MAN Diesel & Turbo

PMI Auto-tuning
Operation
User’s Reference Guide

This guide is part of a series of information guides which explains how to use the PMI Auto-tuning system
and software program:

Summary of Menus & Wizards

Operation
System Components Overview
Commissioning
24-09-2014

NOTICE

This edition of the manual applies to PMI 1410. Some screen shots are taken from earlier PMI versions.

Page 1 of 50
MAN Diesel & Turbo

1 Contents
1 Contents ..................................................................................................................................................... 2
2 PMI Auto-tuning ......................................................................................................................................... 4
3 Getting Started ........................................................................................................................................... 5
3.1 PMI Auto-tuning System Overview ................................................................................................... 5
3.2 Tuning of Engine Performance .......................................................................................................... 6
3.3 Quick Guide on Using the ECS MOP-B Auto-tuning Screen ............................................................... 8
3.4 Quick Guide on Using the EMS MOP Application ............................................................................ 10
3.4.1 PMI Auto-tuning .......................................................................................................................... 10
3.4.2 CoCoS-EDS ................................................................................................................................... 10
4 Engine Control and Adjustments (ECS MOP-B) ........................................................................................ 11
4.1 Continuous Automatic Mean Level Tuning ..................................................................................... 12
4.1.1 Enable Continuous Automatic Tuning Mode............................................................................... 13
4.1.2 Continuous Automatic Tuning in Operation................................................................................ 14
4.2 User-Controlled Automatic Adjustments ........................................................................................ 14
4.2.1 Adjust Cylinder Balance ............................................................................................................... 14
4.2.2 Adjust Mean Deviation ................................................................................................................ 15
4.3 Elements of the Auto-tuning Window ............................................................................................. 17
4.3.1 Information Bar ........................................................................................................................... 18
4.3.2 Deviation Panel ............................................................................................................................ 19
4.3.3 Mean Panel .................................................................................................................................. 20
4.3.4 Buttons ........................................................................................................................................ 22
5 Pressure Monitoring and Measurements (EMS MOP) ............................................................................. 24
5.1 Monitoring and Viewing Online Values ........................................................................................... 25
5.1.1 Viewing Modes (step 2, Figure 16) .............................................................................................. 26
5.2 Capture and Store Pressure Measurements ................................................................................... 27
5.2.1 Online Capture (default) .............................................................................................................. 27
5.2.2 Manual Measurement (troubleshooting only) ............................................................................ 29
5.3 Viewing Stored Measurements ....................................................................................................... 32
5.4 Viewing Calibration History ............................................................................................................. 33
5.5 Backup and Restore ......................................................................................................................... 34

Page 2 of 50
MAN Diesel & Turbo

5.5.1 Back up Database ........................................................................................................................ 34

5.5.2 Restore Database ........................................................................................................................ 35
5.6 Printing Stored Measurements ....................................................................................................... 36
5.6.1 Print View .................................................................................................................................... 36
5.6.2 Print Report ................................................................................................................................. 37
6 Sensor Recalibration ................................................................................................................................ 38
6.1 How to Calibrate the Online Sensors............................................................................................... 38
7 Appendix .................................................................................................................................................. 43
7.1 PMI Calibration Box Description ...................................................................................................... 43
7.2 Engine Shaft Power Estimation ....................................................................................................... 45
7.3 PMI Status Messages ....................................................................................................................... 47
7.4 Technical Data ................................................................................................................................. 49
7.4.1 Pressure Sensors.......................................................................................................................... 49

Page 3 of 50
MAN Diesel & Turbo

2 PMI Auto-tuning

PMI Auto-tuning is designed to provide engineers and service staff on testbed, onboard ship and at power
plants with a computerised tool for cylinder pressure measurements on MAN Diesel’s two-stroke diesel
engines. Its primary purpose is for:

 Tuning of engine performance – based on observed changes in the combustion characteristic

parameters Pi, Pcomp, and Pmax.
 Continuous monitoring of the combustion process
 Enhanced fault finding and analysis
 Cost-efficient commissioning of MAN Diesel two stroke engines at testbed and sea-trial

Serving a secondary purpose, PMI Auto-tuning also provides an estimate of the engine shaft power.

Page 4 of 50
MAN Diesel & Turbo

3 Getting Started

3.1 PMI Auto-tuning System Overview

The Data Acquisition Unit collects the measured combustion pressure cycles from the Online sensors and
forwards the processed data to the CoCoS-EDS and PMI Auto-tuning programs running on the EMS MOP for
logging, visualisation, and analysis. The evaluated key pressure values (Pi, Pcomp, and Pmax ) are transferred
via the network to the ECS MOP-B and the units of the engine control system, Figure 1.

EMS MOP ECS MOP-B

Figure 1: Closed-loop tuning of engine performance

Page 5 of 50
MAN Diesel & Turbo

The PMI Auto-tuning system is divided into two sections, each with its own user interface and PC:

1. EMS MOP (Engine Monitoring System Main Operating Panel) contains the PMI Auto-tuning and
CoCoS-EDS programs for logging, monitoring and analysis of the combustion process. From this
interface performance of the engine can be monitored and examined. These include monitoring of
the actual combustion cycles and trend of the key pressure values.

2. ECS MOP-B (Engine Control System Main Operating Panel B) contains the engine control system
user interface. This includes commanding and controlling adjustments of the combustion process.
From this interface the performance of the engine can be tuned by adjusting the fuel injection
timing and the exhaust valve closing time.

3.2 Tuning of Engine Performance

Tuning the combustion process for best performance consists of two operations:

 Balancing cylinder pressures to minimise deviation from mean.

Cylinder pressure

Mean

Balancing

Non-optimized engine Balanced engine

 Adjusting cylinder mean pressures to ensure engine operation at the “ordered” (design) level.

