Bear - Wear MS PDF

Doosan B-WACS
Getting Start
Doosan Engine Co.,Ltd.

69-3, Sinchon-dong, Seongsan-gu, Changwon-si, Gyeongsangnam-do,
SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
E: ebiz.engine@doosan.com
Operators have to read carefully this manual and use it in compliance with usage
procedures and safety regulations before starting B-WACS. Doosan Engine
owes the copyright of this manual. Please don’t use this manual for other
purposes than B-WACS.
DOC. No. B-WACS-G005 February 2014

1
Revision History
<Rev.5>
1. Change a picture in ‘Manual Setting’ menu (p.6 ~ p.7)
<Rev.4>
1. Notice page modified. (p.3)
- It is essential to execute RPM Compensation again after sea trial.
2. Picture of the back side of DMU (Please refer to p.4)

- Change of the mismatched picture of SCU-DMU-COM cable
3. Picture of the front side of DMU (Please refer to p.1)

- Power lamp and one USB port are added to the front side of DMU

2
Notice!!
Before using B-WACS, be sure to comply with ‘Getting Start’
procedure!
If there are some troubles when ‘Getting Start’ procedure is

progressed, refer to the trouble shooting in 3 types of Manual
(Technical / Installation / Software Manual) or contact service
engineer.
Without the completion of RPM Compensation, B-WACS can’t

measure the accurate bearing wear. So ‘RPM Compensation’
should be done according to this ‘Getting Start’ manual and
more detail procedure is described at the ‘RPM Compensation
Procedure’ in Software Manual of B-WACS.
After sea trial, RPM Compensation should be executed

again by chief engineer during a maiden voyage.
Please refer to 1)the section of sensor replacement in Installation Manual
and 2)the section of software setting in Software Manual for the execution
of RPM Compensation after sea trial for more detailed information.

3
1. Turn on the power switch of DMU (Start DMU Software)
< ECR Console Front Panel > < ECR Console Inside >
The front side of DMU The back side of DMU
DMU Power Switch
USB Port
SAU-DMU Cable

4
2. Select B-WACS
Click!!
3. Check whether ‘Engine Status’ is ‘RUN’ and ‘BWM Mode’ is

‘IDLE’

5
4. Manual Setting
The update should be performed when engine is

stopped

6
After manual setting, Update button should be clicked in
order to reflect the result

7
5. RPM Compensation
5-1 Click ‘RPM Compensation’ and Run main engine as

specified RPM
Specified RPM
※ Recommend Engine Speed
■ 1st RPM Compensation: Dead Slow RPM

- 20% ~ 50% of MCR
■ 2nd RPM Compensation: Half RPM
- 50% ~ 80% of MCR
■ 3rd RPM Compensation: Navigation Full RPM
- 80% ~ 100% of MCR
The three speeds for each step should be spaced by

minimum 20 % of MCR.

8
5-2. Click ‘Start’ in Step 1 when main engine is running in
20~50% of MCR (The RPM should be fixed in the range during the Steps.)
5-3. Don’t touch the others menu during RPM compensation!

9
5-4. If RPM compensation is finished, RPM value will be
displayed and completion box will be checked.
5-5. Do ‘Step 2’ and ‘Step 3’ as ‘Step 1’ procedure

10
5-6. Check the completion of ‘RPM Compensation’ from
‘Step 1’ to ‘Step 3’
5-7. Check the result of Compensation on the event list

11
< System Check Sheet >
No. Task Method Result Note
If DMU Power doesn’t

turn on, check power
line form Power Supply to
1 DMU Power Chk. Turn on DMU and check the power OK / NG
DMU refer to the
Installation Manual
(3.3.3)
2 Select B-WACS Chk. Click the B-WACS in Main screen OK / NG Touch screen
When engine is running, confirm If engine stops, Engine

3 Engine Status Chk. that Engine Status is activated OK / NG Status in Monitoring S/W
as “RUN” displays ‘STOP’
Confirm that “Step 1” Completion

OK / NG
is finished
RPM Compensation Confirm that “Step 2” Completion Don’t change the Engine
4 OK / NG
Chk. is finished RPM during each Step

OK / NG
is finished

12
Doosan B-WACS
Technical Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
DOC. No. B-WACS-T005 February 2014

1
Revision History
<Rev.5>
1. Pictures change and additional trouble shooting case (p.28 ~ 35)
<Rev.4>
1. Picture and Drawing of Power Supply (Please refer to p.6, 12, 25)
- Change of the mismatched picture and drawing of power supply.
2. Picture and Drawing of SCU Bracket (Please refer to p. 7, 20)

- Change of the number of holes on SCU Bracket.
3. Picture of DMU (Please refer to p. 10)

- Power button and one USB port are added to the front side of DMU.

2
CONTENT
1. Overview
1.1 Introduction of B-WACS ----------------------------------------------------------------------------- 4
1.2 Introduction of Manual ------------------------------------------------------------------------------- 5
2. B-WACS Configuration
2.1 System Configuration Diagram --------------------------------------------------------------------6
2.2 System Connection Diagram --------------------------------------------------------------------- 13
2.3 System Monitoring Program ---------------------------------------------------------------------- 14
3. B-WACS Installation
3.1 Product supplied ------------------------------------------------------------------------------------- 17
3.2 Mechanical Installation Part ----------------------------------------------------------------------- 18
3.3 Electrical Installation Part -------------------------------------------------------------------------- 19
4. B-WACS Specification
4.1 External Measurement ---------------------------------------------------------------------------- 20
4.2 Specification ------------------------------------------------------------------------------------------- 26
5. Trouble Shooting ------------------------------------------------------------------------------------------ 28
The copyright of this manual belongs to Doosan Engine Co., Ltd. The
manual which is provided together with B-WACS shall not be used for
other purpose without a consent of Doosan Engine Co., Ltd.

3
1. Overview
1.1 Introduction of B-WACS

B-WACS(Bearing Warning and Control System) is specially developed by Doosan
Engine to measure bearing wear in a low speed diesel engine. B-WACS, which is a
BWM(Bearing Wear Monitoring) System, diagnoses integrated wear status of Main
Bearing, Crank Pin Bearing and Crosshead Bearing. The aims of B-WACS are to
prevent the major bearings from severe damage and to get not the time based
open-up which is time consuming and a risk of initiating failure but the condition
based open-up.
< Fig. 1-1 Principle of B-WACS >
B-WACS has three kinds of main components, SCU(Signal Capture Unit),

SAU(Signal Analysis Unit) and DMU(Data Monitoring Unit).
SCU is installed on the low part of the crosshead guide and measures relative
position between each guide-shoe and the proximity sensor at BDC(Bottom Dead
Center) whenever engine operates.
SAU is installed on the inside of main console in ECR(Engine Control Room). The
measured data is analyzed by SAU to determine bearing status such as WARNING,

4
ALARM and SLOW-DOWN. Analyzed data can be stored up to 5 years for
investigating long term status of bearing.
DMU is mounted on the main console in ECR and offers operator user interface so
that operator can check wear condition of bearings and see the final bearing wear
value and wear trend.
1.2 Introduction of Manual

The objective of this manual is to help operator understand whole system and to
indicate the technical specification or inform operators about it. For this reason,
usage procedure and safety regulation shall be fully understood by reading this
manual before installation and operation of B-WACS.
The technical manual of B-WACS explains the entire system configuration and
specification and summarizes how to install and operate B-WACS. The detail
instructions of B-WACS installation and user program shall be explained in each
installation manual and program manual.
B-WACS manual shall be composed as below
A. Technical Manual
▣ B-WACS configuration
▣ B-WACS installation
▣ B-WACS specification
B. Installation Manual
▣ Mechanical Installation Part
▣ Electrical installation Part
▣ Commissioning Part
C. Program Manual
▣ S/W screen layout
▣ Data monitoring
▣ Alarm handling
▣ System diagnosis & configuration
▣ Maintenance

5
2. B-WACS Configuration
2.1 System Configuration Diagram

B-WACS is composed of 3 main units & 2 sub units. Main units in B-WACS are
SCU(Signal Capture Unit), SAU(Signal Analysis Unit) and DMU(Data Monitoring Unit).
Two sub units, UPS and Power Supply, are the stable source of electric power for B-
WACS.
As SCU have two inductive proximity sensors, a temperature sensor and a control
module, it can measure bearing wear value and send the measured date to SAU. It
analyzes the measured data and then sends the analyzed data to DMU which show
operators the result of wear value and wear trend to operators.
Signal and electric power flow among units in B-WACS is as figure below.
< Fig. 2-1 B-WACS Configuration Diagram >

6
The units for B-WACS shall be as below.
▣ SCU (Signal Capture Unit)

▣ SAU (Signal Analysis Unit)
▣ DMU (Data Monitoring Unit)
▣ UPS (Uninterruptable Power Supply)
▣ Power Supply
2.1.1 SCU(Signal Capture Unit)

SCU is composed of two inductive proximity sensors, a temperature sensor, a
control module and a bracket. It is made of single unit and installed on the low part
of crosshead guide inside of frame-box and measures the value of position of
crosshead guide-shoe. SCU is connected to the front and the rear SCU in sequence.
st nd
Exceptionally, SCU of 1 cylinder is not only connected to 2 SCU but also
connected SAU through Junction Box. SCUs which are installed in the engine send
the measured data to SAU and receive electric power from SAU.
< Fig. 2-2 SCU >

7
A. Inductive Proximity sensor
Two inductive proximity sensors mounted at both sections of bracket of SCU
measure the BDC (Bottom Dead Center) position of the bottom of guide-shoe.
The two cables of inductive proximity sensors are connected with control
module. When installing SCUs, installer should adjust the distance between
two inductive proximity sensors and the bottom of guide-shoe to 4mm. Adjust
the distance using 4mm shim plate supplied according to the instruction of
installation manual.
Don’t turn the engine, until finishing installation of SCUs and adjustment the
distance between two inductive proximity sensors and the bottom of guide-
shoe. If the distance between two inductive proximity sensors and the bottom
of guide-shoe is not adjusted, the bottom of guide-shoe could collide with the
proximity sensors!
B. Temperature Sensor
RTD temperature sensor is mounted on the bracket of SCU in order to
improve the accuracy of inductive sensor. RTD temperature sensor is
released with the control module connected to the cable, therefore extra
adjustment and handling for the temperature sensor is not necessary. The
aims of temperature sensor are to measure the inside temperature and
calibrate inductive sensors distance with regard to environmental
temperature.
C. Control module
The control module mounted at the low part of bracket is installed on the
inside of engine and has function to input value measured from the proximity
sensors and a temperature sensor. It automatically calculates the BDC
position of crosshead.
SCU of each cylinder should be connected with a SCU-SCU-MUL cable. In
order to connect SCU to the neighboring SCU, connect connector of control
module to the connector of neighboring control module with SCU-SCU-MUL
Cable. Refer to the installation manual about how to connect SCUs with SCU-
SCU-MUL Cable in detail.
D. Bracket

8
The bracket can assemble inductive proximity sensors, a temperature sensor
and control module as a single unit and make it installed at the low part of
crosshead guide of the inside of engine. In order to install it at engine, two
tap holes are necessary.
2.1.2 SAU(Signal Analysis Unit)

AC 220V main power used in ECR is converted to DC 24V through Power supply.
And then DC 24V is supplied with SAU. SAU supplies DC 24V power to SCUs
installed at the inside of engine through Junction Box. And SAU receives the
measured sensor values from SCUs.
SAU of B-WACS can be used for all kinds of low speed diesel engines from 5
cylinders to 14 cylinders engines without extra terminal box and interface unit.
Irrespective of the number of cylinders, power supply and communication of the
measured data is possible with SCU-SCU-MUL Cable connected. The sensor
values received from SCUs are processed at SAU and are displayed at DMU(Data
Monitoring Unit).
SAU received the measured data from SCUs and then analyze or calculate the
value of bearing wear. In addition, SAU implements RPM compensation and save
the measured long term data and short term date in nonvolatile memory.
< Fig. 2-3 SAU >

9
2.1.3 DMU(Data Monitoring Unit)
The data analyzed at SAU is sent to DMU(Data Monitoring Unit), which is a Touch
Panel PC, with RS485 communication line. Electric power of DMU receives DC
24V from UPS which is connected as SAU does.
As B-WACS exclusive program is installed at DMU, it displays the bearing wear
status and wear trend of each cylinder. DMU is mounted on the main console of
ECR.
< Fig. 2-4 DMU >

10
2.1.4 UPS
In order to keep normal operation of B-WACS during unexpected power shutdown,
UPS is connected to Power Supply of SAU and DMU. UPS shall be installed at the
place where the console of ECR can be easily connected to SAU and DMU power
supply. UPS is installed in the main console of ECR with DIN-Rail(NS 35/75).
< Fig. 2-5 UPS >

11
2.1.5 Power Supply
Power Supply converts AC 220V of ECR into DC24V and supplies UPS with the
converted power. Power Supply is installed in the main console of ECR with DIN-
Rail(NS 35/75).
< Fig. 2-6 Power Supply >

12
2.2 System Connection Diagram
Below diagram shows the system connection of B-WACS. A solid line is supplied
as a standard cables and a dotted line is option cables.
< Fig. 2-7 B-WACS System Connection Diagram >

13
2.3 System Monitoring Program
B-WACS monitoring program shows the wear value and wear trend of the major
bearings after analyzing sensor measurement data received from SCUs. Alarm shall
appear if wear value is out of wear specifications during engine operation.
Program operators are classified into two different levels as below.

