EGS2200 Std Manual

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Introduction 1

System Description 2

Functional Description 3

Panel Operation Descr iption 4

Panel Alarm and MaintenanceFunctions

5

Alarm Indication and TroubleShooting

6

User Manual Preventive Maintenance 7

EGS2200-STD Customizing tool print-out 8

Engine Governor System Components and spare parts 9

Appendix A: Technical Specification

for EGS2200-STD and Options10

for Appendix B:

Wiring Diagrams11

MAN Diesel MC/MC-C Engines Appendix C:

Installation Specific Adjustments12

Installation Specific Drawings 13

14

15

16

17

815.000.426-03 18

19

List of Lyngs Marine ServiceStations

20


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EGS2200-STDEngine Governor System

forMAN Diesel MC/MC-C Engines

User Manual

Doc. No.: 815.000.426-03

Lyngs Marine A/SLyngs AllDK - 2970 HrsholmDenmark

Telephone: +45 45 16 62 00Telefax: +45 45 16 62 62


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Engine Governor System EGS2200-STD Page 1 of 110User Manual for MAN Diesel MC/MC-C Engines 2007.06.01

815.000.426-03 Lyngs Marine A/SSAM Electronics GmbH

Contents

1. EGS2200-STD INTRODUCTION........................................................................................................................4

1.1 PURPOSE. .....................................................................................................................................................4

1.2

SCOPE. .........................................................................................................................................................41.3 DOCUMENT MAINTENANCE. ...........................................................................................................................4

1.4 RELATEDDOCUMENTS. .................................................................................................................................41.5 ABBREVIATIONS.............................................................................................................................................41.6 CONFIGURATION............................................................................................................................................6

1.6.1 Registration.............................................................................................................................................71.6.2 EGS2200-STD Type. .............................................................................................................................71.6.3 EGS2200-STD Software Version. .........................................................................................................81.6.4 EGS2200-STD Options in this installation.............................................................................................9

1.7 REFERENCES ..............................................................................................................................................111.8 TERMINOLOGY .............................................................................................................................................11

2. EGS2200-STD SYSTEM DESCRIPTION ........................................................................................................12

2.1

MAIN COMPONENTS ....................................................................................................................................122.2 CONTROL CABINET......................................................................................................................................14

2.3 OPERATINGPANEL......................................................................................................................................142.3.1 EGS Operating Panel Functions..........................................................................................................14

2.4 ACTUATOR ..................................................................................................................................................162.5 TRANSFORMER............................................................................................................................................192.6 INTERNAL CIRCUITRY ...................................................................................................................................19

2.6.1 Tachometer...........................................................................................................................................192.6.2 Speed-Setting.......................................................................................................................................19

2.7 MODES OF OPERATION................................................................................................................................212.7.1 Auto Select............................................................................................................................................212.7.2 RPM Mode............................................................................................................................................212.7.3 Power Mode..........................................................................................................................................21

2.7.4

Index mode...........................................................................................................................................21

2.8 HIGHSPEED MODULE....................................................................................................................................222.9 FEATURES AVAILABLE FROM THEOPERATINGPANEL....................................................................................22

2.9.1 Actuator Blocked Indication..................................................................................................................222.9.2 Load Limits............................................................................................................................................222.9.3 Index Max .............................................................................................................................................232.9.4 Acknowledge Alarm..............................................................................................................................24

2.10 FAILURE MODES..........................................................................................................................................242.11 OPTIONS .....................................................................................................................................................24

2.11.1 Engine Load Limit Option................................................................................................................242.11.2 Shaft Generator Option....................................................................................................................252.11.3 Instruments Option...........................................................................................................................252.11.4 Controllable Pitch Propeller Option.................................................................................................25

2.11.5

Variable Injection Timing (VIT)........................................................................................................26

2.11.6 Cylinder Lubrication Oil Dosing.......................................................................................................262.11.7 Cylinder Cut Out System. ................................................................................................................262.11.8 Additional Control Options...............................................................................................................272.11.9 Slowdown Option.............................................................................................................................272.11.10 Barred Range Avoidance (Critical Speed Function) ......................................................................272.11.11 Engine Load Program......................................................................................................................27

3. EGS2200-STD FUNCTIONAL DESCRIPTION ...............................................................................................28

3.1 GENERAL DESCRIPTION ...............................................................................................................................283.2 FUNCTIONS WITHIN THE EGS2200-STD .....................................................................................................29

3.2.1 Actuator Control Loop ..........................................................................................................................303.2.2 Tacho System.......................................................................................................................................313.2.3

The Setpoint Selector...........................................................................................................................31

3.2.4 Shaft Speed Control .............................................................................................................................31


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3.2.5 Engine Limits Module ...........................................................................................................................323.2.6 Engine Limit Prewarnings (Option)......................................................................................................333.2.7 The Minimum Selector .........................................................................................................................333.2.8 Control Mode........................................................................................................................................333.2.9 Alignment of Bridge- and Manual Engine Control Room setpoints....................................................343.2.10 Start / Stop System..........................................................................................................................34

3.2.11

Failure Detection Module.................................................................................................................35

4. EGS2200-STD PANEL OPERATION DESCRIPTION....................................................................................36

4.1 SELECTION OF EGS2200-STD CONTROL FUNCTIONS ................................................................................364.2 BASICMODE OVERVIEW DISPLAY ON EGS2200-STD OPERATORPANEL ...................................................374.3 EGS2200-STD OVERVIEW STATUS LIST....................................................................................................384.4 EGS2200-STD OVERVIEW CONTROL LIST. ................................................................................................394.5 EGS2200-STD OVERVIEW PARAMETERADJUSTMENTS. ............................................................................40

4.5.1 Maximum Index Limit ...........................................................................................................................404.5.2 Fuel Max Factor....................................................................................................................................40

4.6 EGS2200-STD CONTROL OBJECTS...........................................................................................................414.6.1 Mode Selector.......................................................................................................................................42

4.6.1.1 Mode Selector Status List ...........................................................................................................................42

4.6.2

EGS2200 Tacho Selector. ...................................................................................................................434.6.2.1 EGS2200 Tacho System Status List ..........................................................................................................43

4.6.3 Lubrication Oil Dosing System.............................................................................................................444.6.3.1 Lubrication Oil Dosing System Status List ..................................................................................................444.6.3.2 Lubrication Oil Dosing System Settings......................................................................................................45

4.6.4 VIT System ...........................................................................................................................................464.6.4.1 VIT System Status List ................................................................................................................................474.6.4.2 VIT System Parameter Adjustments...........................................................................................................48

4.6.5 Cylinder Cut-out System......................................................................................................................514.6.5.1 Cylinder Cut-out System Status List ...........................................................................................................524.6.5.2 Cylinder Cut-out System Settings ...............................................................................................................52

4.6.6 Shaft Generator Waiting Station Status List..................................................................................534.6.7 Slowdown..............................................................................................................................................54

4.6.7.1 Slowdown Option Status List.......................................................................................................................544.6.8

EGS2200 Test Mode............................................................................................................................55

