Pmi Set

Installation
PMI
Off-line PMI System

Pressure Analyser
1142959 - 6
Contents
Installation Guide
PMI System
(Off-line)
Pressure Analyser
Version 2.0
MAN B&W Diesel A/S February 2000 1142959 - 6.2
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About this Guide
This Installation Guide applies to MAN B&W Diesel's Off-line PMI
System. It provides installation and commissioning personnel with
technical advice and instructions on installing, adjusting and checking the
system to make it ready for use by the technical personnel responsible for
the daily operation of the system.
For instructions on mounting and connecting a crankshaft pickup for
triggering the system, consult the separate Mounting Guide belonging to
the particular pickup which is to be used with the system.
For guidance on the use of the system for cylinder pressure measurements
on diesel engines, a common Users Guide is provided with the system.
Copyright 1999, MAN B&W Diesel

All rights reserved. No part of this publication may be reproduced or distributed
in any form or by any means, without prior consent in writing from MAN B&W
Diesel A/S.
1142959 - 6.2 February 2000 MAN B&W Diesel A/S
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Conditions of Licence
The supply, distribution and use of the PMI System and Data media, including
System Documentation, are subject to your acceptance of the Standard
Conditions of Licence which are supplied in the Software Package containing the
PMI System.
Taking the PMI System in use will indicate your acceptance of these conditions.
Trademarks
Windows is a trademark of the Microsoft Corporation, U.S.A.
MAN B&W Diesel A/S February 2000 1142959 - 6.2
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Table of Contents
1. Before You Begin

1.1 About this Guide ......................................................................................1 - 2
General Overview ....................................................................................1 - 2
PMI 'On-line Help' ...................................................................................1 - 3
Text Conventions .....................................................................................1 - 3
1.2 The Basic System .....................................................................................1 - 3
2. Hardware Installation
2.1 General .....................................................................................................2 - 2
2.2 Intermediate/Freq. Divider & Junction Boxes .........................................2 - 4
2.3 Converter Box ..........................................................................................2 - 5
2.4 Cable and Power Checks ..........................................................................2 - 6
2.5 Engine Address & Pickup TDC Checks ..................................................2 - 9
3. Commissioning the System

3.1 Installing the PMI Software .....................................................................3 - 2
3.2 Checking Engine Registration ................................................................3 - 2
3.3 Setting Up Communication ......................................................................3 - 5
MAN B&W Diesel A/S Off-line PMI System

1142959 - 6.2 Installation Guide 0-1
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Table of Contents
3.4 Trigger and TDC Test ..............................................................................3 - 8

3.5 System Default Measurements ...............................................................3 - 10
'0-Diagram' Measurements .....................................................................3 - 10
'E-Load' Measurements ..........................................................................3 - 12
3.6 Checking & Editing Default Measurements ..........................................3 - 12
3.7 Technical Assistance ..............................................................................3 - 18
Index
Off-line PMI System MAN B&W Diesel A/S

0-2 Installation Guide 1142959 - 6.2
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Chapter 1
Before You Begin
Welcome to MAN B&W Diesel's, Off-line PMI System. It is designed to

provide engineers and service staff on board ship and at power plants with
a computerised tool for cylinder pressure measurements and analysis on
MAN B&W two and four stroke diesel engines.
It consists of a pressure transducer, a PMI Controller and a trigger system
with crankshaft pickup which can be operated using an IBM compatible
PC on which the PMI System software is installed. The system is supplied
with the necessary hardware and software, and is designed to automati-
cally calculate, display and log measurement results.
In this Chapter
About this Guide .......................... 1 - 2 Text Conventions ............................ 1 - 3
General Overview .......................... 1 - 2 The Basic System ......................... 1 - 3
PMI 'On-line Help' ........................ 1 - 3

1142959 - 6.2 Installation Guide 1- 1
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Chapter 1 Before You Begin
About this Guide
1.1 About this Guide
1.1.1 General Overview

This Installation Guide provides information about the initial preparations
and procedures necessary for installing the hardware and software of the
PMI System on board ship and at power plants, as well as for commission-
ing the system.
The guide includes the following chapters:
Chapter 1 Before You Begin: This is the chapter which you are now
reading. It provides brief details about the contents of this
Guide and how to obtain on-line help with the Application
Software of the system. In addition, a short description of
the PMI System and its main components is included, ex-
plaining what you need to know about the system before
installing it.
Chapter 2 Hardware Installation: Provides instructions and advice
on how to mount, connect and adjust the hardware of the
PMI System. For information about the pickup device
which is to used for triggering the system, consult the sep-
arate Mounting Guide for the device.
Chapter 3 Commissioning the System: Explains how to install the
PMI software on your PC and start the system. Also, de-
tails are given about how to make default measurements
for setting up the PMI System.
Wiring diagrams and drawings of the system hardware are supplied in a
separate folder which is included with this and the other documentation
provided.
For information and instructions about operation and use of the system for
cylinder pressure measurements, please consult the separate User's Guide
which is provided.