Cylinder pressure

Ordered mean
Current mean

Mean adjustment

Non-optimized engine Mean pressure tuning

Page 6 of 50
MAN Diesel & Turbo

To perform the above operations, three adjustment modes are offered by the engine control system:

1. Continuous Automatic. The cylinder pressures are continuously monitored and corrected by the
engine control system without intervention by the user. This mode is available for continuous
adjustments of the mean Pcomp and mean Pmax level to ensure that the actual mean pressure level is
adjusted towards the engine’s operating specifications. In this mode, automatic adjustments occur
only during safe and steady state engine operation and only within a narrower adjustment band
compared to User Controlled Automatic or Manual adjustments.

2. User-Controlled Automatic. The cylinder pressures are automatically adjusted once, each time the
user presses a command button. This mode is available for adjusting either the engine balance or
the mean pressure levels and only during steady state engine operation.

3. Manual. The pressure of individual cylinders can be adjusted manually through incremental
changes introduced by the user. This mode is primarily intended for cylinder pressure adjustment,
when the PMI Auto-tuning system is not in use.

Note: PMI Auto-tuning does not prevent undesired pressure levels at any operating condition. PMI
Auto-tuning does not compensate for abnormal operating conditions, e.g. an excessively worn fuel
pump, but only ensures optimised engine performance during steady state engine operation. Thus,
even though auto-tuning is enabled, the crew must still verify correct adjustment on a regular basis,
e.g. each time the engine load is increased.

PMI Auto-tuning reduces the workload required to make adjustments from hours down to a few
minutes or less. At the same time, the quality of the performance adjustment is significantly increased
compared to using offline cylinder pressure equipment, such as MAN Diesel & Turbo's "PMI Offline" or
a mechanical indicator.

Page 7 of 50
MAN Diesel & Turbo

3.3 Quick Guide on Using the ECS MOP-B Auto-tuning Screen

The Auto-tuning window of the ECS MOP-B displays the actual mean pressures and pressure deviations
between cylinders. If these values exceed recommended deviation limits, it will be indicated graphically by
a change in colour.

Auto-tuning functions – both Continuous Automatic and User Controlled Automatic – are allowed and
active only when the engine is operating under specific conditions, e.g. engine load must be stable for safe
tuning of cylinder pressures.

The message “Tuning allowed” will be displayed in the lower Information bar when the engine is running
under conditions permitting auto-tuning.

1. Continuous 5. Manual
Pmax adjustment
0
0 0 0 0 0 0 0 0 0 0 0 0 0
0
4. Auto mean 0 0 0 0 0 0 0 0 0 0 0 0 0 0
level
0
0 0 0 0 0 0 0 0 0 0 0 0 0 3. Auto
0 balancing
0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0

Pmax All

2. Continuous
Pcomp

Figure 2: ECS MOP-B Auto-tuning window

Page 8 of 50
MAN Diesel & Turbo

Tuning the engine

1. Continuous Automatic Mean Level Tuning (item 1 & 2, Figure 2)

Enable this mode by selecting the corresponding deviation panel followed by pressing the “On”
command button in the lower toolbar. It is recommended to run the engine in this mode at all
times.

2. User-controlled Automatic Adjustments

Balance of Key Pressure Values (item 3)

Send a command to balance any one or all of the key pressures values (Pi, Pcomp, or Pmax) by
selecting the corresponding deviation panel followed by pressing the command button in the
lower toolbar. Use this function as needed, e.g. after a change in engine load.

Adjustment of Mean Deviation (item 4)

Send a command to adjust either the mean Pcomp or mean Pmax pressures or both by selecting
the corresponding deviation panel followed by pressing the command button in the lower
toolbar. Use this function when the measured deviation from the ordered value is too large for
Continuous Auto-tuning.

3. Manual Adjustments (item 5)

The horizontal tabs, "Cylinder Load" and "Cylinder Pressure", on the screen in Figure 2 are used for
manual adjustments of the pressure offsets applied to control the injection timing and valve closing
time of each individual cylinder. These are primarily intended for adjusting the performance on
engines not equipped with PMI Auto-tuning and adds a further option for manually adjusting the
engine, even during engine operation when Auto-tuning conditions are not fulfilled. For a
description on how to make a manual adjustment, please refer to the ECS MOP user manual.

Page 9 of 50
MAN Diesel & Turbo

3.4 Quick Guide on Using the EMS MOP Application

3.4.1 PMI Auto-tuning

From the PMI Auto-tuning application you can:

 Setup and configure the PMI Auto-tuning measurement system

 Monitor the actual cylinder pressures, e.g. real time pressure curves and key-values table

Figure 3: EMS MOP: Cylinder pressure curves and key values table

3.4.2 CoCoS-EDS

From the CoCoS-EDS application you can:

 Access the cylinder pressure history from trend views

 Access engine performance analysis and reporting. (CoCoS-EDS Full ver. only)

When operating Auto-tuning at the ECS MOP-B, it is recommended to simultaneously monitor key pressure
values in the CoCoS-EDS trend view. Here the operator can easily monitor the results of the Auto-tuning
process.

Figure 4: EMS MOP: CoCoS-EDS trend view Figure 5: ECS MOP-B: Auto-tuning command screen

Page 10 of 50
MAN Diesel & Turbo

4 Engine Control and Adjustments (ECS MOP-B)

This section describes the functions and components of the ECS MOP-B Auto-tuning screen which allows
for control and adjustment of the cylinder pressures.

Automatic adjustments to the mean pressure level or balance between cylinders are only allowed under
certain conditions. These conditions are:

 Index is stable
Engine is in steady state operation, indicated by a stable governor index.

 Index is sufficient
Index is above a minimum level as adjustments in low load operation are not allowed.

 Sensor values
Cylinder pressure sensors provide valid signals.

 Pressure margin
Deviation from reference must not be too large as this could indicate a mechanical fault.