4.6.8.1 EGS2200 Test Mode Status List.................................................................................................................554.6.8.2 EGS2200 Test Mode Fixed Fuel level ........................................................................................................56

4.6.9 Charge Air Limiter adjustment .............................................................................................................574.6.9.1 Charge Air adjust Status List.......................................................................................................................57

4.6.10 Rpm Torque Limiter adjustment......................................................................................................584.6.10.1 Rpm Torque adjust Status List....................................................................................................................58

5. EGS2200-STD PANEL ALARM AND MAINTENANCE FUNCTIONS..........................................................59

5.1 BASICMODE................................................................................................................................................595.2 HARD -AND SOFTKEYOVERVIEW ................................................................................................................605.3 ALARM LIST MODE.......................................................................................................................................615.4 ADDITIONAL LIST MODE. ..............................................................................................................................63

5.4.1

Selecting the List Type.........................................................................................................................645.4.2 At the List Level ....................................................................................................................................65

5.5 DISPLAYCHANNEL MODE ............................................................................................................................665.5.1 The Text Entry Screen .........................................................................................................................665.5.2 The Stepping/status Screen.................................................................................................................675.5.3 Channel Status Screen. .......................................................................................................................675.5.4 The Entry Selection Screen. ................................................................................................................68

5.6 ADJUST CHANNEL MODE. ............................................................................................................................695.6.1 Entering of Numerical Data and Texts.................................................................................................71

5.7 MAINTENANCE MODE...................................................................................................................................725.7.1 Display Time and Date.........................................................................................................................735.7.2 View Load Sequential Date and Number............................................................................................735.7.3 Set Time and Date (privileged access level 1)....................................................................................74

5.7.4

Lamp Test.............................................................................................................................................76

5.7.5 Select UTC or Local Time (privileged access level 1) ........................................................................77


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5.7.6 Enter Commissioning Mode (privileged access level 4) .....................................................................775.7.7 Change Password - Level N (privileged access level N/N+1)............................................................775.7.8 Enter System Password Level (privileged access level 4) .................................................................785.7.9 Watch Dog Activation (privileged access level 4) ...............................................................................795.7.10 Store Setup (privileged access level 4)...........................................................................................79

5.8 DIMMER MODE ............................................................................................................................................80

6.

EGS2200-STD ALARM INDICATION AND TROUBLE SHOOTING............................................................81

6.1 EGS2200 ENGINE GOVERNOR SYSTEMALARMS........................................................................................816.2 GAMMAMICRO CPU ALARMS .....................................................................................................................956.3 FAULT ISOLATION.........................................................................................................................................95

6.3.1 Tacho System.......................................................................................................................................966.3.2 Actuator Control....................................................................................................................................966.3.3 Operating Panel....................................................................................................................................966.3.4 Cable supervision.................................................................................................................................97

6.4 MALFUNCTIONS BEYOND THE SCOPE OF THE ALARM LIST..............................................................................976.4.1 Actuator BLOCKED indicator error at Operating Panel......................................................................976.4.2 Actuator moving slowly without error indications ................................................................................976.4.3 Actuator is not moving..........................................................................................................................97

6.4.4

Actuator fluctuating...............................................................................................................................98

6.4.5 Engine speed differs from the setpoint ................................................................................................986.4.6 Fuel index 0 at STOP/SHUTDOWN ..............................................................................................986.4.7 Fuel pumps don't move in accordance with the actuator ...................................................................98

6.5 MONITORING CHANNELS FOR DISPLAYPURPOSE .........................................................................................986.6 ASSISTANCE FROMLYNGS MARINE............................................................................................................99

7. PREVENTIVE MAINTENANCE......................................................................................................................100

7.1 REGULAR CHECKS.....................................................................................................................................1007.2 TACHOSYSTEMCHECKS...........................................................................................................................100

7.2.1 Monthly Tacho Pick-up Checks.........................................................................................................1017.3 SERVO MOTOR..........................................................................................................................................1017.4 ACTUATOR GEAR.......................................................................................................................................1017.5

FUEL RACK................................................................................................................................................102

8. EGS2200-STD CUSTOMISING TOOL PRINT-OUT.....................................................................................103

8.1 INPUT/OUTPUT LIST TERMINAL BOARD REPORT.........................................................................................1038.2 OUTPUT FUNCTIONS LIST REPORT.............................................................................................................1048.3 EGS2200-STD FUNCTION BLOCKS LIST REPORT.....................................................................................105

9. EGS2200-STD COMPONENTS AND SPARE-PARTS................................................................................106

9.1 HARDWARE COMPONENTSLIST.................................................................................................................1069.2 HW MODULES LAYOUT ANDJUMPER SETTINGS.........................................................................................1079.3 SPARE-PART LIST......................................................................................................................................110


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1. EGS2200-STD Introduction

The Engine Governor System EGS2200-STD is an Engine governor with actuator for the control of a MAN

Diesel MC/MC-C two-stroke main engine in installations with fixed or controllable pitch propeller. The gov-ernor is based on the proven predecessor EGS2000.

1.1 Purpose.

The purpose of this manual is to provide a thorough understanding of EGS2200 operation for the dailyuser, including faultfinding methodology and maintenance. It is not the purpose to cover service instruc-tions as they are found in a separate manual.

This User Manual gives an overview of the hardware and describes the functionality of the EGS2200-STDand includes wiring diagrams etc.

1.2 Scope.

The manual describes the EGS2200-STD functionality, it's main components and the use of the system.

Data sheets and wiring diagrams provide detailed information on external and internal wiring, and a com-prehensive set of outline drawings gives a presentation of the individual components of EGS2200-STD.

A list of available options is found in section 1.6.4. This section also records the options actually includedin your installation. A thorough description of individual options provided can be found in Appendix A.

1.3 Document Maintenance.

The document describes the EGS2200-STD delivery in the version installed, and it is not normally subjectto updating. If new updates or options are installed Lyngs Marine will provide updates to the owner, whois then asked for updating his samples of the document.

1.4 Related Documents.

EGS2200-STD Service & Commissioning Manual, Doc. no. 810.000.858.

1.5 Abbreviations.

AAM Analog output module type 401A/D Analog to Digital conversionAEM Analog input module type 402BC Bridge ControlCCO Cylinder Cut Out System Optional.CC Closed contactCPP Controllable Pitch Propeller.