1- 2 Installation Guide 1142959 - 6.2
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The Basic System
1.1.2 PMI 'On-line Help'

To help you in hands on use of the PMI System, its application software
includes on-line help information. This is available directly on your PC
whenever using it together with the PMI System. It is activated by pressing
the function key F1 on the keyboard.
1.1.3 Text Conventions
Settings & Values:

The values and settings shown in the displays and stated in accompanying
text throughout the guide, are included as examples only.
Menus & Menu Commands:

References to specific commands that are given in menus and dialogue
boxes are indicated in single quotes, e.g. 'Open Engine' in the 'File' menu.
Commands depicted with a leader, i.e. 'Options ...', open a selection dia-
logue which offer a number of options to choose from, while those without
a leader, i.e. 'Print', immediately initiate the particular action designated.
1.2 The Basic System

A schematic of the Off-line PMI System is shown in Fig. 1-1.
The off-line version of the system employs a high-performance piezo-elec-
tric transducer of well proven design which is mounted on the cylinder
head indicator cock from which the cylinder pressure is measured.
To obtain a pressure indication which accurately describes the change in
cylinder pressure throughout each work cycle of an engine, the pressure
detected by the transducer must be synchronised with the motion of the
engine. For this purpose the PMI System is designed to be used with dif-
ferent types of crankshaft pickup, for example:

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The Basic System
PMI Controller Pressure Transducer
Junction Box
Engine Control
Room
Power Supply
Converter Box
Personal Computer
with PMI System
Application Software
LED
Indicator
Intermediate or
Frequency Divider
Box
Crankshaft Pickup
mounted at free end
Two-Stroke
of crankshaft
Diesel Engine
Fig. 1-1. Schematic of the Off-line PMI System (not to scale)
Angle Encoder: A sealed unit containing an optically encoded disc,

which is fastened to a free end of the crankshaft via a special flexible
coupling.
LE-Pickup: A pair of Light Emitting Sensors which detect the light
reflected from a continuous strip of zebra tape bonded on the drive
shaft of the engine.
PD-Pickup: A pair of Proximity Detectors which are based on induc-
tive pickups. They detect the rotation of a TDC marker and the individ-

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The Basic System
ual teeth of a gear wheel or specially designed trigger ring at the aft of
the crankshaft.
All types of pickup produce a train of electrical pulses which are used to
detect the relative position of the crankshaft. In addition, they produce a
separate pulse which is used to synchronise the PMI System with the TDC
position of Cylinder No. 1.
Pickup Engine Type Mounting Maintenance

& Layout
Angle Main & Aux. Free end of Crankshaft Sealed unit requiring
Encoder Engines via special flexible little or no
without PTO coupling supplied maintenance
LE-Pickup Main & Aux. Zebra tape bonded on Zebra tape must
& Engines with or free section of engine occasionally be
Zebra Tape without PTO drive shaft cleaned
PD-Pickup Main & Aux. Operates from gear wheel Immune to most
Engines with or or specially designed disturbances
without PTO trigger ring on engine
Table 1-1. Crankshaft Pickups for use with the PMI System
As indicated in Table 1-1 the choice of appropriate crankshaft pickup and

its connection with the PMI System (see Fig. 1-2), depends on the engine
layout.
With the Angle Encoder a precise number of true crank angle pulses are
generated (e.g. 1024) per revolution of the crankshaft, while with the other
sensors the number of pulses depends on the diameter of the drive shaft or
the number of teeth on the gear wheel or trigger ring on the engine.
The crankshaft pickup pulses from the engine are first fed to either an
Intermediate Box or Frequency Divider and then on to a Junction Box.
From there they are relayed to the portable PMI Controller which is
attached to the pressure transducer and serves as the system's remote nerve
centre for controlling measurements.

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The Basic System
To Next Engine
Engine Room Junction Box
Engine No. 3
24V DC Gear Wheel or

Trigger Ring
Divider Box PD-Pickup

Control Room Box
Junction Box
Engine No. 2
Personal Computer
with PMI System 24V DC
LE-Pickup Zebra Tape
Box on Drive Shaft
Converter Intermediate
Box Box
Junction Box
PMI Pressure
Controller Transducer
Engine No. 1
Angle Encoder
24V DC plus
flexible coupling
Free End
Intermediate of
Box Crankshaft
Fig. 1-2. Connection of PMI System with an Angle Encoder, Light-emitting and/or
Proximity Pickups

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The Basic System
All of the equipment is powered by an external 24 V DC source and except

for the pressure transducer and portable PMI Controller, are mounted as a
permanent fixture in situ with the engine.
For subsequent calculation, display and storage of the data using the PC,
the software supplied with the PMI System must be installed.

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Chapter 2
Hardware Installation
This chapter explains how to mount, connect and adjust the hardware of
the PMI System.
For information about mounting the crankshaft pickup which is to be used
for triggering the system, consult the separate Mounting Guide which is
supplied with the device.
In this Chapter
General ......................................... 2 - 2 Cable and Power Checks ............. 2 - 6
Intermediate/Freq. Divider Engine Address
& Junction Boxes ......................... 2 - 4 & Pickup TDC Checks ............... 2 - 9
Converter Box .............................. 2 - 5

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Chapter 2 Hardware Installation
General
2.1 General
The connection of the hardware used by the PMI System, including a
Crankshaft Pickup, is illustrated in Fig. 2-1.
To Junction Box
of Next Engine
Control Room
(PMI - 7)*
Junction Box
PMI
Controller
(PMI - 6)
Personal Computer Pressure
with PMI System 24V DC Transducer
(PMI - 1)* Crankshaft Pickup
(PMI - 3*(or 9)*
See separate
Converter Intermediate (or Mounting Guide
Box Freq. Divider)
Box (PMI - 2 (or 8)
(PMI. 4)
(PMI - 5)
* Item not included
Fig. 2-1. Connection of PMI System with an Angle Encoder
To permit easy identification of the appropriate cables used for connecting

the equipment, the cables are numbered from PMI-1 through to PMI- 9 as
indicated above. A brief explanation of each of these cables is given below:
PMI - 1: 24V DC Power Cable to Junction Box:

Item not included. Can be made using the 1 x 2 x 0.75 mm2
screened cable in Table 2-1.
PMI - 2 / 8: Pickup Cable to Intermediate/Freq. Divider Box:
1.5 m long fixed screened cable supplied with the pickup.