■ Ordinary operator level: Have authority only for access to view functions
(Logon is not necessary)
■ Manager level: Has all authorities for system management (Initial P/W: 1830)
(Logon is necessary)
< Fig. 2-8 B-WACS Monitoring Program Layout >
The program is composed of Main Menu, Sub Menu, Screen Window, Tool Menu, and
State Window. Real-time Wear in Monitoring is default screen and by clicking the
selection button in Tool Menu, the operator can see the digital output of wear value in
detail and temperature value of the sensors. According to Main Menu or Sub Menu,
Screen Window is changed such as wear slide graph, wear trend, alarm setting and
rpm compensation etc. The composition of Main Menu and Sub Menu in monitoring
program is as figure below.

14
< Fig. 2-9 Composition of Main Menu and Sub Menu >
2.3.1 Main MENU

The main menu is composed of 4 menus such as monitoring, alarm, system, and
maintenance
A. Monitoring: Display Real-Time Wear, Wear Trend and Sensor Deviation

according to cylinders and output the Report
B. Alarm: Show all Event occurring in B-WACS
C. System: Display System Status and Operation Condition of B-WACS
Components
D. Maintenance: rpm Compensation, Manual Setting as Chief Level (Manager
Level Menu, Logon is necessary)
2.3.2 Sub Menu

Sub Menu is decided according to kind of Main Menu as above picture. Once Main
Menu is selected, Sub Menu is shown at the bottom of Main Menu. In the same
method, Screen Window and tool Menu can be altered according to Sub Menu.
2.3.3 Screen Window

Screen Window shows the Information selected by Sub Menu or Tool Menu.
2.3.4 Tool menu

Tool Menu is optional and additional composition If needs be. Users can operate

15
buttons on Tool Menu to indicate graphs, tables and setting values in Screen
Window.
2.3.5 State Window

State Window shows three status of B-WACS System as below
1) Bearing Status: Display the condition of the three major bearings
- Normal: No detection of wear beyond the warning limits
- Alarm: Detection of wear beyond the alarm limit
- Slowdown: Detection of wear beyond the slowdown limit
2) Engine Status: Display the operating state of engine
- RUN: During the operation of engine at above minimum RPM
- STOP: Engine stop or operation at below minimum RPM
3) BWM Mode: Display engine status
- Compensating: The 3 steps of RPM Compensation are in progress
- Fine Learning: RPM Compensation is being carried out within the full range of
RPM for 500 hrs
- Normal Run : B-WACS is monitoring bearing wear normally.
(after completion of ‘Fine Learning’)
- IDLE : B-WACS is running without RPM Compensation
- ReAdjust : Sensor readjustment algorithm is running for 500 hours
< Fig. 2-10 Configuration of State Window >

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3. B-WACS system Installation
3.1 Products Supplied

Standard products and spare parts shall be supplied by Doosan Engine.
3.1.1 Standard Part
A. SCU (Including Two Inductive Proximity sensors, Temperature sensors,
Control Module and Brackets)
B. SAU
C. DMU (Including B-WACS Monitoring program)
D. Power Supply
E. UPS
F. Cable Gland (Engine Cable Gland)
G. Connection Cable
▣ SCU-SCU-MUL Cable
. Less than 8 Cylinder: (Cyl. Number)EA
. More than 8 Cylinder: (Cyl. Number + 1)EA
▣ SCU-JB-MUL Cable: 1EA
▣ SAU-UPS-POW Cable: 1EA
▣ SAU-DMU-COM Cable: 1EA
▣ DMU-UPS-POW Cable: 1EA
▣ UPS-SUP-POW Cable: 1EA
H. Shim Plate: 1EA
3.1.2 Spare Part

A. SCU: 1EA
B. SCU-SCU-MUL Cable: 1EA
3.1.3 Option Part

A. Connection Cable
▣ JB-SAU-Power Cable: 1EA
▣ JB-SAU-RS485 Cable: 1EA

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3.2 Mechanical Installation Part
Before installing B-WACS, refer to installation manuals. Specially, as SCU

is installed at the inside of engine, make sure that engine is locked and
safety precautions should be taken.
Where to install and how to install mechanical installation part unit shall be
summarized as below
< Table 3.1 B-WACS Unit mechanical installation summary >

Installed Installation
How to Install Remarks
Unit Location
Inside engine SCU can be attaching Adjustment of two

SCU low part of by bolting at low part inductive proximity
crosshead guide of crosshead guide sensors is necessary
Inside ECR
SAU - -
Console
On the main
DMU - -
Console in ECR
Inside ECR Install on DIN-rail

UPS -
Console (DR 35/7.5)
Power Inside ECR Install on DIN-rail

-
Supply Console (DR 35/7.5)

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3.3 Electrical Installation
How to connect the units of electrical installation parts shall be summarized as

below
< Table 3.2 B-WACS Unit electrical installation summary >
Connection
Object Connection method Remarks
Location
Inside Connected by standard

Connect SCU to SCU -
Engine SCU-SCU-MUL cable
Connected by standard Cable gland is

SCU to Junction Box
SCU-JB-MUL cable necessary
External
Engine Connected by standard
SAU to Junction Box JB-SAU-RS485 cable Option item
JB-SAU-POW cable
Connected by standard
SAU to DMU
SAU-DMU-COM cable
SAU to UPS
SAU-UPS-POW cable
-
ECR DMU to UPS
DMU-UPS-POW cable
UPS to Power Supply
UPS-SUP-POW cable
SAU to AMS System Option item
SAU-AMS cable
In the event that additional tap hole are needed during installation of unit of
B-WACS, it shall be approved by engine builder and a ship maker in
advance

19
4. B-WACS Specification
4.1 Drawings
4.1.1 SCU
<Fig. 4-1 Drawings of SCU >

20
4.1.2 SAU
<Fig. 4-2 Drawings of SAU >

21
4.1.3 DMU
VGA Output
N/A
USB 2.0
LAN Port
RS-485 * 2Port
Power Input(24Vdc)
On/Off Switch
<Fig. 4-3 Drawings of DMU >

22
234mm
Panel Cutout 168mm
Panel
<Fig. 4-4 Panel Cutout of DMU >

23
4.1.4 UPS
<Fig. 4-5 Drawings of UPS>

24
4.1.5 Power Supply
<Fig. 4-6 Drawings of Power Supply>

25
4.2 Specification
4.2.1 SCU
4.2.1.1 Proximity Sensor
- Input Voltage : 10V ~ 30V DC
- Current Consumption : 4 mA ~ 20 mA
- Sensing Range : 0 ~ 10 mm
- Housing Material : Chrome-plated brass
- Weight : 55g
4.2.1.2 Temperature Sensor
- Sensor Type : PT100, Class B, 3 wires
- Body Material : Stainless Steel
4.2.1.3 CONTROL UNIT
- Input Voltage : 15 V to 34 V dc
- Current Consumption @24V : 150mA average (200mA max)
- RS232 Data Format : 115,200, N, 8, 1
4.2.2 SAU
- Input Voltage : 15 V to 34 V dc
- Current Consumption @24V : 150mA average (200mA max)
- Internal Memory : 16GBytes
- RS232 Data Format : 115,200, N, 8, 1
4.2.3 Panel PC
- Input Voltage : DC24V
- Touch Screen : 5-wire resistive type
- Processor : Celeron M1.5Ghz
4.2.4 UPS
- Input Voltage : 150V – 294VAC
- Output Voltage : 220VAC
- Power : 1150VA/770Watt
- Interface : USB, Serial Port
4.2.5 Power Supply
- Input Voltage : 100 ~ 240VAC
- Input Fuse : 6.3A
- Input Frequency : 45 ~ 65Hz
- Output Voltage : 24VDC

26
4.2.6 Cable
4.2.6.1 SCU-SCU-MUL/SCU-JB-MUL Cable
- Outer Diameter : 7mm
- Temperature Rating : 95˚C
4.2.7 Environmental
4.2.7.1 SCU
CONTROL UNIT
- Enclosure Material : Aluminum
- Gasket Material : Polyurethane
- Cover Screws Material : Stainless Steel
- IP Rating : IP67
- Vibration 5~25 Hz : +/- 1.6mm
25 ~ 100 Hz : +/- 4g to ABS specification
- Operating Temperature : -20℃ top 70℃
- Storage Temperature : -40℃ top 80℃
- Humidity : 20% to 95% non-condensing
Proximity Sensor
- IP Rating : IP67
- Vibration : > 4g
- Operating Temperature : 25℃ ~ 70℃
4.2.7.2 SAU
- Enclosure Material : Aluminum
- Gasket Material : Polyurethane
- Cover Screws Material : Stainless Steel
- IP Rating : IP67
- Vibration 5~25 Hz : +/- 1.6mm
25~100Hz : +/- 4g to ABS specification
- Operating Temperature : -20℃ top 70℃

27
5. Trouble Shooting
■ Sensor data is out of spec. (3.0 ~ 4.0mm)
- Check point: Distance between inductive proximity sensor and guide-shoe
- Action step
. Action 1: Confirm the measured sensor data in ‘Sensor Data’ of ‘Maintenance’
by clicking ‘Sensor Trig’ and ‘Call Sensor Value’
. Action 2: Readjust the distance between Inductive Proximity Sensors and
Guide-shoe with 4mm shim plate
< Fig. 5-1 Check the sensor data in monitoring program >
< Fig. 5-2 Adjust distance between sensor and guide-shoe with 4mm shim plate >

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■ Some sensor values are shown ‘0’
1) All sensor values after a certain sensor are shown ‘0’
- Action step: SCU to SCU cable for the first sensor whose value is ‘0’ needs to be
replaced.
(eg. If sensor #1 and #2 show normal value, but the others show ‘0’, the SCU to
SCU cable for the sensor #3 needs to be replaced.)
2) A certain sensor value is ‘0’

- Action step: the SCU should be replaced.
■ All sensor values are shown ‘0’

- Check point
1) Power for SAU and all SCUs
2) Cable connection for DMU – SAU
3) Cable connection for SAU – SCU
■ Damage Alarm occurs

- Check point
1) Is the condition for RPM Compensation satisfied?
st
. 1 step : Dead slow (20 ~ 50 % of MCR)
nd
.2 step: Half (50 ~ 80 % of MCR)
rd
. 3 step: Navigation Full (80 ~ 100 % of MCR)
and the three speeds for each step should be spaced by minimum 20% of MCR.
2) If damage alarm still occurs even though the RPM Compensation was correctly
performed
. The data in the following path, ‘C:\WACS\RawData’, and manual setting
information such as Min/Max RPM, firing order and so on need to be sent to
Doosan Engine.
3) If slow wear alarm occurs after damage alarm occurred

. Please, check bearings through overhaul.

