purposes only

For training

ECS Engine Control System

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

ECS (Engine Control System) layout

Components and their functions

MOP Main Operating Panel

Displays ECS data – Human Interface
Parameter Handling
ECS Alarm Handling

EICU Engine Interface Control Unit

ESC
ECR/Bridge Control
HPS Control setpoint
Cylinder Lube Feedrate
General Alarm Relay
Slow Down Relay
Engine Running Mode

CCU Cylinder Control Unit

HCU
HCU ELFI/ELFI-V & supervision
Speed Governor
Local/Remote Control
Shut Down Monitoring

Tacho system
Crankshaft position

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 2 >
purposes only
For training
ECS (Engine Control System) layout
Components and their functions

• The Multi Purpose Controllers are identical

hardware wise.
• They have different software functions.

ESC

• 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 computers.

• At replacement, a new controller is

automatically downloading the correct
software via the control network(s).

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 3 >
purposes only
For training

ECS (Engine Control System) layout

Components and their function

Feed-back sensor

Timing piston…

...adds oil to the

actuator

Only MPC for CCU Control valve…

for Dot 3 engines!

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 4 >
purposes only
For training
MPC
Connections on multi purpose controller

24 VDC, isolated system, A + B have UPS

2 separate 16 A breakers (A & B) for every MPC Authorized service
ONLY

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 5 >
purposes only
For training

MPC
Components on multi purpose controller

Battery for internal clock ID Key plug

LED indicator

Networks
plugs
Reset push button

DIP Switches
DIP Switches

Power Plug
Fuses
MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 6 >
purposes only
For training
MPC
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  05.05.2014 < 7 >
purposes only
For training

MPC
LED Information Code

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 8 >
purposes only
For training
MPC
Multi purpose controller

Topcover with plugs

position and fuses

Network cables
LED indicator

’IP 66’ cabinet

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 9 >
purposes only
For training

CCU for 2 cylinder

One CCU controls a dual hydr. cylinder unit

This screen gives an

overview of the Engine
Control System
Use this screen to
determine which CCU
controls which
cylinder unit.
Alarm text will refer to
e.g. CCU 2 unit A or B;
in this case unit A is
cyl. 3.

IMPORTANT:
On uneven cyl. no.
engines, CCU 1 will
only control cyl. unit 1.
In this case, CCU 2
unit A is most likely to
refer to cyl. unit 2, but
always check this
screen for correct
reference.

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 10 >
purposes only
For training
CCU for 2 cylinder
One CCU controls a dual hydr. cylinder unit

An example:
Alarm text refers to
CCU 2 Lubricator A.
In this case unit A is
cyl. No. 3.

IMPORTANT:
Always check inserted
screen for correct
reference.

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 11 >
purposes only
For training

MPC 10

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 12 >
purposes only
For training
MPC vs MPC10
MPC-10 is used only for CCUs

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 
Option for CCUs
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
Used for all control units

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 13 >
purposes only
For training

MPC or MPC-10
One CCU for two cylinders: Dot 2 engines

Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Tacho

1 2 3 4 5 6 7 8 System

Fuel & Cylinder

lub oil
HCU 1 HCU 2 HCU 3 HCU 4
Hydraulic HPS
HCU Control &
Power
Supervision
Signals

CCU 1 CCU 2 CCU 3 CCU 4

Network

Main Main Control & Supervision

CosCoS Etherne Operating Operating EICU signals
PMI t
Panel A Panel B

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 14 >
purposes only
For training
MPC or MPC-10
One CCU for each cylinder

Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Cyl. Tacho

1 2 3 4 5 6 7 8 System

Fuel & Cylinder

lub oil
HCU 1 HCU 2 HCU 3 HCU 4
HCU Control & Hydraulic
Supervision Signals Power
HPS

CCU 1 CCU 2 CCU 3 CCU 4 CCU 5 CCU 6 CCU 7 CCU 8

Network

Main Main Control & Supervision

CosCoS Etherne Operating Operating EICU signals
PMI t
Panel A Panel B
Redundancy level increased
Only MPC is available on Dot 3 engine
MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 15 >
purposes only
For training

Cabinet design
Can be installed on the engine or in the control room

MPC10 MPC10
MPC

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 16 >
purposes only
For training
Power Supply
Common Minuses in DC supply system

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 17 >
purposes only
For training

UPS, Power supply

With Isometer monitor, Bender Unit

 Insulation Level is monitored by an Isometer.