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General
PMI - 3 / 9: Intermediate/Freq. Divider Box Cable to Junction Box:

Item not included. Can be made using the
4 x (2+1) x 0.5 mm2 multi screened cable in Table 2-1.
PMI - 4: Converter Box Cable to PC:
1.5 m long, fixed cable supplied with Converter. Has Sub-D9
female plug for connecting to free Communication Port on PC.
PMI - 5: Converter Box Cable to Junction Box:
Item not included. Can be made using the 4 x 2 x 0.5 mm2
screened cable in Table 2-1. Max. overall length of PMI - 5
including PMI - 7 must not exceed 1200 m for RS422 opera-
tion.
PMI - 6: PMI Controller Box Cable to Junction Box:
Fixed cable supplied with PMI Controller. Has multipin con-
nector for connecting Junction Box. Either 8 m or 15 m long
cable supplied, depending on engine size.
PMI - 7: Junction Box Cable:
Item not included. Is used for interconnecting Junction Boxes
in a multiple engine installations. Can be made using the
4 x 2 x 0.5 mm2 screened cable in Table 2-1. Max. overall
length of PMI - 5 including PMI - 7 must not exceed 1200 m
for RS422 operation.
The cable connections are shown in the wiring diagrams provided with the
PMI System.
Important: To ensure reliable operation of the PMI System its commu-

nication and power cables must not be routed directly alongside other
power cables. If pmi cables have to be routed over power cables then
they should cross at 90.
Cables not included with the PMI System, can be ordered either from
MAN B&W Diesel A/S or from alternative suppliers. It is important that
the equivalent halogen free, flame retarded, polyolefine HF cables are used
with the same cross section and number of screened conductors as indi-
cated in Table 2-1.

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Intermediate/Freq. Divider & Junction Boxes
Caution: To prevent damage, wait until section 2.4 in this chapter be-
fore applying power to the system.
Electrical Data:
MAN B&W Part No.: 1892023-4 1892019-9 1848035-3
Insulation: Halogen free, flame retardant polyolefine
No. of cores 1 x 2 x 0.75 mm2 4 x 2 x 0.5 mm2 4 x (2 + 1) x 0.5 mm2+0.5 mm2

& cross section:
Outer diameter: 8.5 mm 11.5 mm 10.5 mm
Bending radius: 6 x 8.5 mm 6 x 11.5 mm 10 x 10.5 mm
Weight: 110 kg/km 175 kg/km 135 kg/km
Temperature range: -15 C to +85 C -15 C to +85 C -15 C to +75 C
Loop resistance of pair: 52 /km max at 20 C max 80 /km max at 20 C max 80 /km max at 20 C max
Pair capacitance: 100 nF/km at 800 Hz 90 nF/km at 800 Hz 80 nF/km at 800 Hz
Loop inductance of pair: 0.5 mH/km 0.6 mH/km 0.7 mH/km
Insulation resistance: 240 M x km at 20 C 245 M x km at 20 C 2 G x km at 20 C
Table 2-1. PMI System Screened Cables
2.2 Intermediate/Freq. Divider & Junction Boxes

The Junction Box is to be mounted on the indicator side on the top section
of the engine with the Intermediate Box or Freq. Divider Box close by the
Crankshaft Pickup (1,4 m max.). Make sure that the Junction Box is
located not more than 7 metres or 14 metres (depends on length of PMI
Controller cable supplied) away from the furthest cylinder cock, as other-
wise it will be out of reach of the Pressure Transducer.
The diverse boxes have two holes for bolting them to a flat, vibration-free
surface. The Junction Box is to be bolted on a raised support with it con-

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Converter Box
nectors protruding over one the side of the support (see Fig. 2-2), so as to
allow room for fastening the multipin connector of the PMI Controller.
42
6 238 6
14
52
14
23
Mounting Holes Junction Box 35
2 x 5 for
M4 Screws 52
6 113 6
Mounting Holes
14
2 x 5 for
M4 Screws
52
Intermediate, Freq.
14 Divider or Converter
Box
Fig. 2-2. Location of the mounting holes in the PMI Junction Box, Intermediate Box,
Freq. Divider Box and Converter Box
2.3 Converter Box

After connecting the Crankshaft Pickup, Intermediate Box and Junction
Box, etc., the output of the Junction Box should be coupled to the Con-
verter Box.
The Converter Box must be mounted close to the PC which is stationed
either in the engine control room or in some other convenient location. It is

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Cable and Power Checks
supplied with a 1,5 metre long integral cable (PMI - 4) with Sub-D9
female plug which should be fastened to one of the free communication
ports on the PC.
To PC
Com. Port
1 7
1
2
3
4
5
6
7
To
5 V DC Junction Box
Cable PMI - 4 Cable PMI - 5
Fig. 2-3. Layout of the PMI System's Converter Box. The 5V DC power
input is on terminals 5 and 6
For connecting the Converter Box to the Junction Box, the cable PMI - 5 is
used. This is shown in the wiring diagrams provided with the PMI System
and can be made up using the 4 x 2 x 0.5 mm2 screened cable recom-
mended in Table 2-1. The maximum overall length of the cable, including
the extension cables PMI - 7 if more than one Junction Box is to be
installed, must not exceed 1200 m for RS 422 operation.
2.4 Cable and Power Checks

Before applying power to the entire system the following power check and
power start up procedure should be carried out to reduce risk of damaging
the system:
1. Unplug all terminal blocks in the PMI boxes.