CPU Central Processor UnitCSR Critical Speed Range


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List of abbreviations - continued:

CTL Control OptionsD/A Digital to Analog conversionDB DeadbandDEM Digital Input Module type 401 (32 channel binary input)

DRM Digital Relay Module type 401 (16 channel relay output)DMS2100i Diesel Manoeuvring System - Bridge Manoeuvring SystemECR Engine Control RoomEGS Engine Governor SystemELL Engine Load Limits optionEPROM Erasable Programmable Read-Only MemoryER Engine RoomETA Estimated Time of ArrivalETD Estimated Time of DepartureFIM405 Filter Module for 24 Vdc Power SupplyFPP Fixed Pitch PropellerHMI Human Machine InterfaceHW Hardware

LCD Liquid Crystal DisplayLED Light Emitting DiodeLLC Load Limit CancelLM Lyngs Marine A/SLOD Lubrication Oil Dosing System - Optional.LP Load Program optionMAM MIC40 Input/Output Adapter, Gamma to digital I/O modulesMCR Maximum Continuous RatingMIC40 Input/Output Adapter, Gamma to digital I/O modulesNC Normally Closed: Open contact, when alarm is presentNO Normally Open: Closed contact, when alarm is presentOAA Open Automation ArchitectureOC Open contactOP Open contactOPS Overload Protection SystemP2 Electrical switch at pressure switch P2 in MAN Diesel Manoeuvring

Diagram = Select Local control = Closed contact.P7 Electrical switch at pressure switch P7 in MAN Diesel Manoeuvring

Diagram = Select Engine Control Room control = Closed contact.P9 Electrical switch at pressure switch P9 in MAN Diesel Manoeuvring

Diagram = Select Bridge Control = Closed contact.PI Proportional Integral ControllerPSU Power Supply UnitRAM Random Access MemoryRCS Remote Control SystemROM Read-Only MemoryRPM Revolutions Per MinuteSAM SAM Electronics GmbHSG ShaftgeneratorSIF Serial interface to the DMS2100i-STD via the MIC40M-Bus (RS-485 communication)SIM Serial Input/Output Interface ModuleSLD Slowdown optionSW SoftwareTAM Tacho Adapter Module type 401TDC Top Dead CentreUCS Universal Alarm, Monitoring & Control SystemUMS Universal Alarm & Monitoring SystemVIT Variable Injection Timing System - Optional.

WCH Wrtsil Switzerland Ltd. (a.k.a. Sulzer RTA Engines)X Terminal connection Board for external wiring to the EGS2200.ZM Gamma Micro CPU Module (Zentral Modul) type 411


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1.6 Configuration.

This section provides the information required for specification of your EGS2200-STD, should any inquiryto Lyngs Marine be needed. A list of options are furthermore included with this section. When reading

this manual, sections not relevant for the options in your installation are to be disregarded. Such sectionsare clearly marked in the text.


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1.6.1 Registration.

Lyngs Marine has registered your EGS2200-STD with the following information on Yard, New Buildingnumber, Owner, and Engine Type:

Owner: Exact Engine Type:

Yard: Newbuilding No.:

1.6.2 EGS2200-STDType.

The type of EGS2200-STD unit in this installation is:

Hardware Version:

Type no. 960.311.600: DMS2100iserial interface incl. MAN Diesel Engine Yes ___

Type no. 815.001.186: Actuator Size 3without earth fault relay

MAN Diesel Engine Yes ___



Type no. 815.001.188: Actuator Size 14

without earth fault relay




Type no. 815.001.216: Actuator Size 3with earth fault relay









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1.6.3 EGS2200-STD Software Version.

The following type numbers identify the software:

CPU Card EPROM Low (EGS Program part 1) 970._____._____

CPU Card EPROM High (EGS Program part 2) 970._____._____

SIM401 Card no.1 EPROM Ch.2 (Load and debug channel) 970.112.381-04

SIM401 Card no. 1 EPROM Ch.1 (Tacho System version 4) 960.511.214

SIM401 Card no. 2 EPROM Ch.1 (Not used) 970.112.381-04

SIM401 Card no. 2 EPROM Ch.2 (DMS 2100iCommunication) 970.112.381-04


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1.6.4 EGS2200-STD Options in this installation.

The list below shows which options are included with this installation.A description of included options are found in Appendix A.The actual adjustments for the options are shown in Appendix C.

Instruments Option

Type no. 960.310.310: Output for RPM instrument

(Note 1).

Analog output

4-20 mA. or 0-10V

Yes ___

Type no. 960.310.320: Output for Index instrument

(Note 1).

Analog output

4-20 mA. or 0-10V

Yes ___

Type no. 960.310.330: Other __________________

(Note 1).

Analog output

4-20 mA. or 0-10V

Yes ___

Shaft Generator Option

Type no. 960.310.220: Generator Engaged and PermissionSignals for range/level A - "WaitingStation".

Binary +24V,dc input andBinary output (dry contact).

Yes ___

Type no. 960.310.230: Generator Engaged and PermissionSignals for range/level B - "WaitingStation".

Binary +24V,dc input andBinary output (dry contact).

Yes ___

Type no. 960.310.210: Constant Speed Order input signal. Binary +24V,dc input. Yes ___

Type no. 960.310.250: Shutdown output: Sh.d. signal toSafety System is activated after time-out with the shaftgenerator engagedand slowdown order present.

Binary output (dry contact). Yes ___

Variable Injection Timing

(MAN Diesel engines)

Type no. 960.310.600 Yes ___

VIT control signal (Note 1). Analog output 4-20 mA.Current-air pressure con-verter not included.

Note 1: A maximum of 2 analog outputs can be chosen including an eventual use of the VIT option. Ifthere is no requirement of a reference voltage for a Manual Rpm Setpoint potentiometer,then an extra analog output is available for instrument output.


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Controllable Pitch Propeller

Type no. 960.310.410: Pitch Angle Signal. Analog input 4-20 mA

or +/- 10 V.

Yes ___

Type no. 960.310.430: EGS2200 OFF-line. The output signalis an open contact, when the actuator isin blocked position.

Binary output (dry contact). Yes ___

Lubrication Oil Dosing


Type no. 960.310.700 Yes ___

Output to lubrication oil dosing unit. 24 V binary output.

Control Options

Type no. 960.310.810: Synchronization pick-up (Note 2). Pick-up is included with4 and 5 cylinder engines.

(Yes ___)

Type no. 960.310.820: Critical Speed module. SW module in EGS2200. Yes ___

Type no. 960.310.860: Controlled passage in the upwards

direction of the Critical SpeedRange for FPP: Awaiting sufficientremaining index for a quick passage. This is a supplement to theCritical Speed module above.

SW module in EGS2200. Yes ___

Type no. 960.310.830: Slope on RPM order module

(Note 2).

SW module in EGS2200. (Yes ___)

Note 2: These options are not customer selectable, but are included if necessary in the actual application.

Engine Load Limit

Type no. 960.310.110: Index Limited Signal. Binary output (dry con-tact).

Yes ___

Type no. 960.310.120: Engine Torque Limit Pre-warning. Binary output (dry con-tact).

Yes ___

Type no. 960.310.130: Scav. Air Press. Limit Pre-warning. Binary output (dry con-tact).

Yes ___


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Slowdown Type no. 960.310.900 Yes ___

Slowdown input. Binary +24V,dc input.

Slowdown Cancel. Binary +24V,dc input.

Manual Slowdown Reset (input signal). Binary +24V,dc input. Yes ___

Automatic Slowdown Reset (Manual Slowdown Reset signal is notrequired, if Automatic Slowdown Reset is selected).

Yes ___

Loadprogram OptionsType no. 960.311.110: RPM Loadprogram. Normally used in

connection with FPP installations.SW module in EGS2200. Yes ___

Type no. 960.311.140: RPM Loadprogram with bi-linear slope SW module in EGS2200. Yes ___

Type no. 960.311.130: Index Loadprogram. Normally used in

connection with CPP installations.