When all the above conditions are met, the engine is said to be in the allowable tuning range. It may be
automatically tuned and the information bar will display the following message:

If any of these conditions is not met, then the engine control system will ignore any attempt to
automatically adjust the mean pressure level or balance between cylinder pressures. The status bar will
display the message, “Tuning not allowed” and a reason given in the right column as shown below:

Reason

Page 11 of 50
MAN Diesel & Turbo

4.1 Continuous Automatic Mean Level Tuning

The system offers continuous and automatic tuning of both Pcomp and Pmax mean pressure levels. It will
automatically adjust the actual mean pressure close to the ordered value to reduce any possible deviation.
This is done automatically without intervention from the engine crew.

Continuous Auto-tuning mode can be set under any operating condition. In this mode, the engine control
system loops through the following operating sequence:

1. Monitors mean pressures

Checks the deviation between the actual mean and ordered mean.

2. Monitors operating conditions

Checks if the engine is operating in the allowable tuning range:
 Index is stable
 Index is sufficient
 Sensors values valid

3. Adjusts mean pressure

If conditions in step 2 are satisfied, the control system adjusts the current mean pressure level
close to the ordered mean.

The engine control system continuously loops through the above three step operations. If conditions in
step 2 do not permit tuning of the mean levels (step 3), then the engine control system puts adjustment of
the mean pressure level on stand-by until the conditions again are met. For example, the engine is
operating under continuous Pmax tuning mode, and the control system is continuously optimising the Pmax
mean level. When the engine operator moves the index below the minimum tuning range, then automatic
adjustments to the Pmax mean level is temporarily interrupted and put on stand-by. When the operator
moves the index back within the allowable tuning range, then automatic adjustments to Pmax is resumed.

The maximum continuous mean pressure level adjustment range varies depending on your particular
engine type, see Figure 6.

Page 12 of 50
MAN Diesel & Turbo

No auto-tuning
*100%

Allowed auto-tuning range

Fuel Index

*45%
No auto-tuning

Time
*Actual limits depend on your particular ECS configuration

Figure 6: The white zone indicates one of the requirements, “Index is sufficient", before continuous auto-tuning is applied

4.1.1 Enable Continuous Automatic Tuning Mode

To enable Continuous Pmax Tuning, make sure that the ECS MOP is in Chief access level, and then follow the
steps in the order shown in Figure 7, below.
2 Select

3 Select
150
145 0.0 1.0 0.5 -2.1 -4.0
0 0.0 -0.5 0
8.0 -0.5 0
2.5 0.9 -5.8
-1.0
5
2 2.0 2.0 -2.0 0.5 0.0 4.0 1.0 1.0 0.4 3.0 0.0 0.0
1 Press

125
123 0.2 0.1 0.9 -0.5 -1.1
0 -0.5 0.4 0.2 0
1.3 -0.2 -0.9 0.1
2
1 1.0 2.0 -2.1 0.5 0.0 2.0 -1.0 3.0 1.2 -1.2 1.3 -3.2

-0.2 0.1 0.1 -0.1 -0.1 0.0 0.1 -0.1 0.0 0

0.4 -0.1 -0.1

2.0 2.0 -2.0 0.5 0.0 4.0 1.0 0.4 3.0 0.0 0.0 1.0

Pmax All

4 Press
Figure 7: Panel with button for enabling continuous Pmax tuning mode

Page 13 of 50
MAN Diesel & Turbo

To enable Continuous Pcomp Tuning, follow the steps given in Figure 7 but this time select the Pcomp Mean
Panel in step 3.

4.1.2 Continuous Automatic Tuning in Operation

When Continuous Tuning mode is enabled, incremental adjustments to the mean pressure level are
displayed in the Mean panel. For example, in Figure 8, continuous Pmax tuning is enabled. The mean panel
on the right shows the pressure adjustment increments introduced by automatic tuning.

150 Continuous Automatic 150

Tuning enabled
145 149
5 1
2 0 2 4.4

Adjustment increments

Figure 8: Incremental pressure adjustments indicating continuous automatic tuning in operation

4.2 User-Controlled Automatic Adjustments

4.2.1 Adjust Cylinder Balance

Varying pressure deviations between cylinders can be automatically balanced through a single command
button. When this button is pressed, the system will adjust the cylinder pressures to reduce any pressure
differences without affecting the mean pressure level. Several minutes may elapse before the results of the
operation will be displayed on the ECS MOP screen.

To adjust the cylinder balance, follow the steps below:

1. Select either the Pi, Pcomp, or Pmax deviation panel, depending on which combustion parameter you
want to balance.
2. Start automatic tuning by clicking the command button in the lower status bar (step 2a, Figure 9) or
click the "All" button (step 2b) to simultaneously tune all three combustion parameters (no matter
which panel is selected in step 1).

Page 14 of 50
MAN Diesel & Turbo

150
147 0.0 -2.1
1.0 0.5 -5.2
-2.1 0.0 0.0 -0.5
8.0 0.0 -0.5 0
2.6 -2.3
0.9 -1.0
3
4 1.0 0.0 -1.3 3.0 0.5 3.0 1.0 2.4 0.5 2.6 1.1 3.2

125
122 -2.1
0.2 -0.8 0.0 -0.5 -2.8
0 -0.5
4.0 0.4 0.6 0
2.5
1.3 -0.9 -0.5 0.1
3 1 Select either
5 3.0 -2.2 -2.1 0.6 -1.2 2.3 -0.9 2.9 1.1 4.1 1.1 -3.5

0.2 0.1 -0.5

0.1 -0.1 -0.1 0.0 0.1 -0.1
0.3 0.0 0.0 -0.1 0.1

0.6 2.2 -1.8 0.6 0.9 3.0 0.0 0.8 -3.0 0.5 -1.0 2.8

Pmax All

Click 2a 2b

Figure 9: Command buttons for automatic tuning of cylinder balance

 Wait for the system to update the screen with the new pressure values.
 Repeat the above steps if the pressure deviation between cylinders need further adjustment.

