purposes only

For training

Engine Control System

MAN Diesel & Turbo Author Current topic  00.00.2012 < 1 >
purposes only
For training

Engine Control System

1) Control system:
- Multi Purpose Controller
- Control Network
- Main Operating Panel
- Local Operating Panel

2) Tacho system

3) Pneumatic Manoeuvring System

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 2 >
purposes only
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Control Systems

Bridge Ctr
System

Engine Ctr
System

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 3 >
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Engine Control System

MPC & Control Network

• The Multi Purpose Controllers are

identical hardware wise.
• They have different software
configurations.

• 2 redundant control networks are

connecting all Multi Purpose Controllers
and both Main Operating Panels
computers.
• A backup of the application- and
setup- software is stored on both
Main Operation Panels.
• At replacement, the new controller
is automatically configured with
correct software via the control
networks.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 4 >
purposes only
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Multi Purpose Controller, MPC

24 VDC, isolated system, A & B have UPS (Accessible by

2 separate 16 A breakers (A & B) for authorized service
every MPC personnel only)

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 5 >
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Multi Purpose Controller, MPC

Battery for internal clock
LED indicator
Reset push button

DIP Switches
DIP Switches &

Power Plug
Fuses
MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 6 >
purposes only
For training Multi Purpose Controller
LED Information Code
The LED gives information, either
as a constant light or by
flashing.

A flashing LED is a coded message

from the controller. The code
consists of 2 digits:

1. Digit is given by red flashes on

yellow/orange background

2. Digit is given by green flashes on

yellow/orange background

The 2 digits are separated by a 1

sec. yellow/orange pulse.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 7 >
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Multi Purpose Controller, MPC

Multi Purpose Controller

Amplifier for CW FIVA (CCU’s)

and hydraulic pumps (ACU’s)

’IP 66’ cabinet

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 8 >
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MPC-10 for CCUs

Power Plug Network cables
F1 fuse

LED indicator

ID Key

S1 DIP Switches

Input/output Ch. for CCUs

CPU DIP switches & Reset button
MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 9 >
purposes only
For training

MPC-10

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 10 >
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MPC versus MPC-10

MPC‐10

Size: 310 x 135 x 98 mm
Weight: 2.5 kg
Cabinet: 380 x 300 x 210 mm
20 external connectors
Sheltered electronics 

MPC

Size: 370 x 280 x 87 mm
Weight: 4.2 kg
Cabinet: 500 x 400 x 210 mm
55 external connectors
Not sheltered electronics

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 11 >
purposes only
For training

MPC’s Nordic Brasilia – 6S70ME-C

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 12 >
purposes only
For training

Multi Purpose Controller, MPC-10

…in new cabinets

max 8 per cabinet

…in classical cabinets

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 13 >
purposes only
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Control Network
120 Ω 120 Ω

 Net A  Net B

120 Ω 120 Ω

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 14 >
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Engine Interface Control Unit, EICU
Interface to External Systems

Manouvre-handle

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 15 >
purposes only
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Engine Interface Control Unit, EICU

Speed Setpoint

 Pre defined RPM for starting.

 Stop
 Gives the minimum speed set point
 Gives the maximum speed set point
 ONLY for CPP plants - Fixed speed set point when ’Bridge command take’ is active
 Shut Down  Stop
 Speed set point reduced to Slow Down Speed
 Speed set point set inside RPM range for shaft generator
 Speed ramp up / down, 3 RPM / Sec. Not cancellable
 80 – 100 % RPM in 90 min. on largebore engines. Cancelled by ’Increase Limits’
 Modifies setpoint to be outside the barred speed range
 Fine adjustment of speedset active
 Running up/Down program active (optional)
 Chief can set engine max sped
 T/C cut out activated for low load operations, engine speed is limited (optional)
 Waste Heat Recovery . Engine speed is higher than ordered to keep shaft gen connected, (option)

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 16 >
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Engine Control Unit, ECU
Start Block

Check list of conditions which must be in

order before engine start
One list for ’Standby’ and another list for
’FWE’ (Finished With Engine),

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 17 >
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Engine Control Unit, ECU