29
■ System Status in DMU Software displays ‘System is not connected’
< Fig. 5-3 System status of B-WACS >
<Fig. 5-3 System Connection error>

- Check point: SAU Power, SAU-DMU cable
- Action step
. Action 1: Open the cover of SAU. Confirm whether the SW1 turn on or not,
turn on the SW1.
. Action 2: Check the cable connector between SAU and DMU.
. Action 3: Change the communication line between SAU and DMU
. Action 4: Replace SAU with new one.
. Action 5: If the connection problem is still not solved after following the above
actions, call Doosan service engineer.

30
< Fig. 5-4 Switch position of SAU >

31
■ Engine Status in DMU Software display ‘STOP’
< Fig. 5-5 Engine status of B-WACS >

- Check point 1: SAU Power, SCU Power, B-WACS Parameter
- Action Step
. Action 1: Open the cover of SAU. Confirm whether the SW1 turn on or not,
turn on the SW1.
. Action 2: If the SW2 turned off, turn it on.
. Action 3: Input the firing order correctly and click the ‘Update’ button
- Check point 2: If the sensor values change when you click ‘Call Sensor Value’
button, check the following:
1) Is Min. RPM correctly set? (20% of MCR)
2) All SCUs are installed in the right position. (If some SCUs are
installed in the wrong position, the engine status is displayed
‘STOP’ even though the engine is running.)
(eg. SCU #3 is installed in the position for SCU #4 and SCU #4 is
installed to the position for SCU #3.)
- Check point 3: If the sensor values change only when the ‘Call Sensor Value’
button is clicked after ‘Sensor Trigger’ button is clicked, there is
a possibility that the inductive sensor of SCU #1 is broken. SCU
#1 should be replaced.

32
< Fig. 5-6 Check the firing order and click ‘Update’ button >

33
■ Temperature sensing data error
- Check point: SCU Power, SCU-SCU-MUL cable
- Action Step
. Action 1: Check the cable connection between Junction Box and SAU as
Drawings
. Action 2: Open the cover of SAU and confirm whether the SW2 turn on or not,
turn on the SW2
. Action 3: Check the connector and SCU-SCU-MUL cable which connect
between SCU and SCU. Especially, confirm whether the wire is
broken or not.
. Action 4: Check the voltage of Junction Box which is connected with SCU.
If the voltage value is less than 25V, raise the voltage of UPS up to
near by 28V ~ 30V (Recommended voltage: 28V).
. Action 5: Replace a malfunctioned SCU with new spare SCU.
< Fig. 5-7 Normal status of temperature sensor >

34
< Fig. 5-8 Error status of temperature sensor >
- Copyright -
The copyright of this manual belongs to Doosan Engine Co.,Ltd. The B-WACS system which is
provided together with this manual shall not be used for other purpose without a consent of

35
Doosan B-WACS
Installation Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
This manual has to be read carefully and used in compliance with usage
procedures and safety regulations before installing all units of B-WACS. Doosan
Engine owes the copyright of this manual. Please don’t use B-WACS and the
manual for other purposes.
DOC. No. B-WACS-I005 February 2014

1
Revision History
<Rev.5>
1. Change of a picture in ‘Manual Setting’ menu. (p.52)
<Rev.4>
1. Picture and Drawing of Power Supply (Please refer to p. 6, 11, 16, 17, 24, 33)
- Change of the mismatched picture and drawing of power supply.
2. Picture and Drawing of SCU Bracket (Please refer to p. 5, 8, 21, 22)

- Change of the number of holes on SCU Bracket.
3. Picture of DMU (Please refer to p. 6)

- Power button and one USB port are added to the front side of DMU.
4. Picture and Drawing of SCU-DMU-COM Cable (Please refer to p. 15, 28)
5. Drawing of SCU quantity per cylinder (Please refer to p. 18)

- Change of the mismatched drawing.

2
CONTENT
1. Overview
1.1 Introduction ------------------------------------------------------------------------------------------------- 4
1.2 Supplied Products ------------------------------------------------------------------------------------- --- 5
1.3 Precaution in Installation -------------------------------------------------------------------------------- 9
2. Mechanical Parts
2.1 Overview -----------------------------------------------------------------------------------------------------10
2.2 Entire Mechanical Block Diagram ------------------------------------------------------------------ 11
2.3 Installation of Mechanical Parts ----------------------------------------------------------------------------
12
2.3.1 SCU (Signal Capture Unit) Installation -------------------------------------------------------12
2.3.2 SAU (Signal Analysis Unit) Installation -------------------------------------------------------14
2.3.3 DMU (Data Monitoring Unit) Installation ---------------------------------------------------- 15
2.3.4 UPS Installation ---------------------------------------------------------------------------------- 16
2.3.5 Power Supply Installation ---------------------------------------------------------------------- 17
2.4 Mechanical Drawings -------------------------------------------------------------------------------- 18
3. Electrical Parts
3.1 Overview -------------------------------------------------------------------------------------------------------
32
3.2 Entire Electrical Block Diagram -------------------------------------------------------------------- 33
3.3 Installation of Electrical Parts -------------------------------------------------------------------------34
3.3.1 Engine Inside -------------------------------------------------------------------------------------- 34
3.3.2 Engine Outside ----------------------------------------------------------------------------------- 37
3.3.3 Engine Control Room -----------------------------------------------------------------------------40
3.4 Electrical Drawings ----------------------------------------------------------------------------------- 43
4. Commissioning
4.1 Overview ------------------------------------------------------------------------------------------------- 44
4.2 Commissioning Procedure ---------------------------------------------------------------------------------
45
4.3 RPM Compensation ------------------------------------------------------------------------------------ 48
4.4 Sensor Readjustment --------------------------------------------------------------------------------------
51
4.5 Manual Setting --------------------------------------------------------------------------------------------52

3
1. Overview
1.1 Introduction
This document contains important information as well as warning and safety instructions
regarding properly installing mechanical and electrical parts and commissioning of B-WACS.
Note that this manual is read thoroughly and then B-WACS should be set up in compliance with
installation procedures.
This manual is largely composed of 4 parts as Figure 1-1 below. Mechanical installation part
explains how to install the components of B-WACS. Electrical installation part provides the
information about connecting the cable and power line of each unit of B-WACS. The last chapter,
Commissioning Part describes B-WACS software parameter settings, RPM Compensation
procedures, and Check List for commissioning procedure. Refer to each chapter for detailed
information.
Content
1. Overview
2. Mechanical Installation Part
3. Electrical Installation Part
4. Commissioning Part
< Fig. 1-1 Main contents of Installation manual>
The WARNING symbol ( ) means that operators have to be careful for safely setting up B-
WACS. Before installing B-WACS, Installation & Software Manual should be carefully read and
then, installation work has to be done with reference to these manuals. Please note that Doosan
Engine is not responsible for accidents or problems happening when the safety instructions
don’t be followed.

4
1.2 Supplied Products
1.2.1 Standard Products

The standard products as below will be supplied when purchasing B-WACS, check the kind and
quantity of products.
Part No. Fig. Quantities
Refer to the
SCU explanation
in the low
part of figure
- Less than 8 cylinders: (Cyl.Number+1) EA

- More than 8 cylinders: (Cyl.Number+2) EA
SAU 1EA

5
DMU 1EA
※ DMU Software has been installed at DMU
Power
1EA
Supply
UPS 1EA

6
Cable
2EA
Gland
- Engine Cable Gland: 2EA
Refer to the
Connecting explanation
Cable - SCU-SCU-MUL Cable in the low
. Less than 8 Cylinder: (Cyl. Number)EA part of figure
. More than 8 Cylinder: (Cyl. Number + 1)EA
- SCU-JB-MUL Cable: 1EA
- SAU-UPS-POW Cable: 1EA
- SAU-DMU-COM Cable: 1EA
- DMU-UPS-POW Cable: 1EA
- UPS-SUP-POW Cable: 1EA
- POWER SUPPLY Cable: 1EA
Shim
1EA
plate
※ Thickness: 4mm

7
1.2.2 Spare Parts
SCU 1EA
Refer to the
Cable in the low
part of figure
- SCU-SCU-MUL Cable : 1EA

8
1.2.3 Option Parts
Refer to the
Cable in the low
part of Fig.
- JB-SAU-POWER Cable: 1EA

- JB-SAU-RS485 Cable: 1EA
1.3 Precaution in Installation
B-WACS should be installed by qualified engineers according to manuals and drawings. In case
of drilling holes or other processing works during installing B-WACS, previous permission of
Doosan Engine is needed.
The relevant actions for safety such as wearing protective safety equipment have to be taken
before setting up B-WACS. Ensure that there are not any garbage and metal chips inside
engine after SCU installation and poor ventilation while at work. Engine must be stopped and
locked during SCU installation.

9
2. Mechanical Parts
2.1 Overview
Mechanical Parts explains how to install units of B-WACS which consists of SCU(Signal
Capture Unit), SAU(Signal Analysis Unit), DMU(Data Monitoring Unit), UPS, and Power Supply.
Other components except SCU are installed outside engine or at ECR(Engine Control Room),
but SCU is set up inside engine.
Protective safety equipment has to be worn and safety precautions are followed before installing
SCU. Don’t leave any other materials such as garbage and metal chips which are produced
during installing of B-WACS inside engine, and remove all dirty things which left inside of engine
after installing SCU. All units including SCU have to be installed properly according to manuals
and drawings, refer to Electrical Parts for connection of power supply and installation of
communication lines.
There are 4 parts such as Overview, Block Diagram, Installation, and Drawings as Figure 2-1
below in this chapter.
2. Mechanical Parts
2.3.1 SCU Installation

2.1 Overview
2.3.2 SAU Installation

2.2 Entire Mechanical Block Diagram
2.3.3 DMU Installation

2.3 Installation of Mechanical Parts
2.3.4 UPS Installation

2.4 Mechanical Drawings
2.3.5 Power Supply Installation
< Fig. 2-1 Main sections of Mechanical Parts >

10
2.2 Entire Mechanical Block Diagram
The components of B-WACS such as SCU, SAU, DMU, Power supply and UPS are installed at
inside engine and ECR as Figure 2-2 below. In other words, SCU is only set up inside engine
and other units are installed at ECR. SCU is placed between two adjacent cylinders at the lower
part of guide shoe rail. If the number of cylinders is more than 8, SCU should be installed which
is one plus the total number of cylinders. DMU is fixed on ECR Console panel in order for
operators to easily monitor bearing wear values and trends. SAU, UPS, and Power Supply are
also installed inside of ECR Console.
< Fig. 2-2 Mechanical block diagram of B-WACS>

11
2.3 Installation of Mechanical Parts
2.3.1 SCU (Signal Capture Unit) Installation
SCU consists of two proximity sensors, a temperature sensor, a control box receiving signals
measured from sensors, and the bracket which is fixed needs to be attached. B-WACS is
provided to customer as a unit which is assembled. The shape of bracket is a little different
according to the type of engine but functions of SCU are the same.
Before installing SCU, make sure that engine should be ‘locked’. The installation
should be carried out by qualified engineer.
1) Check the holes for mounting SCU

Refer to the drawings and confirm the holes where SCU is installed because the location of
hole is different according to the engine type. There are two holes (M10, Tab hole) drilled in
the vertical direction at the bottom of Crosshead Guide for fixing the bracket of SCU and
another additional one or two cable clamp holes in the horizontal direction for fixing SCU-
SCU-MUL Cable as below Figure 2-3.
< Fig. 2-3 SCU mounting holes and cable clamps >
After completing the installation of SCU, remove all metal chips and other materials
which may cause critical damages like scratches on engine driving parts. Don’t drop
any other materials on engine bedplate or crankcase and leave any tools after
installing SCU.