4.2.2 Adjust Mean Deviation

The difference between the current and ordered mean pressure of the cylinders can be reduced by
pressing a single command button. When this button is pressed, the system will adjust the current mean
towards the ordered mean without affecting the pressure balance between the cylinders. Several minutes
may elapse before the results of the operation will be displayed on the screen.

To reduce the deviation between the current and ordered Pcomp or Pmax mean deviations, follow the steps
below:

1. Select either the Pcomp or Pmax Mean panel, depending on which mean deviation needs adjusting.

Page 15 of 50
MAN Diesel & Turbo

2. Start automatic tuning by clicking the command button in the lower status bar (step 2a, Figure 10)
or click the "All" button (step 2b) to simultaneously tune both mean deviations (no matter which
panel is selected in step 1).

150
146 0.6 1.0 0.3 -2.1 0.1 0.0 -0.5 0
2.9 -0.8 0.2 -0.8 -0.9
4
2 0.9 1.0 -2.0 2.5 0.7 2.0 1.1 3.2 0.8 0.0 -2.0 1.5
1 Select either
125
120 0.2 -1.9
-0.8 0.5 -2.0
-0.5 0.4 -0.6 -0.3 0.9 0
1.4 -0.9
1.2 0.6 -0.4
5
3 2.2 -3.1 2.5 0.8 -2.2 2.5 -0.6 3.0 2.1 3.2 4.2 -3.5

-0.1 0.0 0.1 0.1 -0.4

-0.1 -0.2 0.0 -0.1 0.0 0.3
0 0.1 0.2

0.9 3.4 -2.0 -0.7 1.2 3.2 0.5 1.9 -2.0 1.1 -0.9 3.6

Pmax All

Click 2a 2b

Figure 10; Command buttons for automatic tuning of Mean deviation pressures

 Wait for the system to update the screen with the new pressure values.
 Repeat the above steps if the pressure deviation between cylinders need further adjustment.

Page 16 of 50
MAN Diesel & Turbo

4.3 Elements of the Auto-tuning Window

Mean panels Horizontal tabs Deviation panels

150
150 0.2 0.1 0.1 -0.1 -0.3 0.0 0.1 0.3 -0.4 -0.1 0.0 0.1
0
1 0.5 0.7 3.0 2.0 -2.5 0.0 5.0 -3.1 -1.0 1.5 3.0 2.4 4.2

125
124 0.3 -0.1 0.5 0.2 -0.2 0.1 -0.3 0.1 0.2 0.0 -0.6 -0.2
1
2 0.8 -0.8 2.5 0.0 4.2 -2.0 -2.0 2.5 7.0 -5.0 6.0 -2.4 4.0

-0.1 0.0 0.1 0.0 -0.1 -0.2 0.1 0.2 -0.1 0.0 0.2 -0.1

-5.0 2.6 4.0 2.4 1.5 -3.0 2.4 3.2 0.0 -1.0 2.0 0.9

Pmax All

Mode button Information bar Command buttons

Figure 11: ECS MOP Auto-tuning window

Page 17 of 50
MAN Diesel & Turbo

4.3.1 Information Bar

Running state Operating requirements Notification

a. Running state

This field indicates whether continuous tuning is in progress or not. Even if continuous tuning is
enabled (Auto-tuning mode), certain requirements listed in the Operating Requirements field must
be met. If one of these requirements is not met, then continuous tuning is temporarily interrupted
and put on standby until a change in engine operating conditions causes the requirement again to
be fulfilled.

Messages Description
Tuning allowed Engine is operating in the allowable tuning range.
Tuning not available Engine is not operating in the allowable tuning range.
Tuning in progress The engine control system is either balancing or
adjusting the mean pressure levels.

b. Operating requirements

These are conditions that must be met before automatic tuning is applied.

 Index stable: fuel index must be reasonably stable (see Process Information menu of ECS MOP)
 Sufficient index: fuel index must be within a specified range set by the manufacturer
 Sensor values: data received from the cylinder pressure sensors must be valid.

Symbols Description
Meets requirements
Not in range
Error

Page 18 of 50
MAN Diesel & Turbo

c. Notification

The user is informed on the results of the last tuning operation.

Messages
Last tuning successful
Tuning rejected due to invalid
sensor values
Tuning incomplete due to
max. adjust limit
Tuning rejected ECU or CCU
not available
Tuning rejected EICU not
available
Tuning rejected ATCU not
available
Description
Operator initiated tuning completed successfully
A pressure sensor is defective or pressure values are not
valid.
Deviation too high or above adjustable range.
Tuning cannot be made because the particular MPC device
is busy with another task.
Tuning cannot be made because the particular MPC device
is busy with another task.
Tuning cannot be made because the particular MPC device
is busy with another task.

4.3.2 Deviation Panel

Cylinder pressure

Offset Cyl 4 = 4. 2 bar 4.2

Mean

Threshold icon

1.1 4.1 3.8 4.2 -13.7 0.5 Offset pressure

1.0 0.0 1.0 1.0 2.0 0.0 Offset adjustment

Figure 12: Pmax deviation of a 6-cylinder engine

Page 19 of 50
MAN Diesel & Turbo

Offset pressure
The pressure deviation of each cylinder with respect to the mean.

Offset adjustment
The compensation value used to reduce offset pressure.