In case of start failure,

3 governor modes: there will be 2
RPM – Torque - Index repeated starts with
increased fuel
(heavy start)

Running modes:
Standard mode Economy

In combination with manoeuvering handle: (nothing happens

while the handle is in ’Stop’ position)
Auto: Slow turn valve - main starting air valve - fuel
Prepare Start: Slow Turn: Only slow turning valve, no fuel
Prelube and aux blower Air Run: Air starting sequence, no fuel
start by pressing MOP or
moving man-handle.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 18 >
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Engine Control Unit, ECU
Governor

ECU A/B are the governors –

calculating the needed fuel
index

 Pre defined index for starting.

 Max fuel set by C/E, for individual or all cylinders.
 A certain Pscav allows a certain index
 A certain RPM allows a certain index
 A certain hydraulic pressure allows a certain index
 TC cut out allows a max speed giving a certain
index

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 19 >
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Engine Control Unit, ECU

Test of different Injection Profiles Tier II Engines

Fuel injection step-profiles

100% load, fuel pump pressure

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 20 >
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Cylinder Control Unit, CCU

FIVA: Fuel Injection Valve Actuation

Proportional valve for fuel injct.
ON/OFF for exhaust operation.

FIVA feedback from

LVDT sensor, 4-20 mA

Fuel plunger position

4-20 mA feedback

Exh. valve spindle position

4-20 mA feedback used in
valve control

Starting air valve,

starting sequence
identical to MC engine

Cylinder lubricator
ON/OFF valve, feedrate
controlled by injection
frequency
One CCU for every cylinder

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 21 >
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Starting Air Systems

MC-C design ME-C design

30 bar Pilot air inlet
Blow-off

7 bar
Pilot air inlet

NC-valves
Starting air Connection
distributor for CCU

Starting valves Starting valves

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 22 >
purposes only
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Starting- and Pilot Air Valve

Connection to ECS Pilot Air valve

Starting Air valve

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 23 >
purposes only
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Auxiliary Control Unit, ACU

Blower Control
The blowers are starting one by one, to prevent
overload of electrical system

In AUTO mode:
 The blowers are started at ’Prepare Start’
 At engine running they are controlled by the scavenge air
pressure, stop at 0.7 bar (time delay), start at 0.4 bar.
 At engine stop they will continue running for default 15 min.

In Manual mode:
 Controlled by the operator

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 24 >
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Auxiliary Control Unit, ACU
Pump Control

ECU A

Electrically driven pumps 1 & 2 are controlled by ACU 1 & 2

ECU B

Engine driven pumps 1, 2 & 3 are controlled by ACU 1, 2 & 3,

The control is modulated, based on the pressure setpoint
and the actual hydraulic pressure.

Engine driven pumps 4 & 5 are the same type as 1, 2 & 3

but are controlled digitally by ECU A & B, either
maximum AHEAD or maximum ASTERN.

If the engine is equipped with 4 or 5 engine driven

pumps, ECU A & B are not 100 % redundant

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 25 >
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Scavenging Air Control Unit, SCU

VTA, WHR, EGB

One control unit to control scavengine air pressure on all engine types, and for all actuators.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 26 >
purposes only
For training
Multi Purpose Controller, MPC
Summary

The MPC’s are identical hardware but software wise configured to

5 different controller functions:
1) Engine Interface Conrol Unit – EICU
• 2 completely redundant units
• Handles the interface to external systems

2) Engine Control Unit – ECU

• 2 completely redundant units (except with more than 3 engine driven pumps)
• Handles the engine specific control functions (the govenor)

3) Cylinder Control Unit – CCU

• 1 for each cylinder unit.
• Handles the cylinder specific functions (fuel injection, exh. valve, cylinder lubrication and
starting air valves)
4) Auxilliary Control Unit – ACU
• 3 units.
• Handles the auxilliary systems (hydraulic power supply, aux blowers)

5) Scavenging Air Control Unit – SCU (Option)

• 1 Unit,
• VTA, EGB, WHRS

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 27 >
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Engine Control System