SW module in EGS2200. Yes ___

Cylinder Cut Out System


Type no. 960.311.500 Yes ___

Outputs to solenoid valves for cut out of cylinder group 1 & 2. Two 24 V binary outputs.

1.7 References[1] Propulsion Control System, PCS2100, System Description[2] Diesel Manoeuvring System, DMS2100i, System Description and User Manual[3] Diesel Protection System, DPS2100, System Description and User Manual[4] Universal Monitoring System, UMS2100, System Description and User Manual[5] Universal Control System, UCS2100, System Description and User Manual

1.8 TerminologyThis document use the following terminology to specify the operation and indications of the EGS2200-STDOperator Panel:- Hard keys, pushbuttons or indication lamps on panels are shown as: [ Bridge Control ]- Softkeys on the EGS2200-STD Operator Panel are shown as START COMMAND- Selector switches and Potentiometers on ECR Manual Control Panel and Local Manual Control Box

are shown as: LOCAL/REMOTE- Alarms and Indications on the EGS2200-STD Operator Panel Display are shown as:


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2. EGS2200-STD System Description

This chapter gives a brief introduction to the main functions and the use of the EGS2200-STD Operating

Panel. This chapter can be read to get an impression of the capabilities and functionality of the governor

system. More detailed information and instructions are found in subsequent chapters.

The basic task of EGS2200-STD is to regulate the shaft speed of the engine to which it is attached. This of

course means the EGS2200-STD must be able to translate the speed commands given by the operator -

e.g. by means of a remote control system - into adequate movement of the fuel rods controlling the injec-

tion of fuel into the engine cylinders. The engine in question may be anything from a two-stroke, slow-

speed Marine Diesel to a 4-stroke, medium-speed Generator Diesel. EGS2200-STD may be tailored to

any manufacture of diesel engine.

2.1 Main Components

EGS2200-STD consists of components installed in the Engine Control Room (ECR) and in the Engine

Room (ER). An outline is shown in figure 2.1. These components and their basic functions are as follows:

Control Cabinet:Located in the ECR. This unit contains all the electronics required to convert incoming

signals and orders into correct Fuel Command signal. This unit also contains the STELLA7GAMMA com-

puter developed by Lyngs Marine A/S.

Operating Panel:Located in the ECR. This unit provides the engine staff with a means of communication

with the EGS2200-STD. This unit is normally placed in the ECR console.

Actuator: Located at the engine. This is the electro-mechanical device, which converts electrical control

signals from the Control Cabinet to mechanical action. It is this device, which actually exerts the required

force on the fuel rod, which causes it to move to the correct position.

Transformer: the required three phases power supply for the actuator control is placed in a separate unit

containing the transformer.

Tacho System:This system allows the EGS2200-STD Control Cabinet to detect the speed of the engine

output shaft. It is therefore located very close to the engine flywheel. The system comprises two induction

pick-ups. The pickups sense the passing of the flywheel teeth. The remainder of the system is located

within the Control Cabinet. It comprises a dedicated computer for rapid processing of the tacho pickup

pulses.

Scavenging Air Sensor:Available engine output power is a function of the Scavenging Air pressure.EGS2200-STD includes a sensor which senses this air pressure and allows the governor to restrict engineoutput power in order to avoid too low air to fuel ratio. This sensor is placed in the scavenging air system.The sensor may optionally be included in the delivery extent of the EGS2200-STD.


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Figure 2.1:Illustration of the Main Components of the Governor System.


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2.2 Control Cabinet

The Control Cabinet contains the STELLA7computer and all the electronics required to translate the sig-nals received from the Operating Panel, ECR Speed Setting Handle, Engine Remote Control System and

external sensors into a movement of the Actuator. The Actuator movement causes the engine fuel pumpsto inject the correct amount of fuel.The Control Cabinet contains facilities, which allow the connection of a Personal Computer (PC) enablingboth adjustment and fault diagnosis to be carried out. This allows the EGS2200-STD System to be pre-adjusted for a particular engine, thereby limiting final adjustment on the engine test-bed and in the vesselto a minimum. Time required for test of the EGS2200-STD System is fast. Once adjusted, the unit requiresno periodical maintenance.

2.3 Operating Panel

The Operating Panel is installed in the ECR console and provides all the facilities required for operation ofthe EGS2200-STD System. In addition, it provides the operator extensive facilities for diagnosis, test andsimulation. The display shows messages in plain language and softkeys are used for operating the gover-nor system.

It is not necessary to make regular checks on the EGS2200-STD System functions, as this is performedby the STELLA7Computer. The Operating Panel front panel is composed of a splash-proof tactile key-board and Liquid Crystal Display (LCD).

The transfer of information between the Operating Panel and the Control Cabinet takes place on a net-work consisting of a twisted pair connecting cable. The Operating Panel only requires power and a sepa-rate actuator "BLOCK."indicator signal, both of which are coming from the Control Cabinet.

Figure 2.3:EGS2200-STD Operating Panel.

2.3.1 EGS Operating Panel Functions

The following main functions are available from the EGS2200-STD Operating Panel:


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ME: 100.0 RPM, StAir 30.00 BARLIMITER:

TLG BC: 120.0 ECR: 120.0 EGS: 20.0 RPM

Four lines display with 40 characters on each line

Softkeys[ S1 ] - [ S4 ]for operation of EGS functions

Six selection keys:[ ESC ], [ ENT ]

and four [ Arrow ]keys

[ Select ]of EGS control functions of[ Status ], [ Control ]and [ Settings ]

Actuator Blocked indication:

[ Block. ]indication lamp for EGS2200-STD Actuator in Blocked condition, i.e. thegovernor no longer controls the main engine rpm.This indication has separate external wiring from the EGS Cabinet.

EGS2200-STD keys for alarm functions:

[ Stop Horn ] operation key:

Activation of this key stops the buzzer in the EGS Operator Panel.

[ Alarm Acknowledge ]operation key:Activation of this key acknowledges the alarms present at the LCD display of the EGSOperator Panel.

[ Alarm List ]operation and indication key:

References: Chapter 5.3.

[ Additional List ]operation and indication key:References: Chapter 5.4.

[Display Channel ]operation and indication key:References: Chapter 5.5.

STOP

HORN

ALARM

ACKN.

ALARM

LIST

ADD.

LIST

DISPLAY

CHANNEL


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[ Adjust Channel ]operation and indication key:References: Chapter 5.6.

[ Maintenance ]operation and indication key:


[ Dimmer ]operation and indication key:


[ Alarm ]indication lamp for EGS2200-STD Alarm detected.Any EGS2200-STD alarm in chapter 6 activates this indication.

[ Block. ]indication lamp for EGS2200-STD actuator blocked.Only some EGS2200-STD alarms in chapter 6 activates blocked.

[ Fault ]indication lamp for EGS2200-STD Operator Panel in Faulty condition,e.g. missing communication to the Gamma Micro CPU or missing EPROM insidethe panel.

Please refer to chapter 5 and the UMS2100 System Description for further information about the alarmsystem functions.