Threshold icon
Used to indicate when certain pressure limits have been exceeded. These limits are shown in the
table below:

Threshold icon Pmax (bar) Pcomp (bar) Pi (bar)

>20 >20 >2

3 to 20 3 to 20 0.5 to 2

1 to 3 1 to 3 0.2 to 0.5

-1 to 1 -1 to 1 -0.2 to 0.2

-1 to -3 -1 to -3 -0.2 to -0.5

-3 to -20 -3 to -20 -0.5 to -2

< -20 < -20 <-2

4.3.3 Mean Panel

Cylinder pressure

Mean

Offset adjustment

Figure 13: Mean Pmax pressure level of a 6-cylinder engine

Ordered
Requested or target mean pressure (set point)

Current
Mean pressure value

Page 20 of 50
MAN Diesel & Turbo

Deviation
Difference between ordered mean and current mean pressure. The value field will change color
depending on how much the deviation is:

Threshold color Pmax (bar) Pcomp (bar) Pi (bar)

-3 to 3 -3 to 3 -3 to 3
3 to 5 or -3 to -5 3 to 5 or -3 to -5 0.5 to 0.8 or –0.5 to -0.8
>5 or <-5 >5 or <-5 >0.8 or <-0.8

Offset
A compensation value used to reduce the deviation between mean pressures.

Pmax Mean Panel :

The offset consists of two parts given by a “Static offset” and an “Increment”

Continuous Pmax tuning mode = Disabled Continuous Pmax tuning mode = Enabled

121 121
131 123
9.7 2
-4 -4 -8

Offset = Static offset Offset = Static offset + Increment

Increment
Pressure adjustments introduced by Auto-tuning.
Adjustment limits*: –8 to 8 bar

Static Offset
Static offset value that is manually set in the Cylinder Pressure menu (see “Cylinder Press.” tab,
Figure 11).
Adjustment limits*: –20 to 20 bar

*Limits may vary depending on your particular engine type.

Page 21 of 50
MAN Diesel & Turbo

4.3.4 Buttons

Mode button (item 1) Command buttons (item 2)

Figure 14: Panel buttons

Continuous Tuning Mode Button (item 1, Figure 14)

Enables or disables continuous and automatic tuning of mean pressure (Pcomp or Pmax).

Disabled: Enabled:

Balance and Deviation Command Buttons (item 2)

Key pressure values are adjusted automatically each time the button is pressed. The function of the left
button will change depending on which mean or deviation panel has been selected:

All

Pmax All Pmax deviation or mean panel selected

Pcomp All Pcomp deviation or mean panel selected

Pi All Pi deviation or mean panel selected

Page 22 of 50
MAN Diesel & Turbo

Command Button Function

Command
Panel Selected Button Function When Pressed
Button Displayed

Pmax Deviation Balance of Pmax deviation between each cylinder

Reduction of deviation between Pmax ordered mean and

Pmax Mean
current mean

Pcomp Deviation Balance of Pcomp deviation between each cylinder

Reduction of deviation between Pcomp ordered mean and

Pcomp Mean
current mean

Pi Deviation Balance of Pi deviation between each cylinder

Reduction of deviation between Pi ordered mean and current

Pi Mean
mean

Simultaneous balance of all three key pressure values: Pi,

Any deviation panel
Pcomp, and Pmax

Simultaneous reduction of all three mean deviation values: Pi,

Any mean panel
Pcomp, and Pmax

Page 23 of 50
MAN Diesel & Turbo

5 Pressure Monitoring and Measurements (EMS MOP)

Figure 15: Monitoring combustion pressures ’live’ on a 12 cylinder engine

Cylinder pressures can be monitored in either the PMI Auto-tuning application running on the EMS MOP or
the ECS MOP B. The ECS MOP B displays key pressure values only, while the PMI Auto-tuning application
offers both key pressure values and a visual display of the actual pressure curve from each cylinder. The
PMI Auto-tuning application receives pressure data via a controller from sensors mounted on each cylinder,
calculates key pressure values, and sends the results through a network cable to the ECS MOP B. This
section will provide a brief description of the daily use and operation of the PMI Auto-tuning application.

Page 24 of 50
MAN Diesel & Turbo

5.1 Monitoring and Viewing Online Values

Cylinder pressure data are continuously monitored and can be viewed ‘live’ in the Monitor menu window.
The menu contains different graphical representation of live data measured by the cylinder sensors. Each
graphical representation can be selected from the vertical tab bar found on the left section of the screen.
The following viewing modes are provided:

 Table
 Balance plot
 PT
 P-CA
 PV
 PT Raw

For example, the steps shown in Figure 16 show how to monitor online values.

2 Select view

1 Select

Figure 16: Monitoring key pressure values continuously on a 12-cylinder engine

Page 25 of 50
MAN Diesel & Turbo

5.1.1 Viewing Modes (step 2, Figure 16)

Menu Items Description

Key pressure values from each cylinder and power output are listed in tabular
form.

Key pressure value deviations from ‘mean’ values are shown for each cylinder.

Cylinder pressures are plotted relative to each cylinder’s TDC angle.

Cylinder pressures are plotted against the crankshaft angle.

Cylinder pressures are plotted against the relative cylinder volume.

A series of cylinder pressure curves are plotted through 10 crankshaft

revolutions. Each curve represents the actual signal measured at the sensor.

To reduce the effects of noise, a series of 10 consecutive pressure curves (raw data) received from the
sensor are averaged, and the resulting curve is rendered in the PV, P-CA, and PT diagrams. The averaged
curve also forms the basis for calculating all the key parameters shown in the Key Values table and the
Balance plot. Each of the 10 consecutive curves that form the average is rendered in the “PT (Raw Data)”
menu.

Page 26 of 50
MAN Diesel & Turbo

5.2 Capture and Store Pressure Measurements

Cylinder pressure measurements are captured and saved using the Online sensors (Online Capture). This is
the default method that should be used by the operator. In case an Online sensor value is missing or is
suspected of being defective, a manual measurement can be performed to troubleshoot a defective sensor.

 Online Capture (default)

 Manual Measurement (troubleshooting only)

5.2.1 Online Capture (default)

Online sensors

EMS MOP

Figure 17: Measurements from the Online sensors are instantly saved to the database

When the save button in the program is clicked, a complete set of online pressure measurements from the
Online sensors is saved with a time stamp.