12
2) Install SCU
When installing SCU, loosen proximity fixing bolts a little for moving two proximity sensors in
order to adjust the distance between proximity sensors and guide shoe with a shim plate.
The bracket should be tightly fixed to crosshead guide with a spanner as Figure 2-4 below
and a locking washer has to be used in order to prevent the loosening of bolts from engine
vibration.
< Fig. 2-4 Fixation of a bracket to crosshead guide >
After fixing the SCU on the crosshead guide, fix the SCU-SCU-MUL Cable with cable clamps.
More detailed instructions on the cable connection are introduced in Electrical Parts chapter.
3) Adjust the distance between a proximity sensor and Guide shoe with a shim plate.
Regulate the distance from a proximity sensor to Guide shoe at BDC with a 4mm shim plate.
How to adjust the gap is following as below.
① Turn engine carefully until Guide shoe comes to BDC.

② Insert 4mm shim plate and adjust the gap which is about same thickness of a 4 mm
shim plate by moving proximity sensors.
③ Fix proximity sensors to crosshead Guide shoe with proximity sensor fixing bolts.
④ Remove a 4 mm shim plate.

13
< Fig. 2-5 Adjustment of the gap with a 4 mm shim plate >
2.3.2 SAU (Signal Analysis Unit) Installation
SAU is a unit which analyzes the value measured by sensors. It is installed on the main console
in ECR. Remove upper cover of SAU and then fix the SAU on ECR Console with 4 bolts (M6
size) as Figure 2-6 below. It is recommended that SAU is installed at the place where SAU is
easily connected with Power supply and DMU.
M6 Bolt Fixing
M6 Bolt Fixing
< Fig. 2-6 SAU Installation in main console of ECR >

14
2.3.3 DMU (Data Monitoring Unit) Installation
DMU is a Panel PC with a touch screen and is supplied including DMU Software. DMU provides
the interface between B-WACS and users and shows the results calculated in SAU on the
screen of it. Install DMU on ECR Console panel where users easily operate DMU and at the
same time its location is near SAU, UPS and Power Supply.
DMU Front DMU Rear
< ECR Console Front Panel > < ECR Console Inside >
< Fig. 2-7 DMU Installation >

15
2.3.4 UPS Installation
UPS is a device which makes B-WACS work properly for a certain period of time when power
turns off suddenly, which is located Inside of ECR Console. UPS will operate with about 30
minutes while the power supply of B-WACS shut down. After installation of UPS, confirm the
input & output voltage of UPS with a multi-meter. The range of input voltage is 24~30VDC and
that of output voltage is 24~30VDC. (Recommended voltage: 28VDC)
UPS
< Fig. 2-8 UPS installation >

16
2.3.5 Power Supply Installation
Power Supply converts AC220V input voltage to DC24V output voltage used for operating SAU
and DMU. Install Power supply on the DIN-Rail inside ECR console. After installation of Power
supply, confirm the input & output voltage of power supply with a multi-meter. The range of Input
voltage is 200~240VAC and that of output voltage is 24~30VDC. (Recommended output
voltage: 28VDC)
In case an ambient temperature is higher and its load is full, keep installation
clearances such as 40mm on top, 20mm on the bottom, and 5mm on the left and
right side. And if there is any heat source near power supply, 15mm clearance is
recommended.
Power
supply
< Fig. 2-9 Power supply installation drawing>

17
2.4 Mechanical Drawings
2.4.1 Quantity of SCU per cylinder

18
2.4.2 Outline Drawing of SAU(Signal Analyze Unit) - I

19
2.4.3 Outline Drawing of SAU(Signal Analyze Unit) - II

20
2.4.4 Outline Drawing of SCU (Signal Capture Unit)

21
2.4.5 Outline Drawing of SCU Bracket

22
2.4.6 Outline drawing for DMU(Data Monitoring Unit)

23
2.4.7 Outline drawing for Power Supply

24
2.4.8 Outline drawing for UPS

25
2.4.9 Outline drawing for SCU-SCU-MUL Cable

26
2.4.10 Outline drawing for SCU-JB-MUL Cable

27
2.4.11 Outline drawing for SAU-DMU-COM Cable

28
2.4.12 Outline drawing for UPS-SAU-POW Cable

29
2.4.13 Outline drawing for UPS-DMU-POW Cable

30
2.4.14 Outline drawing for POWER SUPPLY Cable

31
3. Electrical Parts
3.1 Overview
Electrical Parts provides the information about connecting SCU, SAU, DMU, Power Supply, and
UPS with Communication and Power Cable completely. It is largely composed of Engine Inside
Connection, Engine Outside Connection and Engine Control Room (ECR) connection.
Engine inside connection explains how to connect the cables of all SCUs, and Engine outside
connection shows connections of SCU, Junction Box, and SAU. The last part, Engine control
room connection, explains how to connect the cables of SAU, DMU, Power Supply and UPS in
the engine control room.
In connecting to outside engine, Junction Box to SAU Power Cable and Junction Box to SAU
RS485 cable are option items not basic items to be supplied. Connecting cable for SAU and
Junction Box are option item.
There are 4 parts such as Overview, Block Diagram, Installation, and Drawings as Figure 3-1
below in this chapter
3 Mechanical Parts
3.1 Overview
3.2 Entire Mechanical Installation Diagram
3.3 Installation of Electrical Parts

3.3.1 Engine Inside Connection
3.4 Mechanical Installation Drawings
3.3.2 Engine Outside Connection
3.3.3 Engine Control Room Connection
< Fig. 3-1 Main sections of electrical parts >

32
3.2 Entire Electrical Block Diagram
After installating of B-WACS, connect communication & power cables between components of
B-WACS according to the wiring diagram as Figure 3-2 below. All SCUs are connected with
SCU-SCU-MUL Cables which have communication and power lines together. The other
st
components of B-WACS except SCU are installed in ECR. 1 SCU is connected to SAU through
Junction Box. The cable which connects SCU to Junction Box is supplied as standard items, but
the RS485 cable and 24VDC Power cable between SAU and Junction Box are not supplied.
AMS (Alarm Monitoring System) cable is also not supplied.
Ensure that the electrical power supply is isolated and the UPS is switched off before
wiring connection works and maintenance are regularly carried out.
< Fig. 3-2 Entire electrical block diagram >

33
3.3 Electrical Connection Diagram
3.3.1 Engine Inside

The details of inside engine connection of Electrical Parts are as below
3.3.1 Inside Engine Connection
A. SCU-SCU-MULCable Connection
Connection between SCUs
B. How to Fix SCU-SCU-MUL Cable
1) How to connect SCU-SCU-MUL Cables

SAU provides the 24VDC power to SCUs installed at each cylinder through Junction
st
Box. As Figure 3-3 below, SCUs should be connected to the next SCU in sequence. 1
SCU should be connected to Junction Box through Cable Gland.
< Fig. 3-3 SCU connection diagram >

34
< Fig. 3-4 SCU-SCU-MUL Cable connection >
2) How to clamp SCU-SCU-MUL Cables

After mounting the SCU bracket on the crosshead guide, fasten SCU-SCU-MUL cable
with cable clamp. In order to prevent loosening from engine vibration, it is needed to
use a locking wire on cable clamp as Figure 3-5 below. Fix SCU-SCU-MUL Cable by
using clamps at the intervals of less than 100cm in order to prevent cable from
dropping as Figure 3-6 below. While installing SCU-SCU-MUL Cable, pay special
attention not to touch crank throw of crankshaft while engine operates.
< Fig. 3-5 Clamping SCU-SCU-MUL Cable >

35
< Fig. 3-6 SCU- SCU-MUL Cable installation between cylinders with cable clamps >
When connecting SCU-SCU-MUL cables between cylinders, clamp the SCU-

SCU-MUL cables with cable clamps within 1 meter and use locking washers.

36
3.3.2 Engine Outside
st
In the Engine Outside parts, 1 SCU is connected to SAU through Junction Box as Figure 3-
7 below. Refer to the wiring diagram for B-WACS for wiring connections in Junction Box.
< Fig. 3-7 A Cable from SCU is connected to ECR through Junction Box>
The detailed information about Engine Outside Connection is as follows
3.3.2 Engine Outside Connection
1) Connecting SCU to Junction Box
① How to Install Cable Gland
② How to connect SCU to Junction Box
2) Connecting Junction Box to SAU
① How to connect Junction Box to SAU
② How to fix Junction Box to SAU

37
1) Connecting SCU to Junction Box
① How to install Cable Gland
In order to connect SCU with Junction Box, a hole for cable gland hole is needed.
Cable gland is provided as standard products. Cable gland should be installed on
st
bedplate wall of engine foreside. Through cable gland, 1 SCU-SCU-MUL cable in
cylinder 1 is connected with SCU-JB-MUL cable.
< Fig. 3-8 Installing cable gland on bedplate wall >
② How to connect SCU to Junction Box

SCU is connected to Junction Box with SCU-JB-MULL Cable through cable gland
fixing on cable trays. But if there is no cable tray on the engine plate, use L or U
bracket as Figure 3-8 above in order to fix the cable. The details of connecting SCU-
JB-MUL Cable are as below.
< Fig. 3-9 Terminal Block connection of SCU to Junction Box >

38
2) Connecting Junction Box to SAU
① How to connect Junction Box to SAU
In order to connect cable from Junction Box to SAU, use JB-SAU-Power cable(2.0㎟
x 2) and JB-SAU-RS485 cable(0.75㎟ x 2 twist pair). When connecting Junction Box,
use the end of cable with pin type terminal. The method to connect Junction Box with
SAU is as Figure 3-9 below. Note that JB-SAU-POWER cable and JB-SAU-RS485
cable are option items and not provided with B-WACS.
< Fig. 3-10 Terminal connection diagram of Junction Box and SAU>

39
② How to Fix JB-SAU-POWER Cable
Tie JB-SAU-POWER cable to the tray tightly with cable ties as Figure 3-11 below.
< Fig. 3-11 Fixing JB-SAU-POWER cable with cable ties on cable tray >
3.3.3 Engine Control Room

Engine Control Room Part shows how to connect SAU, DMU, Power Supply and UPS in the
engine control room.
The connections of Engine Control Room Cable are as below.
1) SAU and DMU connection
2) SAU and UPS connection
3.3.3 Engine Control Room Connection 3) SAU and AMS connection
4) DMU and UPS connection
5) Power Supply connection

40
< Fig. 3-12 SAU Electrical Installation >
1) SAU and DMU connection

Connect tightly C1 port of SAU and COM1 port of DMU with SAU-DMU-COM cable in
order to connect SAU and DMU(Panel PC). Cable wirings are should be done by wiring
diagram.
2) SAU and UPS connection

UPS is a backup power supply for SAU and DMU in case of unexpected situations
such as a power failure. C3 port of SAU is connected to UPS with SAU-UPS-POW
Cable.
3) SAU and AMS connection

The cable for connecting SAU to AMS is not supplied with B-WACS, and signal output
terminals such as system fail, alarm, and slowdown should be connected with 0.75㎟ x
6 Cable. The cable is tied with pin type terminal through cable gland.