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2. Switch on the external 24 V power supply for the system.

3. Measure that there is 24 V (18 to 36 V acceptable) on the terminal
block for PMI - 1 and that the supply polarity on the terminals matches
that shown in the wiring diagram provided for PMI - 1.
Off
On
JP3
SW-1
JP3
JP1
JP2
LED-1 LED-2 LED-3
Extra Fuse
1 7 1 7 8 14 15 19
0.8 A Fuse
Fig. 2-4. PMI Junction Box - switch and jumper setting
4. Plug the PMI - 1 terminal block back in the Junction Box and check
that all three power indicator LEDs in the box are lit. See Fig. 2-4.
If one or more of the indicators fails to light, make the checks indicated
in Table 2-2 overleaf.
5. Check that the 5 V supply, communication and terminal block connec-
tions of cable PMI - 5 match the wiring diagram provided and have the
correct polarity.
6. Plug the terminal block for PMI - 5 back in the Junction Box and check
that there is 5 V on the PMI - 5 terminal block in the Converter Box
and that the polarity is correct.
7. Plug the terminal block for PMI - 5 back in the Converter Box and
check the status of the power indicator LEDs in the Junction Box.

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If one or more of the LEDs no longer lights, immediately unplug the

PMI - 5 terminal block and make the checks indicated in Table 2-2.
Junction Box
LED No.
24 V 15 V 5V Comments
1 2 3
Off Off Off Unscrew and check that the 0.8 A fuse in the Junction
Box is intact. An extra fuse is included in the box for
replacement.
Also check that the 24 V DC power input cable PMI - 1
is connected correctly, as indicated on the print board
in the box.
On Off On/Off 15 V power regulation is defective. Replace Junction

Box.
On On Off 5 V power regulation is defective. Replace Junction

Box.
On On On System is OK.
Table 2-2. Junction Box Supply and Cable Checks
8. Check that the 24 V supply, communication and terminal block con-

nections of cable PMI - 3 (or 9) match the wiring diagram provided
and have the correct polarity.
9. Plug the PMI - 3 (or 9) terminal block back in the Junction Box and
check that there is 24 V on the PMI - 3 (or 9) terminal block in the
Intermediate/Freq. Divider Box and that the polarity is correct.
10. Plug the terminal block for PMI - 3 (or 9) back in the Intermediate/
Freq. Divider Box and check the status of the power indicator LEDs in
the Junction Box.
If one or more of the LEDs no longer lights, immediately unplug the ter-
minal block and make the checks indicated in Table 2-2.

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Engine Address & Pickup TDC Checks
11. Check that the 24 V supply, communication and terminal block con-
nections for the Crankshaft Pickup Cable PMI - 2 (or 8) in the Interme-
diate/Freq. Divider Box match the wiring diagram provided and have
the correct polarity.
12. Plug the PMI - 2 (or 8) terminal block back in the Intermediate/Freq.
Divider Box and check the status of the power indicator LEDs in the
Junction Box.
If one or more of the LEDs no longer lights, immediately unplug the ter-
minal block and check it again, as it is likely that one or more of the con-
nections is incorrect.
With multi engine plants, repeat the above procedure for each set of
PMI boxes in the system.
2.5 Engine Address & Pickup TDC Checks

1. Open the Junction Box(es) and set the address switch and jumpers as
indicated in Fig. 2-4 and Table 2-3.
Note: Whereas JP 3 must always be set to 'On', the setting of JP 1

and JP 2 depends on the address switch setting given to the engine.
Multi Engine Plant

Single
1st. Main 2nd. Main Subsequent Last
Engine
Engine or 1st. Aux. Engines Engine
Junction Box Plant
Engine
Address Switch '0' '0' '1' '2','3', '4', etc. 'X'
Jumper JP 1 & 2 'On' 'Off' 'Off' 'Off' 'On'
Jumper JP 3 'On' 'On' 'On' 'On' 'On'
Table 2-3. Junction Box Address switch and Jumper settings

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Engine Address & Pickup TDC Checks
2. Apply power to the Junction Box and engage the turning gear of the
engine until cylinder No. 1 is at TDC.
3. Check that the green indicator light is lit on the Intermediate Box. If
not lit, it is likely that the crankshaft pickup needs readjustment. See
Mounting Guide for the particular pickup.
With multi engine plants, repeat the above procedure to set the appropriate
address and synchronise the PMI System with the TDC of Cylinder No. 1
of each of other engines.

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Chapter 3
Commissioning the System
In this chapter it is explained how to install the PMI software on your PC,
start the entire system and check engine registration, communication and
triggering with the PMI Controller and Crankshaft Pickup. Also, details
are given about how to make default reference measurements.
In this Chapter
Installing the PMI Software ....... 3 - 2 0-Diagram' Measurements ........... 3 - 10
Checking Engine Registration ... 3 - 2 E-Load Measurements ................. 3 - 12
Setting Up Communication ........ 3 - 5 Checking & Editing
Trigger and TDC Test ................. 3 - 8 Default Measurements ............... 3 - 12
System Default Measurements . 3 - 10 Technical Assistance .................. 3 - 18

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Chapter 3 Commissioning the System
Installing the PMI Software
3.1 Installing the PMI Software