2.4 Actuator

The actuator controls the position of the engine fuel rack. The correct actuator to be used on a particularengine is dependant upon the engine type. The actuator is available in different sizes. The size delivereddepends on the force and the inertia of the fuel rack, i.e. upon the engine make, the number of cylindersand the bore. The choice of actuator is made in collaboration with the engine manufacturer to assure opti-mal performance.

All actuators contain a rugged, brush-less servomotor for very fast response and a high torque braking

system, which is able to lock the actuator during specific fault conditions. Gearboxes are sealed and noperiodical maintenance is required at all.

The actuator is protected against overload and other errors, which could cause it to malfunction.An example of the arrangement of the actuator on an engine is shown in figure 2.4.

The actuator is available in four sizes - ranging from 300 to 2900 Nm - with matching controller, servomo-tor and gear unit specified below:

- Size 03 with Servostar 606 Servomotor KSY 666.30 Gear XFCG 110-87- Size 07 with Servostar 610 Servomotor KSY 666.30 Gear F3C-A25-89- Size 14 with Servostar 620 Servomotor KSY 668.30 Gear F3C-A35-119- Size 29 with Servostar 620 Servomotor KSY 6616.30 Gear F3C-A45-119

ADJUST

CHANNEL

MAINTE-

NANCE

DIMMER


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Figure 2.4: Example of retrofit installation with actuator size 7.


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The actuator for the EGS2200-STD is of very simple and rugged design and consists of only four compo-nents

- Servomotor- Reduction gear- Connection lever

- Conical friction coupling

A cycloid gearis used to reduce the high servo motor speed down to the very low output shaft speed. Thistype of gear is practically free of backlash, it is able to withstand sudden high overtorque and requires onlya minimum of maintenance. It has been in use for this purpose already for many years and has provenvery high reliability.

Depending on the different actuator sizes, the gear reduction ratio is between 87 and 119.

The servomotor is attached to the flange of the reduction gear and tightened with four bolts. The gearcomes with a friction coupling on its input shaft. The servo motor shaft fits into this friction coupling, whichwill be secured by tightening of a bolt with a pre-defined torque.

The connection leverserves for transmitting the movement of the actuator output shaft to the engine fuelrack.

The lever is mounted on the gear output shaft by means of a conical friction coupling. This type of cou-pling is secured by tightening a number of bolts with a pre-defined torque.

The use of this type of coupling instead of a slot-key connection for the lever makes it easy to loosen theconnection, if it should become necessary.Furthermore, this allows mounting the actuator in any position, as the lever can be fixed afterwards in anyposition on the gear shaft.Dismantling of a lever on-site is no problem either.

NOTE:When the actuator is shipped, the friction coupling for the actuator connection lever is not tight-ened. It must be tightened to its required value after mounting and adjusting of the lever on the actuatorshaft.

The servomotoris of brushless-type, it is controlled by a digital servo amplifier, which is housed inside thegovernor cabinet.

The servomotor uses a nominal voltage of 400V, this allows installing small wire gauges for the motorsupply.

Position feedback for the actuator shaft is taken from an absolute multi-turn encoder, which is placed wellprotected inside the servo motor casing on the motor shaft. This keeps the actuator output shaft free fromany feedback system.

The use of an absolute encoder makes sure that the actuator position information is available immediatelyafter power supply is on. Thus the actuator will resume operation automatically when power is restored af-ter a blackout.


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2.5 Transformer

The actuator servo motor controller is to be supplied with 400 VAC three-phase current. As the star-pointof the servo motor control system must be grounded, an isolating transformer serves for potential separa-

tion between the ships grid and the servo motor controller.

The standard transformer has inputs for 220/400/450 VAC, 50/60 Hz, 690 VAC is available as an option.The secondary side will supply 400 VAC.

The transformer is mounted into a casing, it shall be placed well ventilated somewhere close to the gover-nor cabinet or alternatively within the main switch board.

NOTE: The star-point of the transformer and the servo motor control circuit must be grounded.See the applicable connection drawings as well as the notes in Appendix A, chapter Cabling.

2.6 Internal Circuitry

2.6.1 Tachometer

The EGS2200-STD System contains a tachometer system for measurement of the engine speed. This ta-chometer system consists of two electro-magnetic pickups located very close to the engine flywheel. Onlyone pickup is necessary to sense the engine speed, so each of the two pickups act as backup for theother. The pickups sense the passing of each tooth on the flywheel and give a pulse to the tacho input cir-cuits in the Control Cabinet. The frequency of these pulses are converted to numbers representing theshaft speed in a dedicated internal computer in the EGS2200-STD. Readout of the shaft speed is availableat the Operating Panel display. An output for an analog RPM instrument is also supplied for remote dis-play, e.g. at the bridge.

SYNC. PICKUP

JUNCTION BOX FORTACHO PICKUPS

1 - 4 mm

2.6.2 Speed-Setting

The EGS2200-STD System is equipped with inputs which enables it to receive two speed-setting signalssimultaneously, i.e. a Rpm setpoint signal from the Bridge Manoeuvring System and a Rpm setpoint signal

during Manual Control with rpm speed-setting control.


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The Rpm speed-setting signal onboard the ship originates from the Bridge Manoeuvring System - Bridgespeed-setting handle (Telegraph) or ECR speed-setting handle (Telegraph) when Automatic Remote Con-trol from ECR is present.

The Basic Picture of the Operating Panel presents both the Bridge speed-setting signal value and the ECRspeed-setting signal value at the same time on its display. This enables the operator to adjust one of the

speed-setting signals to match the other before the change-over takes place. This function is usually called'Bumpless Transfer'.


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2.7 Modes of Operation

The EGS2200-STD System has four modes of normal operation, which are referred to as:

Auto Select,RPM Mode,Power Mode,andIndex Mode.

Please refer to chapter 0 for the description of softkey functions.

2.7.1 Auto Select

Auto Mode is selected when the AUTO SELECTsoftkey is pressed.Auto Select allows the EGS2200-STD System to automatically select either theor , depending upon prevailing engine running conditions. The changeover criterion due to the weather conditions is Sea state 3, i.e. in rough weather Power Mode is selected,and in calm weather RPM Mode is chosen.Index Mode is manually selected and results in fixed Fuel Command signal as long as RPM variationsstay within pre-defined limits.Auto Mode is automatically chosen after power is applied or the Gamma CPU is reset.

2.7.2 RPM Mode

Rpm Mode is selected manually when the SELECT RPMsoftkey is pressed.

The adjusts the Fuel Command to keep the engine at a constant RPM. Optimal fuel con-sumption is given less priority in this mode of operation.

2.7.3 Power Mode

Power Mode is selected manually when the SELECT POWERsoftkey is pressed.In the governor controls the Fuel Command signal in response to shaft speed variationsso that the power delivered by the engine is kept at a constant value. This mode minimizes fluctuations inthermal loading of the engine in a seaway. It will also provide fuel savings e.g. when the ship experienceadded resistance due to waves and wind.

Full protection of the engine is maintained in this mode of operation, as shaft speed is only allowed to varyup to a certain limit, where a more tight control becomes active.

