Hcu Dump [PDF]

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HCU events from a-z …

Examining HCU Events

© MAN Diesel & Turbo

Copenhagen 2018-12

Allan Juul Larsen, MDT LEO9

MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

2018-12

• Basics • What is a “HCU event” (data stored and saved in case of fault, thus FIVA Basic understanding • FIVA Internal parts. • FIVA Flow diagram. • Examining using LDE plot • Signals • Which signals are stored • Examples from service • Selected cases from service • Don’t waste time on bad data… • (jitter profile, engine not running)

Content to cover…




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Electrical signals related to exhaust valve and fuel booster Continuously sampled by each CCU In case of an critical alarm the data is send to the MOP and stored Both data before and after alarm is stored Stores a few seconds of data sampled at 2 kHz (2000 times pr. sec.). FIVA Setpoint, position, Fuel plunger and exhaust valve position

• Data size: 124 kb each. (~50 kb zipped)

• • • • • •

• Tells us what is going on in the FIVA control loop • VERY important for troubleshooting Fuel and Exhaust valve problems! • Many names: “HCU Event” “HCU Dump” “Log Dump” “Burst Log”

• Hydraulic Control Unit Event

What is a HCU event

HCU Events - Basics

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

• If more dumps are needed they may be copied using explorer: D:\MANDiesel\MAD

• HCU Event retrieved from the MOP GUI one by one • Select one and export to USB

What is a HCU event

HCU Events - Basics

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

• Make manual dumps from all cylinders for reference. • The specific list of alarms triggering alarms is shown later.

• Header is composed of: • MPC type. • Date and time for event • Trigger reason, actual alarm or manual dump.

• HCU events are store either manually or triggered by a specific alarm. • Information about the reason is stored in the HCU event.

When is a HCU event stored

HCU Events - Basics

2018-12




= Hydraulic high pressure supply = Fuel booster = Fuel booster to tank = Exhaust actuator = Exhaust actuator to tank

MAN Diesel & Turbo

P CFI TFI CVA TVA

Main spool

Internal part MDB FIVA

HCU Events - FIVA

Allan Juul Larsen LOE9

A T

P

TFI

P

CVA TVA Examining HCU events

CFI

2018-12




MAN Diesel & Turbo

Main spool

FIVA main spool

HCU Events - FIVA

Examining HCU events

= Exhaust actuator = Exhaust actuator to tank

CVA TVA Allan Juul Larsen LOE9

= Fuel booster = Fuel booster to tank

CVA TVA

CFI TFI

P

= Hydraulic high pressure supply

CFI

P

TFI

2018-12




MAN Diesel & Turbo

Opening diagram

HCU Events - FIVA

Allan Juul Larsen LOE9

Examining HCU events

2018-12

2 Fuel plunger drained to tank




MAN Diesel & Turbo

Position mm.

Allan Juul Larsen LOE9

Exhaust valve opening

Examining HCU events

“Preparation” return plunger and close exhaust valve

Fuel injection

FIVA Set Point – For ME-C engine one engine revolution

HCU Events - Basics

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

FIVA Feedback CH30 – Setpoint

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Prepare for fuel injection

Fuel profile

Allan Juul Larsen LOE9

FIVA Feedback CH30 – Fuel profile

HCU Events - Signals

Examining HCU events

2018-12

Offset is a few ms.

No overshoot




MAN Diesel & Turbo

Examining HCU events

Lets just say 0 mm

Flow towards fuel injection start between -0.5 and 0.75 mm

Allan Juul Larsen LOE9

Flow diagram – Fuel injection

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Mechanical system with some reaction time

Allan Juul Larsen LOE9

Feedback passes 0.0 mm

Flow to plunger

Plunger position CH31 – Fuel profile start

HCU Events - Signals

Examining HCU events

2018-12

Start of fuel profile




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Profile shape determines plunger acceleration

Plunger position CH31 – Fuel profile shape

HCU Events - Signals

Examining HCU events

2018-12

Start of fuel profile




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Feedback passes 0.0 mm

After small time delay Flow to plunger plunger is stationary stops

Plunger position CH31 – Fuel profile end

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Main spool in negative position

Flow from plunger to tank will allow plunger to return.

Plunger position CH31 – Fuel plunger return

HCU Events - Signals

Examining HCU events

More negative position.