The PMI software is normally supplied on a CD, containing both the PMI
application program and engine specific data concerning your diesel
engine plant.
To install the PMI program and its data:
1. Insert the CD in your CD-ROM drive.
2. Open the 'Start' menu in the bottom left corner of the display and
choose 'Run'.
3. Type d:\setup.exe. (If your CD-ROM Drive is not letter D, type the
appropriate letter instead.)
4. Select OK.
5. Follow the instructions on screen.
With WIN NT 3.5.1, WIN95 or later, the installation software will auto-
matically install a 'PMI System' icon on the windows desktop for opening
the program. In addition, it will be listed in the programs menu and sub
folder contained in the 'Start' menu.
3.2 Checking Engine Registration

1. Click on the PMI System icon on the windows desktop or on the corre-
PMI System
sponding program listed in the Program menu on your PC.
The main window of the PMI System should now appear as indicated
in Fig. 3-1 overleaf.
2. Select 'Open Engine' contained in the 'File' menu on the far left of the
display.
The 'Open Engine' dialogue shown in Fig. 3-2 will now appear which
lists the individual names and types of engines in your plant that are reg-
istered for use with the PMI System.

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Checking Engine Registration
Title bar
Menu bar
Toolbar
Status line
Fig. 3-1. The primary elements of the PMI System's main window
Fig. 3-2. The 'Open Engine' dialogue

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Checking Engine Registration
Note: If the name of the engine to be checked is not listed, then

select an engine type that matches the particular engine. Later the
name of the engine can be edited.
3. Click on the name of the engine or type of engine on which communi-
cation is to be checked and activate the 'Edit' tool button at the top of
the dialogue. Alternatively, right-click anywhere in the dialogue to
open the quick-access menu, and then select 'Edit'.
Fig. 3-3. The 'Edit Engine Data Torsion' dialogue
4. Select the 'Torsion' tab of the 'Edit Engine' dialogue which is opened
(see Fig. 3-3) and check that the address number indicated near the top
right-hand corner of the dialogue matches the SW1 address switch set-
ting of the particular engine. See section 2.5 for recommended settings.
If they do not match, change the dialogue's address number accordingly.
Note: Only entries which are not dimmed may edited.
5. Set the 'Trigger System' section of the dialogue to correspond with the
location (i.e. Fore' or 'Aft') of the Crankshaft Pickup on the engine.

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Setting Up Communication
If an LE-Pickup is installed at the drive end (normally aft) of the crank-

shaft, then the following additional data must be keyed in:
The diameter of the drive shaft. Units: metre.
The distance of the triggering system to the turning wheel. Units:
metre.
When another type of pickup is used, both the 'Diameter ...' and 'Dis-
tance ....' should normally be left blank or set to 0.
6. Click the 'OK' button to store the settings chosen and return to the
'Open Engine' dialogue.
7. For multi engine plants, repeat steps 3 to 6 for the other engines listed
in the 'Open Engine' dialogue and then close the dialogue by clicking
on the 'Cancel' button.
8. Select 'Exit' in the 'File' menu and then switch off the PC and the 24 V
supply to the PMI System.
9. Next, fasten the standard plug of the Converter Box to a free communi-
cation port on the back of the PC and then switch the 24 V supply and
the PC back on again to make the system ready for the remainder of the
setup procedure given below.
3.3 Setting Up Communication

1. Check that all hardware has been mounted, connected and adjusted as
described in the previous sections of this and the preceding chapter.
2. Connect the Pressure Transducer to the PMI Controller Box. See
Fig. 3-4.
3. Fasten the multipole plug of the PMI Controller to the Junction Box on
the engine to be checked.
Caution: Always connect the Transducer to the PMI Controller
before connecting the Controller to the Junction Box. Connecting

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the Transducer while powering the Controller can damage the Con-
troller.
Power Start Cancel PMI

'On' Ready Error Transducer
Green Green Red

Indicator Button Button
Fig. 3-4. The top panel of the PMI Controller box.
4. Start the PMI Program on the PC and check that the name of the engine
PMI System is shown in the title bar of the main window.
If the name of another engine is shown instead, then select 'Open En-
gine' in the 'File' menu and then choose the correct engine in the 'Open
Engine' dialogue.
Fig. 3-5. The 'Tools' menu 'Options' dialogue
5. Select Options' in the 'Tools' menu.

This opens the dialogue shown in Fig. 3-5, which should be set as fol-
lows:

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Communication Port: 1, 2, 3 or 4, depending on which port of the PC

is coupled to the Converter Box of the PMI
System.
Calibration Factors: 'Transducer Value' The transducer sensitiv-

ity at 20 - 23 C and 250 bar, as specified on
the calibration chart supplied with the trans-
ducer.
'System Value' A fixed value of 0.95 match-

ing the system amplification of the Off-line
PMI System.
Measuring Settings: Averaging Period' Sets the number of work

cycles over which the measurement is aver-
aged. Should normally be set for averaging
over 10 work cycles.
'Single Trig.' Normal setting for triggering

with an Angle Encoder.
'Double Trig.' Normal setting for other pick-

ups.
Click the 'OK' button at the bottom of the dialogue to save the settings
chosen and exit the dialogue.
6. Select 'Communication - On' in the 'Tools' menu.
After a short wait the PMI System will respond by opening the 'Trigger
and TDC Test' dialogue explained in section 3.4 below.
If a No connection ........ status message is flagged instead, then it will

be necessary to check the communication port setting or the cable con-
nections to the Junction Box. See section 3.3 and 2.3 respectively.
Similarly, if the status message Missing trigger pulses is obtained and

the engine is running, check the cable connections to the Crankshaft
Pickup and Intermediate or Freq. Divider Box. See section 2.2.