How to capture an online measurement:

Follow the steps shown in Figure 18 to capture an online measurement and save it to the database.

Page 27 of 50
MAN Diesel & Turbo

3 Click

2 Select any

4 Add optional comment

5 Click
1 Select

Figure 18: Saving pressure measurements to the database

Page 28 of 50
MAN Diesel & Turbo

5.2.2 Manual Measurement (troubleshooting only)

Reference sensor PMI Calibration Box

EMS MOP

Figure 19: A manual measurement on each cylinder is performed using the Reference
sensor and PMI Calibration Box.

A user proceeds to the engine and performs a manual pressure measurement on one or more cylinders
using the Reference sensor and PMI Calibration Box. The program guides the user through each step of the
measuring process with the help of a wizard. A manual measurement is intended for use only as an aid in
troubleshooting a defective Online sensor.

How to Perform a Manual Measurement:

Please refer to the appendix for a brief description of the PMI Calibration Box.

a. Start the wizard

To start the wizard, follow the steps in Figure 20. Read the welcome text and click “Next >” after the system
is finished initialising.

Page 29 of 50
MAN Diesel & Turbo

2 Select

3 Click

1 Select

Figure 20: Starting the manual measurement wizard

b. Follow the wizard

In the next window, the system is waiting to receive measurements. To make a pressure measurement,
follow the steps in the order given in Figure 21.

Page 30 of 50
MAN Diesel & Turbo

1 Attach

Indicator valve

2 Open

3 Verify green

5 Wait for Results

4 Press ’OK’

PMI Calibration Box

Figure 21: Sequence of steps used for performing a manual measurement

Steps (see Figure 21):

1) Attach Reference sensor to indicator valve on cylinder.

2) Open indicator valve.

Note: If this is the first cylinder being measured, make sure the sensor has reached working
temperature by keeping the indicator valve open for one minute before proceeding to the
next step.

3) Verify that ‘Ready’ green lamp is on – not flashing. A steady light indicates ready for
measurement.
4) Press “OK” button to start a measurement. The flashing ‘Ready’ lamp indicates the system is
measuring.
5) Wait to receive pressure curve.

Page 31 of 50
MAN Diesel & Turbo

Note: If a measurement is not successful, the red ‘Error’ indicator lamp on the PMI
Calibration Box will turn on. Check the Event Log on the PC screen for additional information
and instructions.

Close the indicator valve when the measurement appears on the screen. Then move to the next
cylinder to be measured and repeat the previous steps.

When all measurements have been completed, click “Next >” and follow the wizard to completion.

5.3 Viewing Stored Measurements

All saved measurements are stored in the database. To view any previously saved measurement, follow the
steps in Figure 22, below.

2 Select measurement
3 Select a view

1 Select

Figure 22: Viewing key pressure values from a stored measurement

Page 32 of 50
MAN Diesel & Turbo

5.4 Viewing Calibration History

To view the calibration history of the Online sensors and the TDC angles, follow the steps in Figure 23.

Select 2

Select 1

Figure 23: Calibration date and time listed under the General Configuration Information table.

Page 33 of 50
MAN Diesel & Turbo

5.5 Backup and Restore

All measurements and engine configuration data are stored in the PMI Auto-tuning database. The database
can be backed-up locally to another folder location on the PC hard disk or to an external drive to prevent
loss of data in case of a system failure. A previously backed-up database can be restored or loaded into the
PMI Auto-tuning application.

5.5.1 Back up Database

To back-up the database, follow the steps in Figure 24, below.

2 Select

4 Click

Click 3

1 Select

Figure 24: Storing a backup copy of the database to a selected location

Page 34 of 50
MAN Diesel & Turbo

5.5.2 Restore Database

To restore a previously backed-up database, follow the steps in Figure 25, below:

2 Select

4 Select database

5 Click

Click 3

1 Select

Figure 25: Replacing the current database with another

Warning: Restoring a database will cause the currently active database to be overwritten. All data and
measurements in the current database will be lost.

Page 35 of 50
MAN Diesel & Turbo

5.6 Printing Stored Measurements

Graphs, tables, and engine set-up information from stored measurements can be printed in two ways:

 Print View
 Print Report

5.6.1 Print View

A selected graph or table from a stored measurement is printed on a single page together with
engine performance information.

Follow the steps in Figure 26 to print a specific graph or table.

4 Click

2 Select measurement
3 Select a view

1 Select

Figure 26: Printing a selected graph or table from a stored measurement

Page 36 of 50
MAN Diesel & Turbo

5.6.2 Print Report

All graphs and tables of the selected measurement are printed in a multi-page report.

Follow the steps in Figure 27 to print a report for a selected measurement.

3 Click

2 Select measurement

4 Select items

1 Select
5 Click

Figure 27: Printing a report from a selected measurement

Page 37 of 50
MAN Diesel & Turbo

6 Sensor Recalibration

On a new PMI Auto-tuning installation, the Online sensors are calibrated when the system is commissioned,
while the Reference sensor has been calibrated by the sensor manufacturer prior to installation. The
Reference sensor is a certified, traceable calibrated sensor which is accompanied by a calibration
certificate. Both types of sensors must be recalibrated at different intervals. In service, the Online sensors
must be calibrated at least every 12 months according to the IMO - NOx Technical Code. However, it is
recommended that calibration is performed more often, e.g. every 3 or 6 months. See the Maintenance
menu for information on the last calibration date (section 5.4).

The calibration certificate included with the Reference sensor has a maximum validity of 5 years. However,
once the sensor is brought into use, the calibration certificate will expire after 2 years or at the end of the
certificate's maximum duration, whichever comes first. Once the certificate has expired, the sensor must be
recalibrated.