 One Bender Unit on UPS A

Type : IRDH375-UFDK

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 18 >
purposes only
For training
EICU
Insulation Level of the Installation

Installation the alarm level is 70kΩ and 24k Ω

On a new and well made installation it will be in the range of
200-1000kΩ

The Bender supplies the value as a mA output and ECS 0905

and newer supports this as an input

 Bender

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 19 >
purposes only
For training

CCU
Electrical Noise in the Installation

The layout of the noise detect functionality:

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 20 >
purposes only
For training
Isolated Power Supply
Isolated power supply for each MPC

 MPC

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 21 >
purposes only
For training

IRM Module

ME-B-SW-1110 supports the MDT Insulation Resistance Monitoring Module

(IRM Module)

Pictures from an ME-B Simulator at MDT-CPH

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 22 >
purposes only
For training
CCU
Electrical Noise in the Installation

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 23 >
purposes only
For training

Network on 40-50 ME-B

120 ohm resistors are necessary on each end of network

120 Ω 120 Ω

B B A

MOP A EICU MOP B

A A B

Control room
Engine room

J65 (A) J66 (B)

A B C A B C

1 2 1 2
Shield

Shield

120 Ω 120 Ω

120 Ω

A A A

CCU 1 CCU 2 CCU n

B B B

120 Ω

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 24 >
purposes only
For training
Network on 35 ME-B
120 ohm resistors are necessary on each end of network

120 Ω 120 Ω

B A

MOP A MOP B
A B

Bridge or Engine Control room

Engine Control Room or Engine room

J65 (A) J66 (B)

A B C A B C

1 2 1 2
Shield

Shield
120 Ω 120 Ω

120 Ω

A A A A

EICU CCU 1 CCU 2 CCU n

B B B B

120 Ω

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 25 >
purposes only
For training

EICU
Engine interface control unit

Remote Control System

ECR/Bridge Control
Speed setpoint relayed to CCU’s
Cancelled limiter relayed to CCU’s
ESC

HPS setpoint control according to engine

speed and load

Engine Running Mode

Economy/Emission available
Pressure

Pressure
Booster

Booster
Pressure

Pressure
Booster

Booster

Fuel injection profile and timing

HCU
Cylinder Lubrication Feedrate
M PUMP 1

M PUMP 2
Pressure
Control

General Alarm Relay

Slow Down Request Relay

Slow Down Command Relay

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 26 >
purposes only
For training
CCU
Cylinder Control Unit

Speed Governor / Index limiter

3 Governor modes available

HCU ELFI/ELFI-V control & supervision

Fuel injection timing and amount
ESC

Monitors Shut Down from Safety System

Pressure
Monitors Crankshaft position via Tacho signals
Pressure
Booster

Booster
Pressure

Pressure
Booster

Booster

CCU 1:
Engine Side Control/Remote selection
Input from scavenge air pressure sensor
Powers Encoder A
M PUMP 1

M PUMP 2
Pressure
Control

CCU 2:
Powers Encoder B

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 27 >
purposes only
For training

Supervision of input channel

The resistor used for connection supervision.