41
4) DMU and UPS connection
DMU should be normally operated in case of the sudden shut down of power supply for
a while. Power ports of DMU are connected to UPS with DMU-UPS-POW cable.
5) Power Supply connection

As the power source of DMU and SAU are 24VDC, Power Supply provides DMU and
SAU with 24VDC through UPS. At the time, UPS-SUP-POW cable is used in order to
connect Power Supply to UPS. Refer to Figure 3-13 below for detailed information.
< Fig. 3-13 SAU wiring to UPS, Power Supply and DMU >

42
3.4 Electrical Drawings

43
4. Commissioning
4.1 Overview
This chapter describes how to do RPM Compensation based on the engine speed after
installing B-WACS and confirmation of system status. In addition, the sensor readjustment
procedure shall be described for sensor replacement and checking.
4. Commissioning
4.1 Overview
4.2 System Checking 4.2.1 Preparation
4.3 Sensor Readjustment 4.2.2 Visual Inspection
4.2.3 Power Supply Checking

4.4 RPM Compensation
4.2.4 System Checking

44
4.2 Commissioning Procedure
4.2.1 Preparation
1) B-WACS Units
- SCU, SAU, DMU, Power Supply, and UPS Installation
2) B-WACS Cables
- SCU-SCU-MUL Cable, SCU-JB-MUL Cable, SAU-DMU-COM Cable, SAU-UPS-POW
Cable, DMU-UPS-POW Cable, UPS-SUP-POW Cable, POWER SUPPLY Cable
4.2.2 Visual Inspection
< Table 4.1 Visual Inspection Sheet >
Inspection Item Execution of Inspection
- Cover should be closed after installing

SCU, SAU
- No defect and damage on appearance is allowed
- No defect and damage shall be allowed
- Cable label shall be attached

All Cables
*SCU-JB-MUL Cable and JB-SAU-POWER cable shall be
connected with pressure connection terminal
- Confirm if connector in low part of SCU is tightly fixed

SCU-SCU-MUL Cable
- Fix cable on the bedplate wall with clamp
- Connect to the outside engine with cable gland
- Fix cables on the outside wall with tie using L(U) bracket
SCU-JB-MUL Cable
- Confirm if the end of cable is finished with pin type terminal
- Confirm if it is connected to the designated JB terminal
JB-SAU RS485 Cable - Confirm if communication cable 0.75㎟ * 2 is used
JB-SAU POWER Cable - Confirm if power supply cable 2.0㎟ * 2 is used
*Supplied by Ship Maker - Confirm if the end of cable is finished with pin type terminal
- Confirm if SAU J5(HMI) Port and DMU(Panel PC) COM1 Port are
SAU-DMU-COM Cable connected
- Tightly fix cable with cable tie and cable duct
- Connect to system fail, alarm, slowdown signal output terminal

SAU-AMS Cable
of SAU with communication cable 0.75㎟ * 6
* Supplied by Ship Maker
- Confirm if the end of cable is finished with pin type terminal

45
4.2.3 Power Supply Checking
1) Preparation
① Tool: Multi-meter tester
② All units (SCU, SAU, DMU, UPS, Power Supply) turn off
2) Power supply test procedure
The power of B-WACS units should be turned on in order:
Power Supply  UPS  SAU  DMU  SCU
In case output voltage is more than 250V or less than 200V, stop the power supply
test and contact the service engineer.
< Table 4.2 Power Supply Inspection Sheet >
Main Power Input Measured Main Power should be in OK / Checked by

1
Check the range 200 ~ 240 VAC NG Multi-meter
Power Supply Measured Power Supply Output OK / Checked by

2
Output Check should be in the range 28 ~ 30 VDC NG Multi-meter
UPS Input Measured UPS Input should be in the OK / Checked by

3
Check range 28 ~ 30 VDC NG Multi-meter
UPS Output Measured UPS Output should be in the OK / Checked by

4
Check range 28 ~ 30 VDC NG Multi-meter
DMU Power Measured DMU Power Input should be OK / Checked by

5
Input Check in the range 28 ~ 30 VDC NG Multi-meter
Switch on the SW1 in SAU and check

SAU Booting OK / Visual
6 LED status. LED should be flicked
Test NG inspection
up/down
SCU Input Measured SCU Power Input should be OK / Checked by

7
Power Check in the range 26 ~ 30 VDC NG Multi-meter

46
4.2.4 Function checking
Turn on the DMU power, and then select Diagnosis menu in DMU software. Record the
input value on B-WACS Initial Test Sheet after inputting the data of engine information &
Alarm limit line.
Operate Diagnosis menu by executing B-WACS monitoring system. After confirming if all
sensors in SAU, SCU, and inside SCU are active on screen, record the result on B-
WACS Initial Test Sheet.
< Table 4-3 Function Check Sheet >
1 Select B-WACS Chk. Click the B-WACS in Main screen OK / NG
2 Select O-WACS Chk. Click the O-WACS in Main screen OK / NG
Engine Status Chk. Confirm that Engine Status is activated

3 OK / NG Depend on engine status
In B-WACS as “Running”

OK / NG
is finished
RPM Compensation Confirm that “Step 2” Completion Reference to Software

4 OK / NG
Chk. is finished Manual

OK / NG
is finished

47
4.3 RPM Compensation
4.3.1 Execution Procedure

1) System Installation and Check
Refer to Mechanical Installation Part and Electrical Installation Part for system
installation, and execute according to the system checking items of Manual 4.2.4.
2) Engine Driving and B-WACS Power Application
For rpm Compensation, engine shall turn 1,000 times in stable speed (RPM) of 3 types
without stopping.
Accordingly, recommend that it shall be done during engine trial operation at factory or
on sea. In the event it is installed on ship in operation first, certain speed should be kept
during service intentionally. The speed range of 3 types shall be as below
<Table 4.4 rpm Compensation speed range >
Speed Section Speed Range Reference
Step 1 20-50% of MCR speed Dead Slow
Step 2 50-80% MCR speed Half
Step 3 80-100% of MCR speed Navigation Full
The 3 speeds for each step of RPM compensation should be spaced by

minimum 20% of MCR.

48
3) Manual Calibration
< Fig. 4-1 RPM Compensation Screen of B-WACS Monitoring Program>
Manual calibration shall be executed by obtaining 1,000 data 1 times in each section.
User starts manual calibration by clicking start button on below menu at the relevant
speed. When clicking “start button” for step1 in rpm Compensation of monitoring
program, the compensation starts.

49
The completion time of step 1 shall be automatically calculated by the system, and
completion check box on the right shall be checked after step 1 is finished as below
picture.
<Fig. 4-2 Completion of rpm Compensation ‘Step1’ >
If RPM compensation is finished, RPM value will be displayed. Do ‘Step 2’ and ‘Step 3’
as ‘Step 1’ procedure. If the engine speed is not kept due to unexpected problems while
executing each step, it is highly recommended that ‘Factory Reset’ & ‘Update’ in Manual
Setting in Monitoring Program.
Manual calibration shall be completed by executing step 1, 2 and 3 in the same method.
Precise calibration shall be automatically executed after manual calibration is finished.
4) Automatic Calibration
After manual calibration is completed, the calibration is automatically done by B-WACS.
The result shall be shown on the log file of system.

50
4.4 Sensor Replacement
If SCU is exchanged by new one for trouble shooting or it is reinstalled for bearing overhaul
Please use ‘System Diagnosis' and 'rpm Compensation' menu of B-WACS Monitoring Program
below in two case
- Case 1: Completion of ‘rpm Compensation’ and ‘Fine Learning’

(BWM Mode is ‘Normal Run’.)
Replace a SCU, select the check box of the replaced sensor and click the ‘Replace’ button.
Sensor Replace function will be carried out by B-WACS monitoring program
- Case 2: Incompletion of ‘rpm Compensation’ and ‘Fine Learning’

(BWM Mode is NOT ‘Normal Run’.)
After exchange a new SCU or reinstall a SCU, carry out ‘Factory Reset’ in the first place
and ‘Update’ in ‘Manual Setting’ of Monitoring program and then Do ‘rpm Compensation’
* Fine Learning: 500 running hrs after finish all of rpm compensation Step1,2 and 3
< Fig. 4-3 Sensor Replacement Screen >

51
4.5 Manual Setting
1) To log-in ‘Manual Setting’, it is necessary to get administrator privileges

(Initial Password:6670).
Administrator can set ‘B-WACS Main Parameter’, ‘Firing Order’, ‘Relay Test’ and can
see the sensor raw data. But It is highly recommended to contact Doosan Engine
service engineer in case of changing main parameter.
2) Refer to the B-WACS Program Manual for more detail information.
< Fig. 4-4 Manual Setting Screen >
- Copyright -

52
Doosan B-WACS
DMU Software Manual for Bearing Wear Monitoring System

SEOUL 641-370 KOREA
T: +82-55-260-6260
F: +82-55-260-6783
This manual has to be read carefully and used in compliance with usage procedures
and safety regulations before installing all units of B-WACS. Doosan Engine owes
the copyright of this manual. Please don’t use B-WACS and the manual for other
purposes.
DOC. No. B-WACS-S006 February 2014

1
Revision History
<Rev.6>
1. Change of some pictures and description in report menu (p. 11 ~ p.13)
2. Additional explanation of alarm description and P-parameters (p.15 ~ p.18)
3. Addition of “Save as a default” button in configuration menu (p.23)
4. Addition of the communication testing function (p.28 ~ p.30)
5. Addition of software & firmware version information (p.31)
6. Addition of ID set function for spare SCU (p.32 ~ p.36)
<Rev.5>
1. Display Design renewal (every figure)
2. Some menu tree change (Please refer to p. 7)

- The location of ‘sensor replacement’ function is changed to ‘System > Diagnosis’
menu.
3. Status Window information change (Please refer to p. 6)

- Indicator of ‘Connection Status of system’ changed

2
CONTENT
1. Introduction
1.1 DMU Software Overview ------------------------------------------------------------------------------- 4
1.2 DMU Software Manual Introduction ----------------------------------------------------------------------
4
2. Screen Layout
2.1 DMU Software Screen Composition ---------------------------------------------------------------------
5
2.2 Status Window -------------------------------------------------------------------------------------------------
6
2.3 Menu Introduction ------------------------------------------------------------------------------------------7
2.4 Toolbar & Screen Window ----------------------------------------------------------------------------------
7
3. Software Composition
3.1 Monitoring -----------------------------------------------------------------------------------------------------
8
3.1.1 Real-Time Wear ---------------------------------------------------------------------------------------
8
3.1.2 Wear Trend ---------------------------------------------------------------------------------------------
10
3.1.3 Report ---------------------------------------------------------------------------------------------------
11
3.2 Alarm ----------------------------------------------------------------------------------------------------------14
3.2.1 Alarm List ----------------------------------------------------------------------------------------- 14
3.2.2 Event List ----------------------------------------------------------------------------------------- 15
3.3 System -------------------------------------------------------------------------------------------------------19
3.3.1 Diagnosis ---------------------------------------------------------------------------------------3.3.2
19
3.3.2 Configuration ------------------------------------------------------------------------------------ 21
3.4 Maintenance ----------------------------------------------------------------------------------------------------
24
3.4.1 RPM Compensation ---------------------------------------------------------------------------------
24
3.4.2 Manual Setting -------------------------------------------------------------------------------------26
4. Software Setting
4.1 Commissioning Check Sheet ------------------------------------------------------------------------------
37
4.2 RPM Compensation Procedure --------------------------------------------------------------------------
38
4.3 Sensor Replacement Procedure ----------------------------------------------------------------------44

3
1. Introduction
1.1 DMU Software Overview
DMU Software is a B-WACS monitoring software, which shows measured bearing wear data
such as wear values and sensor deviation values of all cylinders in real time. It has already
been set up at DMU(Data Monitoring Unit) by the manufacturer, so this software doesn’t have to
be installed in DMU. DMU, a component of B-WACS, provides a touch screen for handling DMU
Software. When DMU is turned on, this software automatically starts without additional settings.
Before starting DMU Software, confirm the communication line between DMU and
SAU(Signal Analysis Unit). Alarm Limit, Min/Max RPM, and Firing Order are fixed at
the installation of B-WACS. After completion of RPM Compensation, DMU Software
can correctly measure the bearing wear.
1.2 DMU Software Manual Introduction
This manual is supplied together with B-WACS and is largely composed of 4 chapters. The first
chapter, Introduction sector briefly introduces total composition of the manual. In chapter 2, this
gives a screen layout and details of all screens. There are functions and components of every
menu in chapter 3. The last chapter, Software Setting describes commissioning procedures and
its operation procedures after installing B-WACS and DMU Software.
CONTENT
1. Introduction
2. Screen Layout
4. Software Setting
< Fig 1-1 Main contents of DMU Software manual >
Please contact Doosan Engine if there is any trouble or problems with the software
installed at DMU or RPM Compensation procedures of B-WACS.