2.7.4 Index mode

Operation in allows the EGS2200-STD Fuel Pump Index to maintain its position withoutmoving as long as engine RPM variations are inside pre-set limits. These limits are fairly wide, which al-lows this mode to be used when carrying out measurements on the engine, which require the Fuel PumpIndex to be "Fixed".

The pre-set limits refer to the actual speedsetting command, i.e. manoeuvring is possible in Index Mode, if

the limits are not too wide.


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is selected manually when the SELECT INDEXsoftkey is pressed and cannot be se-lected automatically by the computer.

2.8 Highspeed module

The Highspeed module decreases the fuel pump index, when an overspeed situation is approached. Thusthe main engine rpm is reduced temporarily in order to avoid an overspeed shutdown situation.

The activated highspeed function is automatically reset again, when the RPM is decreasing below RPM atMCR due to the reduced fuel pump index.

The function of the Highspeed Module is shown in figure 2.7 below.

Figure 2.7:Illustration of the function of the highspeed module.

2.9 Features available from the Operating Panel

2.9.1 Actuator Blocked Indication

When the actuator 'Blocked' indicator is illuminated, then the EGS2200-STD System is no longer able to

control the engine speed. The Operating Panel is only indicating this condition when certain serious fail-ures occur.

2.9.2 Load Limits

In order to protect the engine from overload, the EGS2200-STD System contains two load limit functions.One function ensures that the fuel pump index is limited according to scavenging air pressure. The otherensures that the fuel pump index is limited according to engine RPM. The curves involved depend uponthe engine type. These curves are loaded into the EGS2200-STD System during the factory acceptancetest, but may be modified later.


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The Load Limits may be cancelled by the Bridge Manoeuvring System or from the EGS2200-STD Operat-ing Panel by the LOAD LIMIT CANCELsoftkey. Partial or full cancellation of the Load Limits is custom-ized during commissioning of the EGS2200-STD.

Two EGS2200-STD System options contain curves of the same type as that of the Load Limit curves.

These are the "Charge Air Limit Pre-warning" and Engine Torque Limit Pre-Warning" curves. When fitted,they give a warning when the engine approaches pre-defined limit values.

2.9.3 Index Max

The INDEX MAX facility allows the operator to limit the Fuel Pump Index available from 50% to 100% ofthe pre-adjusted maximum, a.k.a. Index Max Seatrial:

Pressing the [SETTINGS]softkey will go to the Max Index and Fuel Max Factor adjustments when theEGS2200 Overview picture is selected:

EGS2200 EGS2200-STDINDEX MAX 100.0 %FUEL MAX FACTOR 1.00

The relevant parameter may be selected by means of the [Arrow]and [Enter]keys.

The actual present Index Max limit can be observed in the EGS2200-STD Status List as= Index Max ([SETTINGS]) * Fuel Max Factor * Index Max Seatrial.

When the EGS2200-STD System starts up after electric power is applied, the Index Max value is auto-matically set to the value it had prior to power loss.

Adjustment of the Fuel Max Factor for the Ship is possible from the Operating Panel via PASSWORD (themechanical maximum fuel limiter on the engine itself shall of course be adjusted, so that it is neverreached). For details please refer to chapter 4.5.2.

Note:The operator has the full responsibility for the use of this adjustment. Any overload conditions whichbecome, or are effective due to increased Index Max will not be compensated for by theEGS2200-STD.


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2.9.4 Acknowledge Alarm

When the EGS2200-STD alarm is activated for any reason, the light in the upper left hand corner of thiskey begins to flash. Pressing the [ ALARM ACKN.]key causes a fixed light. The LED is lit as long asalarms are present. Further details are explained in chapter 6.

When the alarm is activated, the cause is displayed in clear text in the display window.

In case more than one alarm is present, a list of the alarms is available for display in the display window.Arrow keys may be used to scroll up and down in the list once this has been selected via the [ ALARMLIST ]key.

Occurrence of an alarm will activate an output connected to the statutory alarm system. The alert providedby the alarm system can distinguish between a power failure and an EGS alarm. The reason for the alarmcan be read in clear text on the EGS2200-STD alphanumeric display to enable rapid and correct remedyaction.

2.10 Failure Modes

A power failure in the EGS2200-STD System will cause an alarm contact to be activated, if the 24V DCsupply should be interrupted. EGS2200-STD will perform slow actuator movement if a failure in one of thephases of the 220/400/450V AC supply occurs, an EGS alarm is activated and the cause can be observedat the LCD display at the front of the Servostar power drive inside the Control Cabinet. However, shouldmore phases be interrupted, the actuator is blocked to maintain it's position.

Failure of the electric power supply to the EGS2200-STD Operating Panel does not interfere with thespeed control ability of the EGS2200-STD System, but the EGS Alarm will be activated. Details of theEGS2200-STD reaction to various faults and a list of error messages are given in chapter 6.

2.11 Options

EGS2200-STD System does not require any optional equipment in order to function perfectly. Experienceshows, however, that some users have individual requirements with regard to additional controls, instru-mentation and alarms. Therefore the EGS2200-STD System has been developed to support a number ofoptions. A detailed description is provided in the options data sheets, and the options installed with yourEGS2200-STD are listed in chapter 1.6.4.

2.11.1 Engine Load Limit Option

This option provides outputs for external use of whether an index limit is reached or a pre-warning ispassed by before reaching a limit. The following signals are available:

- Fuel Index Limited signal (contact output)- Engine Torque Load Limit Prewarning (contact output)- Scavenging Air Load Limit Prewarning (contact output)


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2.11.2 Shaft Generator Option

This option is intended for plants with a shaft generator, offering safe operation. The following modules areavailable:

- Shaft Generator Connected signal range A (binary input)- Permission for Shaft Generator signal range A (contact output)- Shaft Generator Connected signal range B (binary input)- Permission for Shaft Generator signal range B (contact output)- Constant Speed Command (binary input)

The 'RPM slope', the RPM change rate, is individually adjustable for running with- and without shaft gen-erator.

2.11.3 Instruments Option

The instruments option comprises 2 separate voltage/current outputs for driving of e.g. instruments andcontrol purposes. Examples of signals are:

- RPM signal (0-10V / 4-20 mA output)- Fuel Index signal (0-10V / 4-20 mA output)

Other signals are available on request, see also Remaining Index signal (Controllable Pitch Propeller op-tion).A maximum of 2 analog outputs can be chosen including an eventual use of the VIT option. If there is norequirement of a reference voltage for a Manual Rpm Setpoint potentiometer, then an extra analog outputis available for instrument output.

2.11.4 Controllable Pitch Propeller Option

A set of modules is available for CPP installations. The modules assure that EGS2200-STD can be cus-tomized to almost any particular installation. The EGS2200-STD needs a signal of the actual pitch. The fol-lowing signals are offered:

- Pitch Angle Signal (4-20 mA or +/- 10V input signal)- Remaining Index Signal (4-20 mA or 0-10V output signal)

The pitch signal is used to improve the performance of the RPM control and to adjust the start level indexas function of propeller pitch. This secures safe start and prevents high RPM overshoots during start of theengine.

