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Tel : +82 52 204 7765 / FAX: +82 52 204 7801 / Web : http://www.hyundai-gs.com/ E-MAIL : service@hyundai-gs.com

Service Letter

Date: 23. NOV. 2020

Ref. No.: HGS-MAN-SL-20-010

ㆍ Subject : Top Controlled Exh. Valve (TCEV)

ㆍConcerns : Owners and Operators of Hyundai - MAN B&W Two-Stroke
Marine Diesel Engines with TCEV
Type: G90ME-C & GI10.5, G95ME-C

To whom it may concern,

For your guidance, we enclose a copy of the following Circular Letter;

CL23949-2020 dated October 2020

Top Controlled Exh. Valve (TCEV)

- HPS start-up pressure difficulties

Action Code: WHEN CONVENIENT

Faithfully yours,

H. L. Oh

Machinery Service Dep’t

Technical Division
Tel. +82 52 204 7860 Fax. +82 52 202 7801
E-mail : service@hyundai-gs.com
Web : http://www.hyundai-gs.com

< Enclosed : Circular Letter CL23949-2020 >

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 Circular Letter CL23949-2020

ACTION CODE: WHEN CONVENIENT

Top Controlled Exh. Valve (TCEV) -

HPS start-up pressure difficulties

Concerns:
Owners and Operators of MAN B&W Two-Stroke
Marine Diesel Engines with TCEV:

Type: G90ME-C & GI10.5, G95ME-C

Direction of oil from TCEV HCU-block

19 October 2020

Dear Sirs,

We have recently received information that some operators with Top Controlled Exhaust Valves – TCEV may
experience HPS start-up pressure difficulties if, previously, one – or more - exhaust valves have been in fail-safe
mode prior to starting the pumps.

The phenomenon can manifest itself after overhaul or replacement of control valves (ELFI/PEVA), or dismounting
of the cabling in the junction boxes, as if there is a defect or failure on a valve or with the cabling.

Due to a very slow opening of the TCEV when spooling up start-up pumps, as function of slowly increasing the
pressure, the actuator slide in the TCEV will stagnate in a position where pressure is relieved directly to the drain
manifold on the engine. This will lock the actuator slide with a fixed leakage, causing the pressure build-up to
stagnate.

In some cases, the phenomenon may be accompanied by a vibrating/surging sound on the affected exhaust valve
– and piping. There is no damage or danger connected with the phenomenon and a safe operation of the engine
is not affected either.
 Circular Letter CL23949-2020

Figure no. 1 illustrates the direction of oil from the TCEV HCU-block through the actuator slide and to drainage
volume.

Figure No. 1

The instructions in the next page for building up pressure during this situation, will also be contained in the
updated instruction manual. Troubleshooting of control valves, cabling, sensors etc. will not be covered here.
 Circular Letter CL23949-2020

Counter remedy if fail-safe-mode is present and pressure stagnation occurs after removal - and installation of;
cylinder cover, exhaust valve, control valves etc:

 Check - and reset HCU fault state on MOP.

o On ECS 1609-6.4 and earlier: under MOP/Engine/Chief limiters. – Reset fault manually on the
screen.
o On ECS versions later than 1609-6.4: under MOP/Engine/Status/Cylinder Valve Status. – Reset
fault manually on the screen.

Figure 2 - ECS 1609-6.4

 If resetting the respective CCU fault state per the above does not solve the problem, then power cycle
the respective CCU/MPC by removing the main power to the respective CCU board in the EC-cabinet
for a couple of seconds, followed by a remounting of the power plug.

Identify the affected unit according to below:

o During fail-safe the PEVA valve feedback (ch33) will have a low [mA] value on the MOP close
to 4mA.

o During fail-safe the PEVA valve control output (ch71) will have a low and fixed [mA] value on
the MOP close to 4mA.

o Alternatively, identify by the sound from the units on the engine.

 Circular Letter CL23949-2020

Counter remedy if the above has been attempted, faulty control valves have been replaced, fault persists and
hydraulic start-up pressure must be established:

 Stop start-up pumps.

 Ventilate spring-air manifold from air control rack to zero bar.
 On above-found affected cylinder unit, perform the below sequence of events:
a. Dismount spring-air inlet pipe to affected TCEV and puncture the non-return valve on the inlet so
that the exhaust valve spindle falls all the way down to mechanical stop.
b. Mount the inlet pipe again but do not open the spring air.
c. Start the start-up pumps again and let the pressure rise to set-point.
 Open spring-air on air control rack again.

The above guideline will ensure that the pressure can reach the set-point, but in any case of fail-safe, the exhaust
valve on the respective cylinder will continue to stay open.

In cases with inoperable cylinder units, we always refer to the Operating Instruction covering “Running with
Cylinders or Turbochargers out of Operation” for specifics related to running with either open - or closed exhaust
valve(s).

In case you have any questions, please do not hesitate to contact MAN Energy Solutions, Operation Department,
Fuel Equipment, Hydraulics and Mechanics at OperationFuelHydraulicMechanic2S@man-es.com.

Best regards

MAN Energy Solutions

Jakob Gjørtsvang Knudsen

Head of EEEEOM, Fuel Equipment, Hydraulics and Mechanics

Operation Department