4
2. Screen Layout
2.1 DMU Software Screen Composition
User-friendly interface of DMU Software is made in order to monitor the combined physical wear
of the crosshead bearings, crankpin bearings and main bearings. Status Window at the top of all
menus as Figure 2-1 below shows three status of B-WACS System such as a condition of the
three major bearings, an operating status of engine, and a connection status of system. Main
Menus including Sub Menus are located at the right of the screens in order for users to easily
select Menus. Screen Window and Tool Bar are changed according to the menu which is
selected by users. To quit DMU Software or change other programs, click ‘Exit’ Button
( ).
When the program starts, Real-Time Wear screen of Monitoring menu is a default screen
displaying wear values of bearings with bar graphs and related tool bars like RPM,
temperatures & wear values of all sensors.
Status Window Exit Button
Main Menus
Sub Menus
Screen Window
Tool Bar
Current Time
< Fig. 2-1 DMU Software Layout >

5
2.2 Status Window
Status Window shows a wear status of bearings, an operating status of engine, and an
operating mode of BWM’s Speed Compensation when DMU Software is in operation as Figure
2-2 below. It is always displayed at the top of the screen regardless of menus.
Wear status of bearings Connection status of system (Normal Run, Compensating,

(Normal, Alarm, Slowndown) Fine Learning, IDLE, ReAdjust)
Operating status of engine Ending of DMU

(RUN, STOP) Software
< Fig. 2-2 Composition of Status Window >
1) Bearing Status
If some problems occur in bearings, Bearing Status shows the status of bearings with
Alarm and Slowdown as its color and text. Especially if Alarm and Slowdown happen,
additional pop-up window will come on at the same time as below Figure 2-3. Refer to
Table 1 - Alarm IDs & Descriptions on the page 14 about alarm information.
- Normal ( ): Normal status of not detecting any wear beyond the warning limits
- Alarm ( ): Alarm status above Alarm limits
- Slowdown ( ): Slowdown status above Slowdown limits
2) Engine status
- RUN ( ): it shows an engine is running
- STOP ( ): it shows an engine stops
3) BWM Mode
- Compensating( ) : The 3 steps of RPM Compensation are in progress.
- Fine Learning ( ) : RPM Compensation is carried out within the full
range of RPM for 500 hours.
- Normal Run ( ) : B-WACS is monitoring bearing wear normally.
- IDLE ( ): B-WACS is running without RPM compensation
- ReAdjust ( ): Sensor readjustment algorithm is running for 500 hours.

6
2.3 Menu Introduction
The menus consist of 4 main menus and 10 sub menus at DMU Software as below Figure 2-3.
Monitoring menu give the information of bearing wear status. And Alarm menu shows all events
including alarms and event. Communications of B-WACS can be checked and engine
information can be entered at the System menu. There are several functions such as RPM
compensation, Sensor replacement, and Manual setting at the Maintenance menu.
< Fig. 2-3 Menu composition of B-WACS Monitoring Program >
2.4 Tool Bar & Screen Window
Tool Bar and Screen Window are automatically changed by the menu. Its parameters can be
entered with a touch pad.

7
3.1 Monitoring
3.1.1 Real-Time Wear

As Real-Time Wear is a default screen of DMU Software, the users intuitively knows wear status
of bearings with bar graphs. There is a unit of wear[mm] at the left side of the screen and
cylinder numbers at the top side of the screen. The ‘F’ character means fore side and ‘A’ does
after side of an engine. The number of cylinders on this screen is automatically changed if
entering cylinder numbers on the ‘Total Cyl. No.’ of Manual Setting screen. Either Wear Value
mode or Wear Deviation mode in Real-Time Wear can be selected.
Show the number of cylinders and the

position of sensors (Fore/After)
Display wear values with bar graphs
Wear Mode (Value/ Deviation)
Output of rpm Output of Selection

wear value & temp. of Sensor
< Fig. 3-1 Real-Time Wear >
Please complete RPM compensation in order to check the exact results because
we are not sure that wear data are perfect before RPM compensation.

8
In order to get correct wear values of all cylinders, users have to input exact parameters and
complete RPM compensation. Wear values are shown as bar graphs whose colors are green,
yellow, and red. And the colors of bar graphs are the same colors of Bearing Status of Status
Window.
- Normal ( ): It shows a normal status with a green bar

- Alarm ( ): It shows an alarm status with a yellow bar
- Slowdown( ): It shows a slowdown status with a red bar
1) Wear Value
Wear Value mode displays filtered wear values from sensors of all cylinders in real time.
Filtered values mean that a simple filter was applied as indicated below in order to minimize
the influence of noise and established as a moving average which updates every time a new
sensor value.
New Filtered = old Filtered * (1 - 0.05) + new Value * 0.05
2) Wear Deviation
Wear Deviation mode shows Deviation Value of each sensor. Sensor Deviation is defined as
the difference between the individual sensor and the average of the others sensor signal.
For example, the deviation of sensor no. 5 engine with a 5 cylinder engine is as below.
D5 = w5 - (w1 + w2 + w3 + w4 + w6 + w7 + w8+ w9 +w10)/9

9
3.1.2 Wear Trend
Wear Trend shows wear trends for a certain period of time. In this mode, the time scale and the
scale of wear value [mm], temperature [°C], and RPM on the y-axis can be changed by clicking
buttons as follow. The graph can be enabled or disabled by selecting lines of sensors.
 : Choose sensors to display
 : Go to the latest point and readjust x,y-axis
 : toggle display mode for deviation and wear trend
 / : Move one grid block before/ after on the x-axis
 / : Move the page before/ after on the x-axis
 / : Set range on the left y-axis
 : Increase/ Decrease the range on the x axis
Wear Value Axis
RPM & Temp. Axis
X/Y Axis Range Adjustment
< Fig. 3-2 Wear Trend >

10
3.1.3 Report
< Fig. 3-3 Report >
The information such as engine info, log, filtered value trend and current status can be saved as
a file by selecting XML Button or Text Button or can be printed out by selecting Print Button.
1) Select the start and end date.
- Click the date on the calendar screen and then click the set button
2) [Print] Click the print button. A pop-up window for selecting printer driver appears. After
selecting the printer driver, click OK button. For printing the report, the printer driver
should be installed already. (Fig. 3-4)
3) [Save the report as a file] After step 1(selecting the start and end date), click ‘XML’
button or ‘Text’ button. You can see the pop-up window of choosing the drive to save
the report file. (Fig. 3-5) “C” drive is the default drive and selected already. Choose the
drive and click ‘Select’ button. If a USB drive is connected to DMU, you can also
choose it to save the report file. (If two USB drives are connected to DMU, three target
drives are activated. So, please make sure where you are saving the file.) After click
the Select button, you can see the pop-up window of showing the save completion and
the save file path. (Fig. 3-6)

11
Pop-up window
For printing
Print Button
< Fig. 3-4 Print >
Drive Select
Button
< Fig. 3-5 Save the report as a txt file >

12
< Fig. 3-6 Pop-up window for notifying the save completion of the report file >
The report file(in the format of txt or XML) is saved in the following path(as the above Fig. 3-6):
“C:\WACS\Report”

13
3.2 Alarm
All events including alarms are recorded automatically to show the event list of the B-WACS
system on this screen. Items of the list can be scrolled by sliding the buttons ( ). The
detailed information is offered by the maker according to the selected item. The columns of the
list table are as below.
1) No. : Alarm generation order

2) ID : Identification number of Alarm
3) Date : Alarm generation date and time
4) Description :Brief explanation of the alarm
5) P1, P2, P3 : Internal parameters of DMU program
(Refer to Table 2. P-parameter description)
If you select a certain item of the list, you can see the more detailed information of the alarm or
event at the bottom area of the screen
3.2.1 Alarm List

Alarm list contains all alarms such as Warning, Alarm, and Slowdown occurring at B-WACS.
The item of the list can be scrolled by sliding Button ( )..
< Fig. 3-7 Alarm List >

14
3.2.2 Event List
Event list window displays all events including Alarm and Slowdown in numerical order as
below Figure 3-8. Refer to Table 1 on the next page for ID and related descriptions.
< Fig. 3-8 Event List >
<Table 1 Alarm IDs & Descriptions >

ID Description
4 Alarm Free[Filtered], Filtered Sensor Alarm is free.
5 Alarm Release[Filtered], Filtered Sensor Alarm is released.
6 Slowdown Free[Filtered], Filtered Sensor Slowdown is free.
7 Slowdown Release[Filtered], Filtered Sensor Slowdown is released.
8 Alarm Free[Sensor Dev.], Sensor Deviation Alarm is free.
9 Alarm Release[Sensor Dev.], Sensor Deviation Alarm is released.
10 Slowdown Free[Sensor Dev.], Sensor Deviation Slowdown is free.
11 Slowdown Release[Sensor Dev.], Sensor Deviation Slowdown is released.
12 Alarm Free[Cylinder Dev.], Cylinder Deviation Alarm is free.
13 Alarm Release[Cylinder Dev.], Cylinder Deviation Alarm is released.
28 Temperature Alarm is released. Temperature value of SCU sensor is out of normal range.
29 Temperature Alarm is free. Temperature value of SCU sensor is in normal range.
30 Sensor fault is free.
31 Sensor fault is released.

15
32 Alarm Free[S. Sensor Dmg.], Single Sensor Damage Alarm is free.
33 Alarm Release[S. Sensor. Dmg], Single Sensor Damage Alarm is released.
36 Alarm Free[Cyl. Sum Dmg.], Cyl. Sum Damage Alarm is free.
37 Alarm Release[Cyl. Sum Dmg.], Cyl. Sum Damage Alarm is released.
40 Alarm Free[TwinCyl. Dmg.], Twin Cylinder Damage Alarm is free.
41 Alarm Release[TwinCyl. Dmg.], Twin Cylinder Damage Alarm is released.
64 Pre-Warning is free.
65 Pre-Warning is released.
129 Engine is Started.
130 Engine is stopped.
131 Rough Compensation Start.
132 Rough Compensation Finish.
133 Fine Compensation Start.
134 Fine Compensation Finish.
135 Curve large change. The sensor reference value is largely changed.
144 Sensor Replacement Start.
145 Sensor Replacement Finish.
146 Change[Flt. Al. Lv.],
Filtered Sensor Alarm Level is changed[LEARNING] from previous value to new value.
147 Change[Sensor Dev. Al. Lv.],
Sensor Deviation Alarm Level is changed[LEARNING] from previous value to new value.
148 Change[Cyl. Dev. Lv.],
Cylinder Deviation Alarm Level is changed[LEARNING] from previous value to new value.
149 Change[Flt. S_down Lv.],
Filtered Sensor Slowdown Level is changed[LEARNING] from previous value to new value.
150 Change[Sensor Dev. S_down Lv.],
Sensor Deviation Slowdown Level is changed[LEARNING] from previous value to new value.
151 Change[Flt Al. Lv.],
Filtered Sensor Alarm Level is changed[NORMAL] from previous value to new value.
152 Change[Sensor Dev. Al. Lv.],
Sensor Deviation Alarm Level is changed[NORMAL] from previous value to new value.
153 Change[Cyl. Dev. Lv.],
Cylinder Deviation Alarm Level is changed[NORMAL] from previous value to new value.
154 Change[Flt. Sensor S_down Lv.],
Filtered Sensor Slowdown Level is changed[NORMAL] from previous value to new value.
155 Change[Sensor Dev. S_down Lv.],
Sensor Deviation Slowdown Level is changed[NORMAL] from previous value to new value.