Increases tank flow and plunger return speed

Final position

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Plunger position CH31 – Different loads

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Lets just say -5 mm

Allan Juul Larsen LOE9

Flow towards exhaust valve opening start between -4 and -6 mm

Flow diagram – Exhaust valve opening

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Feedback passes -5.0 mm

Flow to Exhaust valve actuator

Examining HCU events

Exhaust valve Position CH34 – Exhaust valve opening

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Constant main spool position

Opening speed determined by constant flow rate.

Exhaust valve Position CH34 – Exhaust valve

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Feedback passes -5.0 mm

Speed determined by flow rate to tank

Exh.v. closing will start.

Exhaust valve Position CH34 – Exhaust valve close

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Final close speed is controlled by exh.v. damper step one and step two.

Exhaust valve Position CH34 – Exhaust valve damp

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Dampened opening

Allan Juul Larsen LOE9

Examining HCU events

Step 2 damper

Step 1 damper

Good ability to stay open

Exhaust valve Position CH34 – High force Exhaust valve

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Slow open and close slopes

Examining HCU events

Exhaust valve Position CH34 – High force Exhaust valve

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Fast open and close slopes

Examining HCU events

Exhaust valve Position CH34 – Low force Exhaust valve

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Overshoot at open stroke

Allan Juul Larsen LOE9

Examining HCU events

Slowly closes due to leakage

Exhaust valve Position CH34 – Low force Exhaust valve

HCU Events - Signals

2018-12




MAN Diesel & Turbo

Opening diagram

HCU Events - FIVA

Allan Juul Larsen LOE9

Examining HCU events

2018-12




MAN Diesel & Turbo

Opening diagram

HCU Events - FIVA

Allan Juul Larsen LOE9

Examining HCU events

2018-12




MAN Diesel & Turbo

Opening diagram

HCU Events - FIVA

Allan Juul Larsen LOE9

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

HCU Events - Signals

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

The up wards flank is “preparing” the ME-V Timing is not critical.

ME-V feedback. 1 – Digital “position” signal

HCU Events - Signals

Examining HCU events

Return flank is critical. Time is adusted to get accurate timing of exh.v. close

2018-12

Return stroke timing is important. Will control Pcomp/Pscav ratio




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

2018-12

• Y-axis is scaled according to the signals being displayed: • The resolution is 1 and the span is ±32767 (16 bit values). • FIVA Set Point / Feedback are shown in mm * 1000 • Electrical current is shown in A/D Counts • Electrical voltage is shown in A/D Counts • Exhaust valve position in mm but must be scaled according to parameter • Tacho angle is shown in deg.

• X-axis shows time in ms. • Resolution is in 500µs (½ms) • Resolution locked to MPC CPU clock of 2 kHz.

How are axis scaled

HCU Events - Basics




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

• Marker line indicated the time where the HCU event was triggered. • ECS Parameters determine the time before and after Marker line.

• In total 31500 samples are stored.

• Time stored dependents on the number of signals. • Number of signals depend on engine type: • ME-C 6 signals = 5.250 sec. • ME-B DOT3 5 signals = 6.300 sec. • ME-B 4 signals = 7.875 sec. • ME-B (2 cyl. pr. MPC) 7 signals = 4.500 sec.

Amount of data stored

HCU Events - Basics

2018-12




MAN Diesel & Turbo

• Show short DEMO

Allan Juul Larsen LOE9

Examining HCU events

• Windows application to examine HCU Events at office. • Intuitive user interface and proper screen resolution. • Sort multiple events based on: • Dump cause. • CCU number. • Data / Time. • Change colors and line width. • Export and print to improve documentation.

Examining using LDE plot

HCU Events - Basics

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

HCU Events from service

Exhaust valve stroke low.

HCU events from service

2018-12




MAN Diesel & Turbo

Exhaust valve stroke low.

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Exhaust valve stroke low.

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12

SW related? Exh.v. Mech? Hydraulic? Sensor?

Reason:




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Manual dump - Feed back not following well.

HCU events from service

Examining HCU events

2018-12

Exh.v. OK




MAN Diesel & Turbo

Feed back not following well.

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Illegal FIVA Position

Allan Juul Larsen LOE9

Examining HCU events

Exhaust valve open to avoid Cover lifting.