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Trigger and TDC Test
3.4 Trigger and TDC Test
Fig. 3-6. The 'Trigger and TDC Test' dialogue
When communication is achieved for the first time, the PMI System will
display the 'Trigger and TDC Test' dialogue shown in Fig. 3-6.
The use of the 'Trigger and TDC Test' dialogue is as follows:
No. of pulses detected: This provides an actual count of the number of
crank angle pulses detected per work cycle.
When triggering is stable only one count will be displayed. To store the
count for future trigger tests, click the 'Save' button. You can then pro-
ceed with the reference measurements described in section 3.5.
If triggering is unstable, then the latest five counts will be listed. See be-
low to help determine the cause.
No. of pulses stored for engine: The crank angle pulse count. Zero is
indicated for the first test.
Pulse deviation (min./max): Gives the minimum and maximum per-
centage deviation of the crank angle pulses relative to their mean repe-
tition time.
Large deviations indicate irregular rotation or defective operation of the
pickup.
To obtain a graphic view of the trigger pulse deviation, click on the 'Dis-
play' button in the dialogue. See Fig. 3-7.

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Trigger and TDC Test
Fig. 3-7. The 'Trigger Deviation' dialogue
TDC pulse relative to trigger pulse: Gives the percentage overlap and
non overlap of the crank angle pulse that is closest to the trailing edge
of the TDC pulse (see Fig. 3-8).
TDC Pulse
Crank Angle Pulses
Fig. 3-8. Timing of the TDC and Crank Angle Pulses
If either of the readings is less than 15 % or greater than 85 %, then the

pickup is not correctly adjusted or is defective.

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System Default Measurements
Repeating the Test:

To repeat the Trigger Test, click on the 'Repeat' button in the dialogue.
Storing Test Count:

When a stable trigger pulse count is displayed, click on the 'Save' button
in the dialogue. This will store the pulse count for use in subsequent
trigger tests.
After storing a count, click on the 'Close' button to return to the main
window.
For multi engine plants, repeat section 3.3 and 3.4 to check communication
and triggering with the other engines.
3.5 System Default Measurements
3.5.1 '0-Diagram' Measurements

'0-Diagram' measurements are used to correct pressure measurements so
that they reflect the actual TDC of each of the respective cylinders of an
engine. In order to do this, a set of '0-Diagram' measurements must be
made at the time of installing the PMI System on an engine.
For main engines, reference measurements are to be made in calm weather
conditions and deep water. No rudder movements or change of ships
course are to be made during measurements.
The procedure for making '0-Diagram' measurements is as follows:
1. Run the engine at 60 to 75% load.
2. Start the PMI Program on the PC and check that the name of the engine
is shown in the title bar of the main window.
If not, open the appropriate engine by selecting 'Open Engine' in the
'File' menu and select it in the dialogue which is opened.

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System Default Measurements
3. Select 'Communication On' in the Tools menu.

The PMI Program will now check communication. At first the status
line will flag a red marker which shortly after should change to a green
marker showing that the system is ready.
Note: If the program continues to show a red marker, then it is
likely that the PMI Controller and Transducer have yet to be con-
nected to the engine. See next step.
4. If not already connected, connect the Pressure Transducer to the PMI
Controller and the multipole plug of the PMI Controller to the Junction
Box. See Fig. 2-1 and 3-4.
Caution: Always connect the Pressure Transducer to the PMI Con-
troller before connecting the Controller to the Junction Box. Con-
necting the Transducer while powering the Controller can damage
the Controller.
5. Set the fuel pump index to zero (or lift the fuel pump roller guide,
depending on the type of engine) to shut off the fuel oil to the particu-
lar cylinder to be measured and wait for approximately 20 seconds.
6. Mount the Pressure Transducer on the indicator cock of Cylinder No. 1
and open the indicator cock.
The system is ready for measurements when the green light on the PMI
Controller begins to repeatedly flash.
7. Press the green 'Start' button on the PMI Controller to start the meas-
urement.
The green light will then be extinguished for a period and then light
again when the measurement has been completed.
8. Immediately close the indicator cock when the measurement has been
completed and return the fuel pump index to its original setting (or
lower the fuel pump roller, depending on the type of engine).
9. Remove the Pressure Transducer from the indicator cock and mount it
on the indicator cock of the next cylinder to be measured.
! Warning: Always check that the indicator cock is closed
before removing the transducer. Failure to do this can result in

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Checking & Editing Default Measurements
release of extremely hot combustion gasses which can severely

injure personnel.
10. Repeat steps 5 to 9 until you have completed measurements on all cyl-
inders.
11. Return to the PC and stop measurements by pressing the Esc. key on
the keyboard or by selecting 'End Measurement' in the 'Tools' menu.
Alternatively, you can stop measurements by unscrewing the multipole
plug of the PMI Controller from the Junction Box. This is useful if you
want to make another set of measurements before returning to the PC.
Stopping measurements automatically stores them in the PMI System's
database.
The '0-Diagram' measurement file must be renamed and specifically

selected as default as described in section 3.6.
3.5.2 'E-Load' Measurements

Immediately after having prepared a set of '0-Diagram' measurements
another set of reference measurements must be made using the same pro-
cedure and load conditions as stated in section 3.5.1, but this time without
altering the fuel pump index of the cylinders.
With these reference measurements, all cylinders are employed to drive the
engine and therefore play an equal role in powering the engine and share
approximately the same load. In this case the measurements are termed 'E-
Load' measurements and are used to automatically compensate for tor-
sional deflections in the crankshaft.
3.6 Checking & Editing Default Measurements

To ensure that the 'O-Diagram' and 'E-Load' measurements are used for
correcting future pressure measurements on your engine, they must be
renamed and selected as default.