16
156 Change[Pre-warning Lv.],
Pre-warning Level is changed[DAMAGE] from previous value to new value.
157 Change[Al. Basic Single Lv.],
Alarm Basic Single Level is changed[DAMAGE] from previous value to new value.
158 Change[Al. Basic Cyl. Sum Lv.],
Alarm Basic Cyl. Sum Level is changed[DAMAGE] from previous value to new value.
159 Change[Al. Basic MB. Lv.],
Alarm Basic TwinCyl. Rapid Level is changed[DAMAGE] from previous value to new value.
160 Change[K Single Lv.], K Single Level is changed[DAMAGE] from previous value to new value.
161 Change[K Cyl. Sum Lv.], K Cyl. Sum Level is changed[DAMAGE] from previous value to new value.
162 Change[K MB. Lv.], K MB Level is changed[DAMAGE] from previous value to new value.
163 Change[Beta Lv.], Beta Level is changed[DAMAGE] from previous value to new value.
<Table 2. P-parameter description>

ID P Description
P1 Sensor number(sensor position). Sensor #(2N-1) and #(2N) indicate the sensors installed fore and
04~11, after side in Cylinder #(N), respectively.(N=1,2,3...)
32~33, P2 Current value
P3 Alarm/Slowdown level
P1 Sensor number(sensor position)
28~29 P2 Current temperature
P3 Temperature limit
30~31 P2 Current value(BDC value)
P3 The last RMS(Root Mean Square) value of fault sensor
P1 Cylinder number
12~13,
P2 Current value
36~37,
P3 Alarm level
P1 Main Bearing number
40~41, P2 Current value
P3 Alarm level
64~65 P2 Current 6 hours average value
P3 Warning level
129~130 P1 1: Engine start / 0: Engine stop

17
P2 Meaningless
P3 Meaningless
P1 RPM (average value)
131~132 P2 Rough Compensation step
P3 Meaningless
P1 RPM when Fine Compensation started/finished.
133~134 P2 Meaningless
P3 Meaningless
135 P2 Updated reference value
P3 Previous reference value
P1 RPM when sensor replacement started/finished.
144~145 P2 Sensor number(sensor position)
P3 Meaningless
P1 Meaningless
146~163 P2 Changed value (new value)
P3 Previous value
P1 RPM which compensation curve is changed at.
164 P2 Meaningless
P3 Meaningless
*Rapid Wear Algorithm

: detect situations where the BDC-level quickly changes from a stable level even within the
alarm limits in the slow wear algorithms
<Alarm type>
1) Single Sensor Damage Alarm
: occurs when BDC variation of one sensor increase suddenly.
2) Cylinder Sum Damage Alarm

: occurs when the sum of the single sensor damage values of two sensors in one
cylinder increase suddenly.
3) Twin Cylinder Damage Alarm

: occurs when the sum of the single sensor damage values of two sensors beside one
main bearing increase suddenly. (This alarm value is not calculated at the two end
main bearings where only one sensor is installed.)

18
3.3 System
3.3.1 Diagnosis
At this screen, operation status of SCU is shown as below Figure 3-9. The condition of the unit
is classified into two categories such as Normal and Error.
 Normal: Normal status without errors

 Error: Non-operational status that the unit is not working or needs to be repaired or replaced
Explanatory note (Not Buttons)
< Fig. 3-9 Normal Status of SCUs>
If an error occurs in SCU, it is marked with red-box as below Figure 3-10.

19
Error Status
of Sensor
< Fig. 3-10 Error Status of SCU >
When any SCU of B-WACS is not working properly, ‘Replace’ function should be implemented
at Diagnosis of System menu after the sensor is replaced in SCU. The administrator privilege is
necessary to perform the function. Please comply with the ‘Sensor Replacement’ procedures on
installation manual of B-WACS. Once SCU is replaced, select the changed SCU(just like blue
dotted box area in Fig. 3-10) and push Replace Button as Figure 3-10. After completing Sensor
Replacement, a pop-up window will be shown in order to inform the users about the completion
of Sensor Replacement and users should check whether the event list contains this
replacement or not. Please note that RPM Compensation doesn’t need to be done again if
Sensor Replacement had been done after completion of ‘Fine Learning’. (After ‘Fine Learning’
completion, BWM Mode is changed to ‘Normal Run’.)
The procedures of SCU replacement have to be followed by service engineers of

Doosan Engine according to the installation manual of B-WACS. Please note that
users are completely responsible for accidents happening while users replace SCU at
their disposal.

20
3.3.2 Configuration
Configuration screen is consisted of two columns such as Engine information and Alarm limits.
The values of these items can be changed with the virtual keyboard which is automatically
shown by clicking the input data. Engine information and alarm limits should be set by
manufacturer in Normal Running, refer to the Table 3 below. Don’t change the Alarm Limit
without permission of authority. All alarm limits and parameters comply with the guidelines
established by MAN.
< Table 3 Alarm & Slowdown Limits during normal running>
Description Wear Value
Alarm limit, filtered sensor value ±0.5 mm

Alarm limit, sensor deviation ±0.4 mm
Alarm limit. cylinder deviation ±0.3 mm
Slow down limit, filtered sensor value ±0.7 mm
Slow down limit, sensor deviation ±0.5 mm
During learning, the values obtained during learning conditions that are to by-pass the noise
filtering routine and then below limits are to be applied; Table 4
<Table 4 Alarm & Slowdown Limits during Learning>
Description Wear Value
Alarm limit, filtered sensor value ±0.8 mm

Alarm limit, sensor deviation ±0.5 mm
Alarm limit. cylinder deviation ±0.4 mm
Slow down limit, filtered sensor value ±0.9 mm
Slow down limit, sensor deviation ±0.7 mm
The limit to get a pre-warning is Table 5 below.
<Table 5 Pre-warning level>
Pre-warning limit, compensated sensor value (6Hr. avg.) ±0.25 mm
Damage Monitoring Alarm Setting is Table 6 below.

21
<Table 6 Damage Monitoring Alarm Setting>
AlarmBasic, Single 250μm
AlarmBasic, Cyl 180μm

AlarmBasic, TwinCyl. 250μm
k,Single 8
k,Cyl 8
k,MB 8
 300
How to change these data using a virtual keyboard is following as below. First, select and click
the item which needs to be entered, and a virtual keyboard can be shown as below Figure 3-11.
Finally, enter new data through this keyboard and click OK Button or Enter Button.
< Fig. 3-11 Configuration & Screen Keyboard >

22
1) Apply to B-WACS button:
After inputting the new value of each item on this screen, ‘Apply to B-WACS’ button
should be clicked to save the value.
2) Save As Default Button:
If you select this button, the current parameters you input on this screen are saved as
default parameters. When you come back to the configuration menu after doing ‘factory
reset’ in the maintenance menu, you can see that all parameters are automatically filled
up with those you saved previously.
3) Refresh button:
If you input wrong value and not click ‘Apply to B-WACS’ button yet, push ‘Refresh’
button to restore all values to the previous saved values.
Any change of alarm limits by anyone but administrators or authorized representatives

from Doosan Engine is strictly prohibited because of direct influence on the alarm
standards of B-WACS.
< Fig. 3-12 Save the current parameters as default in configuration menu >

23
3.4 Maintenance
3.4.1 RPM Compensation
Three steps of RPM compensation have to be completed in order for B-WACS to work properly.
RPM compensation can be carried out only while an engine is operating. If an engine stops, it is
not possible for operators to compensate B-WACS because buttons for RPM compensation
become disabled. Each step of RPM compensation has to be performed at the RPM in the
range depicted in Figure 3-13 below and last for more than 10 minutes (For example, 25%,
60% and 90% of MCR can be chosen for the step1, step 2 and step 3, respectively.)
Progress Bar of RPM Compensation
< Fig. 3-13 RPM Compensation >
Check that main parameters such as the number of cylinders, min/max RPM,
firing order and cylinder number of first engine block are correctly entered
before starting RPM compensation.
If an engine has been overhauled and a sensor has been reinstalled after RPM
compensation, the three steps of RPM compensation should be performed
again.

24
When the RPM compensation is completed, all progress-bars of each step are filled up and
then RPM values are written and checkboxes of Completion are checked. (Figure 3-14)
< Fig. 3-14 RPM Compensation Completion >
During the compensation, the progress bars display what it has achieved so far. Three steps of
RPM compensation have to be carried out in correct order (Step 1  Step 2  Step3). Start the
first step of RPM compensation at Dead Slow RPM (in 20%~50% of MCR), the second one at
Half RPM (in 50%~80% of MCR), and the last one at Navigation Full RPM (in 80%~100% of
MCR).
The three speeds for each step should be spaced by minimum 20 % of MCR.

25
3.4.2 Manual Setting
< Fig. 3-15 Manual Setting >

* Initial password : 6670
Administrator privilege is necessary to log in to “Manual Setting” menu. All items of Manual
Setting are fixed at the installation of B-WACS, and so only administrators can change these
parameters if necessary..
1) Main Parameter
- Total Cylinder No.: the total number of cylinders applying B-WACS
- Max. RPM: Set the value by 110% of MCR
- Min. RPM: Set the value by 20% of MCR
- Cyl. No. of first block : The number of cylinder before chain-case
2) Firing Order
When an operator selects the Total Cylinder No. in B-WACS Main Parameters, the
number of firing order is automatically activated. The number at the left side of firing
order such as 1, 2, 3, … ,14 means a cylinder number on the basis of the engine’s fore
side.

26
Please refer to Engine Specification or contact Doosan Engine for changing of main
parameters and firing orders.
3) Relay Test
Check the relay signal between B-WACS and AMS (Alarm Monitoring System) by using
On/Off Button. When ‘On’ button is clicked, the Lamps turn on and relays are activated.
< Fig. 3-16 Relay Test >
4) Sensor Data
- Sensor Data window shows the Sensor Value and Temperature value of SCU which is
installed at each cylinder.
5) Other items
- Sensor Trigger: Upload sensor values measured from SCU to SAU
- Call Sensor Value: Upload sensor values measured from SAU to DMU

27
6) Comm. Test
Check the communication status among SCUs and SAU. This function can be used only
when engine is stopped. If you click the Comm. Test button when engine is running, an
error message appears. (Fig. 3-17)
<Fig. 3-17 Comm. Test>
If you click the Comm. Test button when engine is stopped, the test will be started. The
test result is shown on the sensor data window. If a SCU has communication problem, its
status is described as FAIL and the connection status needs be checked. If the
connection is OK, the SCU needs to be repaired or replaced.

28
<Fig. 3-18 Comm. Test is in progress>
<Fig. 3-19 Comm. Test is over with no error>

29
<Fig. 3-20 Comm. Test is over with error>

30
7) Tool bar
- Update:
Update main parameters and firing orders which were entered by users. When the
Update button is clicked, a pop-up window for notice message appears.
- Factory Reset:
Reset all current items. (Caution! Every information such as alarm & even list, system
configuration information, engine information, main parameters and firing order is lost.)
- Change Time Zone: Change the DMU software time zone based on UTC
< Fig 3-21 Factory Reset >
* Please, DO CLICK the ‘Update’ button after ‘Factory Reset’ in order to

reflect the result!
- version information:
* WACS & Master: software version number of two programs in DMU
* SAU & SCU: firmware version of each unit

31
8) Set Spare SCU ID
If you install a spare SCU, ID for the SCU should be set before engine running and
bearing wear monitoring.
<Fig. 3-22 Set Spare SCU ID>

[How to set ‘Spare SCU ID’]
(1) Click the Set Spare SCU ID button after install a spare SCU (Fig. 3-22), ID setting
screen appears. The ID for the spare SCU is automatically set by 30 as a default. (Fig.
3-23)
(2) Click the white box of the installed spare SCU to set the ID and then, a pop-up
window for confirmation appears. (Fig. 3-24) Choose ‘Yes’.
(3) You can see a pop-up window with description that reboot SCU power. Turn off and
on SCU power by using the SCU power switch in SAU and then, click ‘OK’
button of the pop-up window. (Fig. 3-25)
(4) The ID is automatically set according to the position of the SCU. (Fig. 3-26) The color
of the SCU is also changed ‘blue’ from ‘white’.