Safety System

CCU 1 CCU 1 CCU 2 CCU 2

CCU ½n

ELFI 1 ELFI 2 ELFI 3 ELFI 4

ELFI n
Pilot Pilot Pilot Pilot
Pilot
Valve Valve Valve Valve
Valve

Engine Control System (ECS)

Resistor used
for connection
supervision

+ 24 Vdc

CCU

ELFI
Pilot Valve

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 28 >
purposes only
For training
Engine control stations
Three control positions same as MC engine

Bridge Control Panel/Throttle is

connected to EICU

ESC

Engine Control Room

Panel/Throttle is connected to
EICU

Engine Side Control (ESC) is

connected to CCU1

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 29 >
purposes only
For training

HMI Human Machine Interface

MOP Main Operating Panels, A+B

EC-MOP

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 30 >
purposes only
For training
Engine control room
MOP A

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 31 >
purposes only
For training

ESC Engine Side Control

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 32 >
purposes only
For training
ESC Engine Side Control
Pneumatic valves and pipes

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 33 >
purposes only
For training

ESC
Engine Side Control

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 34 >
purposes only
For training
Local control box
Detailed picture

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 35 >
purposes only
For training

Different telegraph systems

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 36 >
purposes only
For training

Tacho System

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 37 >
purposes only
For training

Tacho system
Transfers crankshaft position to CCUs

2 Encoders for Tacho system redundency

ESC
 Encoder A
Powered by CCU1

 Encoder B
Powered by CCU2
Pressure

Pressure

Standard is:
Booster

Booster
Pressure

Pressure
Booster

Booster

Angle encoder with one

Reference sensor (MSA) on the
Flying wheel (Encoder A)
M PUMP 1

M PUMP 2
Pressure
Control

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 38 >
purposes only
For training

Tacho System

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 39 >
purposes only
For training

Tacho System
Angle Encoders

4001-A 4001-B
4002-A 4002-B
TSA-A 4003-A All CCUs 4003-B
TSA-B
4004-A 4004-B

0 deg (TDC 1)
45 deg (ATDC 1)

90 deg
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
Angle encoder A Angle encoder B
MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 40 >
purposes only
For training
Tacho system
Angle encoder A + B

System A (powered from ECUA)

TDC 1
MMA = Marker Master A
0 deg. MSA = Marker Slave A
Q1A = Quadratur 1A
ATDC1
Q2A = Quadratur 2A
45 deg.
System B (powered from ECUB)
MMB = Marker Master B
MSB = Marker Slave B
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  05.05.2014 < 41 >
purposes only
For training

Tacho System
MSA on Turning wheel

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 42 >
purposes only
For training Tacho System Amplifier Boxes
TSA-A & TSA-B

TSA-A
TSA-B

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 43 >
purposes only
For training

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  05.05.2014 < 44 >
purposes only
For training
Tacho System
Angle Encoders

 Angle encoder A

 Angle encoder B
47 D 4004-B quadrature slave

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 45 >
purposes only
For training

Tacho system
The calibration of tacho system is available on MOP

Pre-Start Test and

Setting of Fine Adjust
Parameters can be
performed individually.
Pre-Start Test:
Follow the steps and
press done after each
item.
Use turning gear and
readings from the
turning wheel.

After Pre-Start Test,

Check the
‘Cabling Test’
to see the details.

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 46 >
purposes only
For training
Tacho system
Cable test is available on MOP

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 47 >
purposes only
For training

Failures and effects

CCU 1 Fails:
 2 Cylinders misfire/ 1 Cylinder misfire.
 Slow Down Speed is available (40%).
 ’Engine Side Control’ no longer available.
 Scavenge air pressure is not available

EICU Fails:
 Failsafe cylinder lubrication feedrate.
 Failsafe Hydraulic supply pressure.
 Only ’Engine Side Control’ is available.
 Process adjustment is not available

One HPS Pump Fails:

 Max 55% load is available (propeller curve)
or 80% of MCR

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 48 >
purposes only
For training
Pneumatic system

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 49 >
purposes only
For training

Pneumatic system

MAN Diesel & Turbo AAA-CPH Engine Control System  05.05.2014 < 50 >
purposes only
For training

Disclaimer

All data provided in this document 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.

ME-B Engine Control System © MAN Diesel & Turbo 01/01/2012