Fig. -14.
1. Open the 0-Diagram list-box near the bottom right-hand corner of the Edit
Engine Data dialogue and select the name of the 0-Diagram reference
measurement.
14. Open the E-Load list-box and select the name of the E-Load reference
measurement.
15. Press the OK button to exit both the Edit Engine Data and Open Engine
dialogues and store your new 0-Diagram and E-Load as default settings.
3.7 Technical Assistance
If you experience diffculties in installing or using the PMI System, then check
whether you can fnd an answer to the problem by following the instructions
and advice given in the corresponding sections of this guide and in the sepa-
rate Users Guide which is provided.
If you cannot fnd the answer, you are welcome to contact MAN Diesel whose
address and phone number are given on the back cover of this Guide.
When you call by phone, you should have the PMI System documentation at
hand and be prepared to give the following information:
The name of the vessel or plant.
The version and build number of your PMI System software indicated under
About in the Help menu.
The operating system and type of hardware that you are using.
A brief account of what happened and what you were doing when the prob-
lem occurred.
The exact wording of any messages that appeared on your screen.
Details about how you tried to solve the problem.
When you mail us, we ask you to include the above information, plus any rel-
evant computer printouts which might be helpful.

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Index
M
Mounting Guide
Chapter Overview ....................................... 8
Text Conventions ........................................ 8
Mounting PMI Boxes ........................................ 16
O
O-Diagram Measurements .............................. 28
On-line Help ....................................................... 8
P
PD-Pickup .......................................................... 9
PMI System
Basic System .............................................. 9
Cable & Power Checks ............................. 17
Mounting PMI Boxes ........................... 16, 17
On-line Help ................................................ 8
Screened Cables ...................................... 15
System Connections ................................. 14
R
Reference Measurements ................................ 28
S
Screened Cables .............................................. 15
Setting Up Communication.............................. 24
Software Installation ........................................ 22
T
TDC - Pickup Sync. .......................................... 19
Technical Assistance ....................................... 4
Transducer Calibration Factor ......................... 25
Trigger and TDC Test ....................................... 26
A
Angle Encoder .................................................... 9
C
Checks
Cable & Power .......................................... 17
Com. Port ............................................ 25, 26
Communication ......................................... 24
Engine Address ......................................... 19
Engine Registration ................................... 22
Measuring Settings ................................... 25
Reference Measurements ......................... 0
TDC - Pickup Sync.................................... 19
Transducer Calibration .............................. 25
Trigger & TDC Test .................................... 26
Converter Box .................................................. 16
Crankshaft Pickups ............................................ 9
Angle Encoder ............................................. 9
LE-Pickup .................................................... 9
PD-Pickup ................................................... 9
E
Editing Measurements ..................................... 0
E-Load Measurements ..................................... 29
Engine Address Checks ................................... 19
Engine Registration .......................................... 22
F
Freq. Divider Box.............................................. 16
I
Intermediate Box .............................................. 16
J
Junction Box .................................................... 16
L
LE-Pickup ............................................................ 9
MAN Diesel A/S
Teglholmsgade 41
DK-2450 Copenhagen SV
Denmark
Telephone: +45 33 85 11 00
Telefax: +45 33 85 10 30
manbw@dk.manbw.com
www.mandiesel.com
Copyright MAN Diesel A/S. Reg. No. 39 66 13 14
Reproduction permitted provided source is given
Subject to modifcation in the interest of technical progress
3520-0006-00ppr May 2007 Item no. 1142959-6
MAN Diesel - a member of the MAN Group