32
Click here to set the spare SCU ID
<Fig. 3-23 Spare SCU ID setting start>
<Fig. 3-24 Pop-up window for ID setting confirmation>

33
<Fig. 3-25 SCU power reboot for ID setting>
<Fig. 3-26 ID setting completion>

34
If you click the ‘Set spare SCU ID’ button (Fig. 3-23) before you replace the
malfunctioned SCU with a spare SCU, or remove the malfunctioned SCU but not install a
spare SCU yet, you can see the Fig. 3-27. The removed SCU is indicated as white box,
but the default ID cannot be given. (The white box is blank.)
<Fig. 3-27 ID setting screen when nothing is installed

in the position of the removed SCU>

35
[Error message]
You can see the following error messages when click ‘Yes’ button in Fig. 3-24
(confirmation pop-up window)
(1) The SCU ID cannot be set by the software because the ID is set by Dip switch.
- Cause: Dip switch in SCU has higher priority for setting ID than B-WACS software.
- Solution: Set the ID to ‘0’ by using Dip switch and then, restart the ‘spare SCU ID
set’ process. (Please refer to ‘Table 7. Dip switch binary code in SCU’ at
the end of this manual for ID setting. All switch should be set to OFF.)
(2) This SCU firmware version does not support ID change through BWACS software.
Please set the SCU ID by Dip switch.
- Cause: SCU firmware does not support the ID setting function of BWACS software.
- Solution: Set the ID manually by using Dip switch. You don’t have to restart the
‘spare SCU ID set’ process. (Please refer to Table 7. Dip switch binary code
in SCU’ at the end of this manual.)
Only one SCU should be replaced and its ID should be set at a time. If two or
more SCU need to be replaced, the other SCU should be supplied with pre-set
ID except one spare SCU.

36
4. Software Setting
4.1. Commissioning Check Sheet
< Table 7 Commissioning Check Sheet>
Item No. Task Method Result Note
Main Power Measured Main Power should be in Checked by

1 OK / NG
Input Chk. the range 200 ~ 240 VAC Multi-meter
Power Supply Measured Power Supply Output should Checked by
2 OK / NG
Output Chk. be in the range 24 ~ 30 VDC Multi-meter
Measured UPS Input should be in the range Checked by
3 UPS Input Chk. OK / NG
24 ~ 30 VDC Multi-meter
Measured UPS Output should be in the Checked by
Power 4 UPS Output Chk. OK / NG
range 24 ~ 30 VDC Multi-meter
DMU Power Measured DMU Power Input should be Checked by
5 OK / NG
Input Chk. in the range 24 ~ 30 VDC Multi-meter
SAU Booting Switch on the SW1 in SAU and check LED
6 OK / NG
Test status. LED should be flicked up/down
SCU Input Measured SCU Power Input should be Checked by
7 OK / NG
Power Chk. in the range 24 ~ 30 VDC Multi-meter
Upload Min RPM Data and check the value Checked by
8 Min RPM Chk OK / NG
(ex. Min RPM : 25) Engine Spec.
Upload Min RPM Data and check the value Checked by
9 Max RPM Chk. OK / NG
Internal (ex. Min RPM : 100) Engine Spec.
Para-
Upload Firing Order Data and check Checked by
meters 10 Firing Order Chk. OK / NG
the value (ex. Firing Order: 1-5-3-4-2-6) Engine Spec.
Upload Alarm Limit Data and check Checked by

11 Alarm Limit Chk. OK / NG
the value Engine Spec.
Click 1st “Start” button and wait about 10
1st RPM
12 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
is correctly Uploaded, the task is OK
Click 2nd “Start” button and wait about 10
2nd RPM
RPM 13 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
Comp- is correctly Uploaded, the task is OK
ensation Click 3rd “Start” button and wait about 10
3rd RPM
14 minutes. If RPM value and Finish Check box OK / NG
Comp. Test
is correctly Uploaded, the task is OK
After finishing RPM Compensation, Wear
15 Wear Value Chk. OK / NG
value should be in the range +/- 0.25mm
System Fail Click “System Fail Alarm” set button.
16 OK / NG
Alarm Chk. If the AMS alarm is set, the task is OK
Refer to
Bearing Wear Click “Alarm” set button.
Alarm 17 OK / NG Installation
Alarm Chk. If the AMS alarm is set, the task is OK
Manual
Bearing Wear Click “Slowdown” set button.
18 OK / NG
Slowdown Chk. If the AMS alarm is set, the task is OK

37
4.2. RPM Compensation Procedure
* After sea trial, this procedure must be executed by chief engineer during a maiden
voyage.
DMU Software should be used after RPM Compensation in compliance with procedures of RPM
Compensation as Figure 4-1 below, if DMU Software needs to be used after installing B-WACS.
Start
① Factory Reset Initialize input data
② Input Main Parameter Refer to Engine Spec.
③ Input Firing Order Refer to Engine Spec.
Manual Setting ④ Update Parameters Save and check input parameters
Engine Turning Rotate the engine over two times
⑤ Check Sensor Data Check transfer of Sensor Data
⑥ Restart System Restart of S/W program
⑦ Input Engine Info Refer to Engine Spec.

Configuration
⑧ Download/Upload Save/check Engine Info & Limits
⑨ Compensation RPM Fix the screen

1. Check ‘Engine RUN’
RPM ※ Compensation RPM Range
2. Click ‘Start’ button
Compensation 3. Check Process Bar st
Step 1 : Dead Slow
4. Finish Compensation
nd
at Step1 Step 2 : Half
5. Repeat Compensation rd
at Step 2 & Step3 Step 3 : Navigation Full
Alarm ⑩ Check Event List Check the result of Compensation
End
< Fig 4-1 RPM Compensation Procedures of B-WACS >

(*Please, refer to section 3.4.1 to choose RPM for RPM compensation.)

38
1) Factory Reset
2) Update main parameters and firing orders.
(After ‘Factory Reset’, Update Button should be clicked to reflect the result.)

39
3) When engine is turning, check the sensor data and restart B-WACS monitoring software
4) Input engine information and apply to B-WACS

40
5) Complete RPM Compensation
① Please check that Engine status is RUN on State Window of DMU Software. If an engine
stops, it is not possible for operators to RPM compensate because buttons for RPM
Compensation become disabled.
① Check RUN
② Check Start
Button

41
② During the compensation, Process Bar displays what it has achieved so far. It takes over
10 minutes to compensate RPM every step.
③ Check Process Bar
Any change of screens during RPM compensation is strictly prohibited. If the screen is
changed, it has to go back to this screen before completing the step of RPM
Compensation, or DMU Software have to be initialized by clicking Factory Reset
Button on Manual Setting screen and then RPM Compensation is completed again.
③ If RPM compensation is completed, RPM shows and the completion check box is filled
with check-mark automatically.

42
④ After completing the first step of RPM compensation, finish the other two steps as the
same way.
④ Check RPM & Completion
⑤⑤‘Step ‘Step23’&실행
2’ 및 Step
Complete Step 3
6) Check the result of Compensation on the event list
⑥
⑫

43
4.3 Sensor Replacement Procedure
Sensor Replacement Procedures of B-WACS are following Figure 4-2 below in numerical order.
Please refer to Installation Manual of B-WACS for SCU replacement before completing Sensor
Replacement.
Start
① SAU/SCU Power OFF . Dip Switch Setting of new SCU is

same to that of Defective SCU
(Refer to Figure 4-3 & Table 4)
② Remove Defective SCU
. There are powers of SCU & SAU in
SCU
SAU (Refer to Figure 4-4)
Replacement ③ Install new SCU
. Fasten fixing bolts loosely in order
to move sensors up and down while
④ Adjust Shim adjusting a shim
※ Please refer to Installation Manual
⑤ SCU/SAU Power ON for detailed information
Engine Turning Rotate the engine over two times
Manual Setting ⑥ Check Sensor Data Screen Check transfer of updated Data
Sensor ⑦ Sensor Replacement
Replacement Select SCU & Click Replace Button

⑧ Click Replace Button
Alarm ⑨ Check Event List Check the result of Compensation
End
< Fig. 4-2 Sensor Replacement Procedure >

44
< Fig. 4-3 SCU Dip Switch >
SCU Power Switch SAU Power Switch
< Fig. 4-4 SAU >

45
< Table 7 Dip Switch Binary Code in SCU >
SCU No. Dip Switch Setting SCU Binary Number Code Remark
1 0-0-0-0-1-0
2 0-0-0-1-0-0
3 0-0-0-1-1-0
4 0-0-1-0-0-0
5 0-0-1-0-1-0
6 0-0-1-1-0-0
The last of Dip
Switches means
the terminating
7 0-0-1-1-1-0 resistance.
Please note that

8 0-1-0-0-0-0 the terminating
resistance of the
last SCU has to be
‘ON’
9 0-1-0-0-1-0
10 0-1-0-1-0-0
11 0-1-0-1-1-0
12 0-1-1-0-0-0
13 0-1-1-0-1-0
14 0-1-1-1-0-0

46
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Doosan B-WACS

Doosan Engine Co.,Ltd.

DOC. No. B-WACS-G005 February 2014

2. Picture of the back side of DMU (Please refer to p.4)

3. Picture of the front side of DMU (Please refer to p.1)

DOC. No. B-WACS-G005 February 2014

If there are some troubles when ‘Getting Start’ procedure is

Without the completion of RPM Compensation, B-WACS can’t

After sea trial, RPM Compensation should be executed

of RPM Compensation after sea trial for more detailed information.

DOC. No. B-WACS-G005 February 2014

The front side of DMU The back side of DMU

DMU Power Switch

DOC. No. B-WACS-G005 February 2014

3. Check whether ‘Engine Status’ is ‘RUN’ and ‘BWM Mode’ is

DOC. No. B-WACS-G005 February 2014

The update should be performed when engine is

DOC. No. B-WACS-G005 February 2014

DOC. No. B-WACS-G005 February 2014

5-1 Click ‘RPM Compensation’ and Run main engine as

※ Recommend Engine Speed

■ 1st RPM Compensation: Dead Slow RPM

The three speeds for each step should be spaced by

DOC. No. B-WACS-G005 February 2014

5-3. Don’t touch the others menu during RPM compensation!

DOC. No. B-WACS-G005 February 2014

5-5. Do ‘Step 2’ and ‘Step 3’ as ‘Step 1’ procedure

DOC. No. B-WACS-G005 February 2014

5-7. Check the result of Compensation on the event list

DOC. No. B-WACS-G005 February 2014

No. Task Method Result Note

If DMU Power doesn’t

When engine is running, confirm If engine stops, Engine

Confirm that “Step 1” Completion

Confirm that “Step 3” Completion

DOC. No. B-WACS-G005 February 2014

Doosan Engine Co.,Ltd.

DOC. No. B-WACS-T005 February 2014

2. Picture and Drawing of SCU Bracket (Please refer to p. 7, 20)

3. Picture of DMU (Please refer to p. 10)

DOC. No. B-WACS-T005 February 2014

5. Trouble Shooting ------------------------------------------------------------------------------------------ 28

DOC. No. B-WACS-T005 February 2014

1.1 Introduction of B-WACS

< Fig. 1-1 Principle of B-WACS >

B-WACS has three kinds of main components, SCU(Signal Capture Unit),

DOC. No. B-WACS-T005 February 2014

1.2 Introduction of Manual

B-WACS manual shall be composed as below

DOC. No. B-WACS-T005 February 2014

2.1 System Configuration Diagram

< Fig. 2-1 B-WACS Configuration Diagram >

DOC. No. B-WACS-T005 February 2014

▣ SCU (Signal Capture Unit)

2.1.1 SCU(Signal Capture Unit)

< Fig. 2-2 SCU >

DOC. No. B-WACS-T005 February 2014

DOC. No. B-WACS-T005 February 2014