The Reference sensor must be calibrated at an approved and accredited institute. Calibration must be
performed according to specifications given by the manufacturer.

6.1 How to Calibrate the Online Sensors

The wizard, "Calibrate the Online Sensors" is used for calibrating the Online sensors to the Reference
sensor. Calibration factors are calculated for each Online sensor by comparing two simultaneous
measurements, one from the Online sensor and the other from the Reference sensor. When stepping
through the wizard, you will be asked to inspect the pressure measurements just taken and decide to
accept or reject them.

a. Start the wizard

To start the wizard, follow the steps in Figure 28. Read the welcome text and click “Next >” after the
system is finished initialising.

Page 38 of 50
MAN Diesel & Turbo

2 Select
3

1 Select

Figure 28: Accessing the wizard for calibrating the Online sensors.

b. Follow the wizard

Perform measurements

In the next window, the system is waiting to receive measurements. Perform measurements using
the PMI Calibration Box by following the steps given in Figure 29.

Page 39 of 50
MAN Diesel & Turbo

1 Attach

Indicator valve

2 Open

3 Verify green

5 Wait for Results

4 Press ’OK’

PMI Calibration Box

Figure 29: Sequence of steps used for performing a manual measurement

Steps (see Figure 29):

1) Attach Reference sensor to indicator valve on cylinder.

2) Open indicator valve.

Note: If this is the first cylinder being measured, make sure the sensor has reached
working temperature by keeping the indicator valve open for one minute before
proceeding to the next step.

3) Verify that ‘Ready’ green lamp is on – not flashing. A steady light indicates ready for
measurement.
4) Press “OK” button to start a measurement. The flashing ‘Ready’ lamp indicates the
system is measuring.
5) Wait to receive pressure curve.

Notes:
 If a measurement is not successful, the red ‘Error’ indicator lamp on the PMI
Calibration Box will turn on. Check the Event Log on the PC screen for additional
information and instructions.

Page 40 of 50
MAN Diesel & Turbo

 The system records pressure measurements from the Online sensors

simultaneously with measurements from the Reference sensor.

Close the indicator valve when the measurement appears on the screen. Then move to the next
cylinder. Repeat the previous steps until all cylinders have been measured.

Validate measurements

When all measurements have been completed, click “Next >”. In the following window (Figure 30), all
measurements must be validated:

 Make a visual inspection of the pressure curves received from each cylinder. Check that the
pressure curve from the Online sensor approximately follows and has the same form as the
pressure curve from the Reference sensor.

 Check the Gain Factors table. Compare the gain factors calculated for each cylinder. The values
should approximately be the same. If a gain factor deviates significantly from the other
cylinders, the measurement should be rejected.

Note: An indicator valve that has not been fully opened or is blocked by deposits will cause a
large deviation between the Online sensor and Reference sensor. In this case, reject the
measurement, correct the problem, and re-measure the cylinder pressure.

‘Accept’ or ‘Reject’ a measurement. If a measurement is rejected, click the ‘Previous’ button and repeat
the measurement of the cylinder in question. Click ‘Next’ when all measurements have been validated.

Page 41 of 50
MAN Diesel & Turbo

Figure 30: Inspection of cylinder 1 pressure curves from both the Online and Reference sensors.

Save measurements

Click “Finish” to store the values in the database. You have now completed the Online Sensor Calibration
wizard. The status icon in the Tools menu will change from red to blue, and a date will be added
indicating when the wizard was completed, Figure 31

Figure 31: Status change after completing Online sensor calibration

Page 42 of 50
MAN Diesel & Turbo

7 Appendix

7.1 PMI Calibration Box Description

1 2

4 3

7 6

8 5

9 10

Figure 32: PMI Calibration Box used for PMI Auto-tuning systems based on PMI DAU-11

Page 43 of 50
MAN Diesel & Turbo

Front Panel

Button or
Number Function
Light
1 [Ready] light  On: The PMI Auto-tuning system is ready to make a measurement and
waiting for a user action.

 Off: The device is idle.

 Blinking: A pressure measurement is being processed and the user must

wait.
2 [Error] light  Off: The device is functioning without error.

 On: An error has occurred. See the LCD display.

3 LCD display Shows status information, user instructions, and error messages.
4 [F1] button Selects the Info menu which displays measurement status and user instructions.
5 [F2] button Selects the Test menu for testing if the LCD display and all LED lights are
operational.
6 [F3] button Selects the About menu. Displays calibration box and sensor information. Press
the button repeatedly to scroll the menu.
7 [OK] button  Starts a pressure measurement in a wizard session

 Acknowledges and clears an error condition if it is clearable.

8 [Power] light Indicates that the device is on. The PMI Calibration Box must be connected to
the Calibration Junction Box to receive power from the PMI-DAU.

Connections

Number Description

9 Connection to Reference sensor

10 Connection for cable leading to Calibration Junction Box

Note: This PMI Calibration Box automatically reads the sensitivity or gain of the Reference sensor. This
data is read online once the Reference sensor is connected to the PMI Calibration Box. Therefore, unlike
earlier systems, the user does not need to key in this information.

Page 44 of 50
MAN Diesel & Turbo

7.2 Engine Shaft Power Estimation

The shaft power is estimated using a Power Map, which has been configured specifically for each engine
during shop test. While commissioning the engine, the Power Map is automatically generated by the ECT
tool, using online pressure measurements from PMI Auto-tuning in combination with the load indication of
the Water Brake. The Power Map accounts for and sums all contributing factors, such as mechanical losses,
sensor accuracy, and effects of indicator pipe geometry, into a single relationship between pi and pe.
Therefore, it is NOT possible to use the Power Map to calculate the engine's mechanical efficiency or isolate
factors contributing to measuring inaccuracies. Using a shaft power estimation map, a more accurate
estimate of the effective power is obtained compared to the traditional constant mechanical friction loss
model.