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To do this proceed as follows:

1. Select 'Open Measurement' in the 'File' menu and locate the set of '0-
Diagram' measurements in the dialogue which is opened.
New measurements are listed with the letter 'm', followed by the date
and time of storage, e.g. m990124_104307. See Fig. 3-9.
Fig. 3-9. The 'Open Measurement' dialogue as viewed with the 'List'
function
2. Select the measurement and then activate the 'Observations' button in

the toolbar of the dialogue or right-click in the dialogue.
The 'Observations...' command opens the dialogue shown in Fig. 3-10.
By clicking on the '+/-' symbol at the start of each cylinder heading you
can expand or contract a heading.
To examine an observation, click on its heading. Its pressure curve
is then displayed on the right-hand side of the dialogue.
3. Check that one observation is present for each cylinder and that their
pressure curves have the approximate shape and form as indicated in
Fig. 3-10 (or Fig. 3-11 for 'E-Load' measurements).
If no observations are listed for a cylinder or their curves appear to be
very distorted, then the measurement must be repeated..

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Fig. 3-10. The 'Edit Cylinder Observations' dialogue. The curve indi-
cated is typical of what can be expected for a 0-Diagram'
observation
Fig. 3-11. The 'Edit Cylinder Observations' dialogue. The curve

indicated is typical of what can be expected for a E-Load'
observation

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If more than one observation is available per cylinder, then delete those
which are not needed by selecting each of them in turn and pressing the
'Delete' button at the bottom of the 'Edit Cylinder Observations' dia-
logue.
4. When all curves look correct, click the 'Close' button to return to the
'Open Measurement' dialogue and then open the measurement by click-
ing the 'Open' button.
Fig. 3-12. A 'Calculated Values' scheme for a 'O-Diagram' reference

measurement on a four cylinder engine
5. Next select 'Calculated Values' in the 'View' menu and check that the
mean indicated pressure pi for each cylinder is negative. See Fig. 3-12.
Negative values signify that there is no combustion of fuel oil as is re-

quired for 'O-Diagram' measurements. You can proceed with step 6.
If the values are positive, then the most likely reasons are:
The fuel pump index has not been set to zero.
The index has been set to zero, but not enough time has elapsed
before the measurement was started, i.e. some fuel oil is still
present in the cylinder and has not had time to fully combust.
The index has been set to zero, but leaking fuel valves result in
combustion or heating of fuel oil in the cylinder.

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In each case the measurement must be repeated after correcting the most
likely cause of the problem.
6. Return to the 'Open Measurement' dialogue and then activate the 'Edit'
command in the toolbar of the dialogue.
This opens the 'Edit Measurement' dialogue shown in Fig. 3-13.
Fig. 3-13. The 'Edit Measurement' dialogue
7. Click in the measurement field of the 'Edit Measurement' dialogue and

rename the measurement to signify that it is a '0-Diagram' reference
measurement.
e.g. 0DIAG_70_990124_1043
where the first five characters indicate the type of file, the next 3 char-
acters indicate the engine load, the next seven characters indicate the
date and the last five characters indicate the time that the measurement
was stored.
8. Open the list-boxes immediately below the measurement field and
reset them so that they appear empty and do not refer to earlier '0-Dia-
gram' and 'E-Load' reference files.
9. Key in the appropriate value for the scavenge air pressure of the engine
in the 'p(scav):' data field and press the 'OK' button to close the 'Edit'
dialogue and save your changes to the reference measurements.

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Note: If no scavenge air pressure reading is available, then the pro-

gram itself will automatically estimate it. For this purpose the
'p(scav):' data field should be kept set at 0.00.
10. Inspect the 'E-Load' reference measurements and check and edit them
as outlined in steps 1 to 9.
Note: The check in step 5 concerns '0-Diagram' measurements
only, and for 'E-Load' measurements should be ignored.'
In this case it is suggested that 'E-Load' measurements be renamed as
follows:
ELOAD_70_990124_1055
11. Press 'OK' to close the 'Edit' dialogue and save your changes to the ref-
erence measurements.
12. Select 'Open Engine' in the 'File' menu and activate the 'Edit' function
in the toolbar of the dialogue.
This opens the 'Edit Engine Data' dialogue shown in Fig. 3-14.
Fig. 3-14. The 'Edit Engine Data General' dialogue

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Technical Assistance
13. Open the '0-Diagram' list-box near the bottom right-hand corner of the
'Edit Engine Data' dialogue and select the name of the '0-Diagram' ref-
erence measurement.
14. Open the 'E-Load' list-box and select the name of the 'E-Load' refer-
ence measurement.
15. Press the 'OK' button to exit both the 'Edit Engine Data' and 'Open
Engine' dialogues and store your new '0-Diagram' and 'E-Load' default
settings.
3.7 Technical Assistance

If you experience difficulties in installing or using the PMI System, then
check whether you can find an answer to the problem by following the
instructions and advice given in the corresponding sections of this guide
and in the separate User's Guide which is provided.
If you cannot find the answer, you are welcome to contact MAN B&W
Diesel A/S whose address and phone number are given on the back cover
of this Guide.
When you call by phone, you should have the PMI System documentation
at hand and be prepared to give the following information:
The name of the vessel or plant.
The version and build number of your PMI System software indicated
under 'About' in the 'Help' menu.
The operating system and type of hardware that you are using.
A brief account of what happened and what you were doing when the
problem occurred.
The exact wording of any messages that appeared on your screen.
Details about how you tried to solve the problem.

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Technical Assistance
When you mail us, we ask you to include the above information, plus any
relevant computer printouts which might be helpful.