The Remaining Index Signal can be connected to the load controller of the CP-propeller control system. Itsignals the remaining available fuel index to the nearest load limit, i.e. scavenging air load limit, enginetorque load limit, index load program and index max limit.


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815.000.426-03 Lyngs Marine A/S

2.11.5 Variable Injection Timing (VIT).

The VIT system assures optimal injection timing over the envelope of operation of the engine.

The EGS2200-STD is controlling the VIT-index, while the diesel engine is running AHEAD during auto-

matic and manual remote control modes of operation.

The algorithm is made as advised by the engine designer and is approved for each type of diesel engine.The option is:

- VIT control signal (4-20 mA output signal)

The option conforms to MAN Diesel's VIT specification.

2.11.6 Cylinder Lubrication Oil Dosing.

Cylinder Lubrication Oil Dosing may be variable in certain installations. The option is:

- High Cylinder Lub Oil Dosing (contact output)

The LOD option conforms to MAN Diesel's LOD specification with extra lubrication request based on per-manent changes in the telegraph position. Closed contact equals extra lubrication request.

2.11.7 Cylinder Cut Out System.

The EGS2200-STD system offers the Cylinder Cut Out System (CCO) as an option with fixed pitch propel-ler installations.

The CCO system cuts out approximately half of the cylinders at low revolutions resulting in a stable runand reduced particle emission in the low revolution area down to minimum rpm.

The CCO system is enabled during automatic and manual remote control in direction of rotation ahead aswell as astern, when the engine is running below a predetermined number of revolutions.

Two binary output signals are activated (closed contact) - one at a time - for making cut out of half thecylinders. Turns between the groups are time based.

In order to obtain a safe start the cut out system is disabled during the starting period and until the engineis stabilised.

With Load Limits Cancelled the CCO system is disabled and all cylinders active.

Extra cylinder oil lubrication (LOD) is set to normal doses during cylinder cut out.

The algorithm is made as advised by the engine designer and is approved for each type of diesel engine.Engines with a limited number of cylinders are excluded.

The following input/output signals are included with the CCO option:

Binary output signals:

P Cut Out of Cylinder Group 1 (24V output signal)P Cut Out of Cylinder Group 2 (24V output signal)

The option conforms to MAN Diesel's CCO specification.

SAM Electronics GmbH


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2.11.8 Additional Control Options.

In addition to customer selectable options, EGS2200-STD has various control options that are used in cer-tain installations. The selection of these is made by Lyngs Marine. The control options include:

- Synchronization pick-up (tacho 3) for two-stroke diesel engines with 4 or 5 cylinders- Slope on RPM order software module

2.11.9 Slowdown Option.

This option is intended for owners, who want automatic slowdown function at Engine Control Room controlin addition to the slowdown function of the bridge manoeuvring system.

- Slowdown Order (binary input)- Cancel Slowdown order (binary input)- Reset Slowdown order (binary input)

- Delayed shutdown (contact output)

Delayed shutdown appears, when the Shaftgenerator option is included Waiting Station and theShaftgenerator is not disconnected from the busbar quickly enough.

The slowdown option extends the MAN Diesel slowdown specification for bridge control to have automaticslowdown function from Engine Control Room.

2.11.10 Barred Range Avoidance (Critical Speed Function)

The Critical Speed function protects the Main Engine RPM from running inside a pre-defined window (ad-justable) for barred speed range, where the Main Engine is not allowed to run due to torsional vibrationson the Main Engine or in the Propeller Shaft.One Barred Speed Range window can be defined in the EGS System.

The option assures that running at critical speeds are avoided:

- Critical speed software module

2.11.11 Engine Load Program

This option assures that load up of the engine at high load levels are done over a certain time. Further-more optional RPM loaddown is available.The available options are:

- RPM Load Program- Index Load program

The RPM- and Index load programs are used with fixed- and controllable pitch propellersrespectively.


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3. EGS2200-STD Functional Description

This chapter gives a detailed assessment of the functions of EGS2200-STD and of the use of the Operat-ing Panel. The topics covered are those available to the daily user in normal operation. Functions used fortroubleshooting and adjustments for the privileged user are treated in chapter 4.

3.1 General description

The Engine Governor System EGS2200-STD is a control system designed to accurately maintain the out-put shaft speed of rotation of a diesel engine to a given order. The EGS2200-STD is a third generationproduct based on the previous EGS 900 and RCS 990 systems. The hardware used in EGS2200-STD isa completely new design in new technology. The latest in the line of dedicated process computers, theGAMMA is used. One GAMMA Computer System is capable of fulfilling all demands placed upon theEGS2200-STD. The GAMMA is designed to operate reliable in the rugged environment aboard ship, andis type approved by major classification societies.

EGS2200-STD controls engine output power automatically in accordance with weather conditions. Thisenables the engine to be run at maximum without risk of engine overload in adverse weather conditions.Should weather conditions permit, the EGS2200-STD will automatically select a less active mode of op-eration in order to reduce wear and tear on the fuel pumps and fuel racks, as well as on the EGS2200-STD actuator.

EGS2200-STD contains a program module which functions as a super-fast high-speed protection whilemaintaining fully automatic shaft speed control. This enables engines to be run closer to design limits.

All parameters and readings used in daily operation can be accessed from the front panel by the operator,and privileged operators may change operational parameters when entering a password. The basic com-missioning data for EGS2200-STD may be programmed aboard by PC-equipment. This can only be doneby authorized Lyngs Marine service engineer.

For commissioning and service Lyngs Marine has developed a PC-based computer program which al-lows the engine-builder to program engine parameters into the EGS2200-STD.


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3.2 Functions within the EGS2200-STD

EGS2200-STD includes a number of functional blocks, which are described below:

a) The actuator control loop.

b) The tacho system.c) The setpoint selector.d) The shaft speed control loop.e) The engine limit curves module.f) Control Mode.g) The start/stop system.h) Minimum selector.i) A failure detection module.

Figure 3.2 illustrates the basic control functions of the EGS2200-STD.

The actuator is situated upon the engine, whilst the actuator control loop is contained in the Control Cabi-

net. The RPM loop is also situated in the EGS2200-STD Control Cabinet, using the tacho pickups forsensing engine speed. These are situated on the engine in proximity to the turning wheel.

The engine limits curve module is a software module situated within the Gamma Computer. Access to limitcurve characteristics and related parameters is available from the Operating Panel.

Figure 3.2:Illustration of the function of the Engine Governor System EGS2200-STD.


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3.2.1 Actuator Control Loop

The actuator control loop consists of a position control loop, which in turn uses fast speed control and cur-rent control loops to drive the actuator motor. A Servostar power drive for control of the actuator position,current and speed, is located inside the EGS2200-STD Control Cabinet. The STELLA7GAMMA Micro

computer simply supplies the actuator position setpoint from the analog output module AAM401 throughan isolation amplifier to keep the Gamma Computer separated from the power drive electronics and highvoltage signals. The actuator control loop power electronic block requires 3-phase 400 V AC. This is sup-plied by the main 220/400/440 V AC 3-phase supply via a transformer positioned in a separate unit nearthe EGS2200-STD Control Cabinet. The transformer size depends upon which of the available actuatorsizes is in use on the engine. The position loop power electronic block is similar for all actuator sizes, buthas an output power rating that match the requirement of the actuator.