How does PMI Auto-tuning estimate shaft power using a Power Map?

PMI Auto-tuning calculates the indicated pressure from pressure measurements received from the Online
sensors. Using the Power Map, each value of pi is mapped to its equivalent pe. Interpolation is used to find a
value between key measuring points.

pe
Effective pressure

Indicated pressure pi
Figure 33: Estimating pe using the Power Map

How does PMI Auto-tuning estimate shaft power when no Power Map is available?

If a Power Map has not been configured, PMI Auto-tuning uses the Constant Mechanical Friction Loss
method, which is the traditional method used earlier and described in the instruction books. This method
provides a less accurate estimation of the engine shaft power.

Page 45 of 50
MAN Diesel & Turbo

Constant Mechanical Friction Loss

This method has been traditionally used for estimating the effective pressure and effective power. It is
based on the assumption that losses in the system are constant throughout the engine’s operating range
(see engine instruction manuals for more information).

= –

ℎ ,

∶ [ ]

∶ [ ]

∶ ( 1 )

This method is now replaced by the Shaft Power Estimation Map and only used when no Power Map data is
available.

Page 46 of 50
MAN Diesel & Turbo

7.3 PMI Status Messages

Status messages are displayed to the user in the status bar, see Figure 34

Status messages

Figure 34: Example of a status message displayed in the status bar.

The table below displays a list of these messages and a brief description.

Page 47 of 50
MAN Diesel & Turbo
Status Bar Message
Waiting for data
No IP address specified
No connection to the PMI-DAU
PMI-DAU blocked (NW)
PMI-DAU rejected
Incompatible DAU connected.
PMI restart required in order to
connect another unit
Fatal PMI-DAU error
Initialising...
Uploading PMI-DAU firmware...
Engine stopped
Direction change
Trigger error
No online sensor calibration
No TDC calibration
Reversing
Signal error, p(scav)
Signal error, Online sensor
Saving data...
Description
The system is waiting to receive data from the PMI-DAU
The IP address of the PMI-DAU is not known. Please specify the IP
address using the PMI Configuration Editor.
The PMI-DAU is unreachable over the network. Please check the unit
and its network connection.
An attempt to access the PMI-DAU has been blocked because another
application currently has access to the device.
PMI Auto-tuning stores the serial number of the last PMI-DAU that was
used. This message appears during start-up if PMI detects a PMI-DAU
with a serial number that is different from the unit previously used. The
user will be asked to confirm that he wishes to use the new unit.
PMI Auto-tuning has detected a DAU with a part no. that is
incompatible for use with the current system. To continue, the user
must restart PMI in order to connect to another unit
PMI Auto-tuning has encountered an unrecoverable problem while
initializing the connection to the PMI-DAU. No further attempts to
connect to the unit will be made.
Startup sequence and checks are in progress.
PMI is uploading the program code to the PMI-DAU hardware.
The trigger system has detected that the engine is stopped. (Trigger
pulse time-out.)
The trigger system has detected a change in running direction.
Trigger count error – too many trigger pulses per revolution. The
Trigger system may be defective or the TDC signal is missing.
Calibration measurements have not been performed on the online
sensors.
TDC calibration measurements have not been performed.
The engine is running in the reverse direction.
A sensor error has occurred. This occurs when the signal exceeds its
maximum (20.5 mA) and minimum (3.5 mA) threshold limits. E.g., when
the sensor wire is disconnected, this message will be displayed because
the current signal falls to 0 mA, which is below the minimum threshold
limit.
A sensor error has occurred. This occurs when the signal exceeds its
maximum (20.5 mA) and minimum (3.5 mA) threshold limits. E.g., when
the sensor wire is disconnected, this message will be displayed because
the current signal falls to 0 mA, which is below the minimum threshold
limit.
Saving of measurements to the PMI database is in progress.
Page 48 of 50
MAN Diesel & Turbo

7.4 Technical Data

7.4.1 Pressure Sensors

Reference Sensor (Type 6013CAQ03SF, source: Kistler)

Pressure range 0 … 250 bar

Overload 400 bar
Sensitivity ~-22 pC/bar
Linearity < ± 0.4 %FSO
Shock acceleration (max) 2000 g
Operating temperature range
Front part of sensor -50...350 °C
Hex-nut to connector -50...150 °C
Electronics in plug -50...90 °C
Sensitivity variation
200 + 150/-177°C ≤ ± 2.5 %
200 ± 50°C ≤±1%
Output impedance <100 Ω
Tightening torque 15 N·m
Weight 160g
Plug type Fischer 103

Online Sensor (Type 6613CQ13, source: Kistler)

Pressure range 0 … 250 bar

Overload 400 bar
Sensitivity ~-22 pC/bar
Linearity < ± 0.4 %FSO
Shock acceleration (max) 2000 g
Temperature range (sensor at -50 … 350 °C
mounting location)
Sensitivity variation
200 + 150/-177°C ≤ ± 2.5 %
200 ± 50°C ≤±1%
Insulation resistance at 20 °C > 1013 Ω
Mounting torque 15 N·m

Page 49 of 50
MAN Diesel & Turbo

Online Sensor (Type PFPL 203, source: ABB)

Sensor diameter 78 mm
Sensor height 126 mm
Thread M30*2
Weight (excluding indicator valve) 2.7 kg
Weight (including indicator valve) 3.2 kg
Power consumption 8.5 W
Degree of protection IP 65
Calibrated measuring range 0 - 250 bar
Max. intermittent pressure that has no 300 bar < 1 minute
deteriorating effect on the measuring
accuracy
Max. static pressure that has no 700 bar
deteriorating effect on the measuring
accuracy
Max. ambient temperature of 200°C
Transducer cable
Transducer cable length 4m
Combined errors (zero drift, sensitivity < ±0.5% of FS
drift, linearity deviation and hysteresis)

Page 50 of 50