Control Panels

Bridge Control system is

connected to EICU

Engine Control Room Panel is

connected to EICU

Local Operating Panel LOP is

connected to ECU

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 28 >
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Main Operating Panel, MOP

MOP-A MOP-B CoCoS/PMI

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 29 >
purposes only
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MOPs
Different MOPs

Standalone PC Integrated PC

EC-MOP

Computer from Beijer

Monitor from Hatteland

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 30 >
purposes only
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Local Operating Panel (LOP)
FPP

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 31 >
purposes only
For training

Local Operating Panel (LOP)

CPP

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 32 >
purposes only
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Engine Control System

1) Control system:
- Multi Purpose Controller
- Control Network
- Main Operating Panel
- Local Operating Panel

2) Tacho system

3) Pneumatic Manoeuvring System

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 33 >
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Engine Control System

Tacho System

There are 2 redundant tacho systems.

 System A

 System B

Standard is:
angle encoders with one
reference sensor on the turning
wheel (A-system)

Option is sensors at the turning wheel

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 34 >
purposes only
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ME Tacho system

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 35 >
purposes only
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Tacho System

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 36 >
purposes only
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Tacho System
Angle Encoders

4001-A All ECU’s 4001-B

4002-A 4002-B
TSA-A 4003-A + 4003-B TSA-B
4004-A All CCU’s 4004-B

90 deg
ATDC

0 deg
45 deg
TDC 1
ATDC

MMA = Marker Master A

MSA = Marker Slave A
Q1A = Quadratur 1A
Q2A = Quadratur 2A
MMB = Marker Master B
MSB = Marker Slave B
Q1B = Quadratur 1B
Q2B = Quadratur 2B

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 37 >
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Tacho system
Angle encoder A + B

System A (powered from ECU A)

MMA = Marker Master A
TDC 1 MSA = Marker Slave A
Q2A 0 deg Q1A = Quadratur 1A
Q1A Q2A = Quadratur 2A

System B (powered from ECU B)

Q2B 45 deg
MMB = Marker Master B
MSB = Marker Slave B
Q1B Q1B = Quadratur 1B
Q2B = Quadratur 2B

90 deg  3 – 4 revolutions of turning

(Turning wheel
engine by using ‘Air-run’ after
Reference) initial power-on of engine
control system.
135 deg

Pos 0-44 45-89 90-134 135-179 180-224 225-269 270-314 315-359

MMA True True True True False False False False
MMB False True True True True False False False
MSA False False True True True True False False
MSB False False False True True True True False
MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 38 >
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Tacho System
MSA on AFT end of Engine

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 39 >
purposes only
For training

Tacho System Amplifier Boxes, TSA

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 40 >
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Tacho System
Angle Encoders

 Angle encoder B

 Angle encoder A

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 41 >
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Tacho System
Trigger Rings + Sensors (option)

• 2 redundant set of sensors.

• Each set measure engine speed and

crankshaft position for synchronization
of the control events.
• Each set consist of four sensors. Two
quadrature sensors measure on a trigger
ring with 360 teeth and two marker
sensors measures on a semicircular ring.

Triggersegment with a sine-curved tooth-profile The

total trigger ring is built by 8 equal segments.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 42 >
purposes only
For training

Engine Control System

1) Control system:
- Multi Purpose Controller
- Control Network
- Main Operating Panel
- Local Operating Panel

2) Tacho system

3) Pneumatic Maneuvering System

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 43 >
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Pneumatic Manoeuvring System

Slow turning.

2 Valves for Redundancy,

93 Controlled from
ECU A, 94 from ECU B

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 44 >
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Pneumatic Manoeuvring System
Starting / Air run.

2 Valves for Redundancy,

93 Controlled from
ECU A, 94 from ECU B

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 45 >
purposes only
For training

Disclaimer

All data provided in these training materials is non-binding.

This data serves informational purposes only and is especially not
guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant
data may be subject to changes and will be assessed and determined
individually for each project. This will depend on the particular
characteristics of each individual project, especially specific site and
operational conditions.

MAN Diesel & Turbo AAA-CPH Engine Control System 13.05.2015 < 46 >