Contents Return
Index
A J
Angle Encoder .................................... 1 - 4 Junction Box ...................................... 2 - 4
C M
Checks Mounting Guide
Cable & Power ................................. 2 - 6 Chapter Overview............................. 1 - 2
Com. Port ........................................ 3 - 7 Text Conventions ............................. 1 - 3
Communication ................................ 3 - 5
Mounting PMI Boxes .......................... 2 - 4
Default Measurements...................... 3 - 12
Engine Address................................. 2 - 9 O
Engine Registration ........................... 3 - 2 O-Diagram Measurements .................. 3 - 10
Measuring Settings ............................ 3 - 7 On-line Help ...................................... 1 - 3
TDC - Pickup Sync. ........................... 2 - 9 P
Transducer Calibration ....................... 3 - 7 PD-Pickup ......................................... 1-4
Trigger & TDC Test .......................... 3 - 8 PMI System
Converter Box .................................... 2 - 5 Basic System ................................... 1-3
Crankshaft Pickups .............................. 1 - 3 Cable & Power Checks ...................... 2-6
Angle Encoder .................................. 1 - 4
Mounting PMI Boxes ................ 2 - 4, 2-5
LE-Pickup ....................................... 1 - 4
On-line Help.................................... 1-3
PD-Pickup ....................................... 1 - 4
Screened Cables ............................... 2-4
D
System Connections .......................... 2-2
Default Measurements ........................ 3 - 10
E S
Editing Measurements ........................ 3 - 12 Screened Cables ................................. 2 - 4
E-Load Measurements ........................ 3 - 12 Setting Up Communication ................... 3 - 5
Engine Address Checks ........................ 2 - 9 Software Installation............................ 3 - 2
Engine Registration.............................. 3 - 2 T
F TDC - Pickup Sync. ............................ 2 - 9
Freq. Divider Box ................................ 2 - 4 Technical Assistance ......................... 3 - 18
I Transducer Calibration Factor ............... 3 - 7
Intermediate Box ................................. 2 - 4 Trigger and TDC Test .......................... 3 - 8

1142959 - 6.2 Installation Guide I-1
Contents Return

Pmi Set

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Installation

Off-line PMI System

MAN B&W Diesel A/S February 2000 1142959 - 6.2

Copyright 1999, MAN B&W Diesel

1142959 - 6.2 February 2000 MAN B&W Diesel A/S

MAN B&W Diesel A/S February 2000 1142959 - 6.2

1. Before You Begin

3. Commissioning the System

MAN B&W Diesel A/S Off-line PMI System

3.4 Trigger and TDC Test ..............................................................................3 - 8

Off-line PMI System MAN B&W Diesel A/S

Before You Begin

Welcome to MAN B&W Diesel's, Off-line PMI System. It is designed to

MAN B&W Diesel A/S Off-line PMI System

1.1 About this Guide

1.1.1 General Overview

Off-line PMI System MAN B&W Diesel A/S

1.1.2 PMI 'On-line Help'

1.1.3 Text Conventions

Settings & Values:

Menus & Menu Commands:

1.2 The Basic System

MAN B&W Diesel A/S Off-line PMI System

PMI Controller Pressure Transducer

Fig. 1-1. Schematic of the Off-line PMI System (not to scale)

Angle Encoder: A sealed unit containing an optically encoded disc,

Off-line PMI System MAN B&W Diesel A/S

Pickup Engine Type Mounting Maintenance

As indicated in Table 1-1 the choice of appropriate crankshaft pickup and

MAN B&W Diesel A/S Off-line PMI System

Engine Room Junction Box

24V DC Gear Wheel or

Divider Box PD-Pickup

Off-line PMI System MAN B&W Diesel A/S

All of the equipment is powered by an external 24 V DC source and except

MAN B&W Diesel A/S Off-line PMI System

MAN B&W Diesel A/S Off-line PMI System

* Item not included

Fig. 2-1. Connection of PMI System with an Angle Encoder

To permit easy identification of the appropriate cables used for connecting

PMI - 1: 24V DC Power Cable to Junction Box:

Off-line PMI System MAN B&W Diesel A/S

PMI - 3 / 9: Intermediate/Freq. Divider Box Cable to Junction Box:

Important: To ensure reliable operation of the PMI System its commu-

MAN B&W Diesel A/S Off-line PMI System

MAN B&W Part No.: 1892023-4 1892019-9 1848035-3

Insulation: Halogen free, flame retardant polyolefine

No. of cores 1 x 2 x 0.75 mm2 4 x 2 x 0.5 mm2 4 x (2 + 1) x 0.5 mm2+0.5 mm2

Outer diameter: 8.5 mm 11.5 mm 10.5 mm

Bending radius: 6 x 8.5 mm 6 x 11.5 mm 10 x 10.5 mm

Weight: 110 kg/km 175 kg/km 135 kg/km

Temperature range: -15 C to +85 C -15 C to +85 C -15 C to +75 C

Pair capacitance: 100 nF/km at 800 Hz 90 nF/km at 800 Hz 80 nF/km at 800 Hz

Loop inductance of pair: 0.5 mH/km 0.6 mH/km 0.7 mH/km

Insulation resistance: 240 M x km at 20 C 245 M x km at 20 C 2 G x km at 20 C

Table 2-1. PMI System Screened Cables

2.2 Intermediate/Freq. Divider & Junction Boxes

Off-line PMI System MAN B&W Diesel A/S

2.3 Converter Box

MAN B&W Diesel A/S Off-line PMI System

Cable PMI - 4 Cable PMI - 5

2.4 Cable and Power Checks

Off-line PMI System MAN B&W Diesel A/S