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Illegal FIVA Position – zommed

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Illegal FIVA Position – zoomed more..

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Exhaust valve closed position changed

HCU events from service

Examining HCU events

2018-12

Large control signal tells that FIVA is not reacting!




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Exhaust valve closed position changed – compare revolutions

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Exhaust valve closed position changed- The good

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Exhaust valve closed position changed – and the bad

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Exhaust valve closed position changed

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

ECS SW 1304-1 Load reduction introduced in this ECS

Examining HCU events

ECS SW 1008-6

• WHY did the control signal NOT go to safe position?

Exhaust valve closed position changed

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Exhaust valve stroke low– OR what is going on?

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Fault on MPC output: CH70 or FIVA input

Exhaust valve stroke low– OR what is going on?

HCU events from service

2018-12

Is Feedback correct CH30?

Which signal?

Electrical fault!




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Exhaust close position change – OR what is going on?

HCU events from service

Look like previous situation.

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Exhaust close position change – OR what is going on?

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Exhaust close position change – OR what is going on?

HCU events from service

2018-12




Allan Juul Larsen LOE9

Examining HCU events

2018-12

Self controlling type Feedback CH30 used by valve itself. In case a FIVA fault is detected the ECS orders FIVA to safe position Safe position must be OPEN Exhaust valve to avoid compression cover lift Safe position is a constant output on CH70 Default is -30 %

MAN Diesel & Turbo

• • • • • •

• IMPORTANT update for Bosch-Rexroth FIVA

A safe safe-position

Update for self-controlling FIVA ME-C




MAN Diesel & Turbo

• Not opening exh. valve!

Allan Juul Larsen LOE9

• -30% main spool position

• Self-Controlling FIVA

• -30% pilot valve position • -30% sets return speed • Return to end stop

• Controlled (regular) FIVA

• Explained on flow diagram

A safe safe-position

Update for self-controlling FIVA

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

• Observation in service • Missing Exh. valve close may lead to cover lifting !

Update for self-controlling FIVA

HCU events from service

2018-12




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12

Which signal?

Same ship different MPC.




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12

SAME SHIP!! MPC replaced and fault removed! Which signal?




MAN Diesel & Turbo

MPC failure

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

OT1515….

Allan Juul Larsen LOE9

Examining HCU events

Affected MPC have Serial Numbers starting with OT And date code before 1515:

MPC failure

HCU events from service

2018-12




MAN Diesel & Turbo

ELFI Fluctuation G95

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

ELFI Fluctuation G95

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

• Check HCU events or send to LEO9

• G95 ELFI Drain kit • Including long plug

ELFI Fluctuation G95

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

• Some examples.

Allan Juul Larsen LOE9

Examining HCU events

• Use your time on the real problems • Many HCU events are triggered by unimportant events. • Start / stop • Remove / apply connections • Electrical noise • Follow alarms to other alarms

Things not to look at….

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Dither function – Zoomed to show feedback

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Dither function – Situation 1

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

All OK

2018-12




MAN Diesel & Turbo

Dither function – Situation 2

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Dither function – Situation 3

Allan Juul Larsen LOE9

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Know what is NOT important look at

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Know what is NOT important look at

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Know what is NOT important look at

HCU events from service

Examining HCU events

Tacho?

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Examining HCU events

Migth setup exh.v. open and then this is “missed” due to the tacho suddenly jumping to a new position.

After TDC it will jump to 0 deg. normal

Know what is NOT important look at

HCU events from service

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Know what is NOT important look at

HCU events from service

Examining HCU events

2018-12




MAN Diesel & Turbo

Allan Juul Larsen LOE9

Know what is NOT important look at

HCU events from service

Examining HCU events

2018-12

HPS pressure drops. Connector removed. Engine not running.




MAN Diesel & Turbo

• Question…..

Allan Juul Larsen LOE9

Examining HCU events

2018-12

• If you have funny looking HCU Events or get some. Let me know and I will comment on them.

• I hope this lecture have given you a : • Practical ways to look at HCU Events. • Better understanding of the signals presented in HCU Events • Understanding that not all HCU Event contain important information • Gained some idea of the complexity of looking at HCU Events

SOMETHING CLEVER

HCU events from service