The Actuator of the EGS2200-STD is available in different sizes. All comprise a motor, a brake, an abso-lute multiturn encoder used as position transmitter and a gearbox. The only difference between the differ-ent versions is the power available from the motor.The EGS2200-STD actuator motor is a brushless servomotor. This means that no periodical service is re-quired.

The EGS2200-STD actuator gear is a high precision epi-cyclic gear containing rotating pinions, whichtransmit power to a common, central pinion. The pinions are supported such that the gear obtains a verylarge part of its surface in contact during rotation and an extremely small backlash on its output. The gearrequires no periodical lubrication.

The actuator has a build in brake included as a safety feature. Such large mechanical powers are involvedin the EGS2200-STD Actuator that during commissioning and service the actuator must be blocked toavoid the possibility of injury to personnel working on the actuator. The brake requires 24 V DC in order todisengage it. If this supply fails, or is disconnected, then the brake will be engaged immediately, blockingthe actuator in its present position. This is the case when the power links in the EGS2200-STD ControlCabinet are removed by service engineer, if a mains power failure occurs, or if the EGS2200-STD shouldmalfunction.

If the actuator is blocked whilst the engine is running then although the EGS2200-STD will be unable tocontrol the speed of the engine, the engine will neither stop nor overspeed. In any case, when the actuatorbrake is engaged and the actuator blocked, an alarm is given by the EGS2200-STD. The brake current ismonitored continuously by the power drive itself.

An absolute encoder Transmitter provides the power drive with details of the position of the actuator.

This signal allow the precise control of the actuator, enabling it to move to a desired position with very littleovershoot, i.e. the motor is accelerated quickly, and its speed is reduced as the actuator approaches its fi-nal destination.

The Servostar power drive combines the inputs and produces the necessary power for the actuator motorin order to move it. Apart from the position transmitter discussed, the Power Drive also handles the follow-ing signal inputs:

1) Index Demand: The Index Demand, modified by the MIN Selector of the EGS2200-STDGamma Micro CPU, is the reference to which the Actuator Power Drivesets and maintains the actuator index.

2) Limit Switches: The MIN and MAX limit switches detect the extremes of mechanicaltravel allowed to the Actuator. The limit switches are implemented assoftware setup values relating to the encoder position feedback signalfrom the servomotor.

If the actuator reaches a Limit Switch, the Actuator Power Drive will then stop the actuator, and ignore allcommands, which would otherwise cause the Actuator to continue moving in the same direction. The Ac-tuator will only be able to move in the opposite direction.


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3.2.2 Tacho System

The speed of the engine is measured by a tacho system, using two independent pickups, TACHO 1 and

TACHO 2. The pickups are located close to the turning wheel. The tacho input circuit is situated on theTAM401 module in the EGS2200-STD Control Cabinet. Tacho signal processing is carried out by a dedi-cated input processor at the Serial Interface Board SIM401 of the Gamma Computer, and from here theRPM signal for the speedcontrol of the main engine is passed on to the Gamma CPU unit. Both units areplaced in the Control Cabinet.

The Tacho Selector selects which of the two signals is to be used. Checking that the two signals are withinthe valid range does this. If both signals are in order, but slightly different, then the Tacho Selector willchoose the signal which is the highest of the two and use this for the calculation of the RPM Value.

In addition to the selection mentioned real time signal processing is used to detect malfunction of a pickupsignal, which is automatically disregarded if a fault is detected. In nearly all cases where a tacho fails, thesignal goes to zero. In these cases the failed tacho will be disregarded and the other tacho is automatically

selected. In the very few cases where a failed tacho gives increased output, the EGS2200-STD will regu-late according to this apparently increased speed, and reduce the actual speed of the engine by an appro-priate amount. This certifies that a failed tacho will never give rise to an overspeed situation. In all cases, afailed tacho will cause an alarm to occur on the EGS2200-STD Operating Panel, and will be visible on thealarm list available via that unit (see the section on Trouble Shooting for further details of this alarm list).

3.2.3 The Setpoint Selector

The Setpoint Selector receives the RPM Setpoint signals from both the bridge and the ECR continuously.In order to determine which of these signals is to be considered as the actual order (they may be differentto each other), the Setpoint Selector also receives information from the attached Remote Operating Panel,which informs it of control location status. The selected setpoint is considered as the RPM Setpoint. This isfed to a slope unit, which keeps a track of the order and performs various functions within the EGS2200-STD. If a cable error on the selected input is detected, or if the manoeuvring system is off-line whilst inBridge-Control, then the Setpoint Selector will maintain the setpoint value in effect prior to the occurrenceof the error. The fault will of course cause an alarm on the EGS2200-STD Operating Panel and will bevisible on the panel. An EGS alarm is furthermore generated to the ordinary alarm system.

3.2.4 Shaft Speed Control

The Optimal Controller takes care of filtering the input signals and calculation of the Actuator Index De-mand. The parameters within the Optimal Controller vary constantly as a result of engine condition. Theresult is that the controller provides three separate modes of operation. These are as follows:

RPM MODE In RPM MODE the EGS2200-STD will maintain constant shaft speed even inrough weather with small fluctuations imposed from the weather. This requireshard work by the actuator of course, and some wear on all mechanical compo-nents on both the engine, the fuel pumps, fuel rack and the actuator is a conse-quence.

POWER MODE In POWER MODE the EGS2200-STD will maintain approximately constantshaft power. This gives optimal engine performance in moderate to roughweather conditions. In this mode of operation wear and tear on the engine fuelracks and the EGS2200-STD actuator is drastically reduced. Engine thermal

load fluctuations are likewise reduced. In the constant power mode, full controlis retained over shaft speed should it become too high.


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INDEX MODE In INDEX MODE the EGS2200-STD will maintain a fixed fuel index. This modeis mainly used when measuring engine performance through cylinder pressureindication. RPM control is automatically retained if RPM becomes too high orthe speed order is altered.

If set to Auto-select, however, the Optimal Controller will automatically select between RPM and POWER

modes to achieve the best operation according to the prevailing weather conditions. The change over cri-terion due to the weather conditions is Sea state 3, i.e. in rough weather Power Mode is selected, and incalm weather RPM Mode is chosen. Each mode of operation can be selected manually via the OperatingPanel.

3.2.5 Engine Limits Module

The filtered Ps (Scavenge Air Pressure) is transmitted to the Scavenge Air Limit block. The filtered RPM istransmitted to the Engine Torque Limit block and the Actuator Index Demand is passed to the MIN Selec-tor.The Scavenge Air Limit function in the EGS2200-STD assures that the correct amount of fuel is provided

for each cylinder in relation to how much scavenge air is available. This ensures clean burning of the fuelinjected.

During periods of acceleration the normal lack of sufficient turbo-charger speed in relation to engine speedmakes the fuel to air ratio within each cylinder too large. This means that not enough air is available toburn all the fuel injected.This again leads to poor combustion and the production of smoke containing sometimes severe pollutants.Restricting the Actuator Fuel Index in accordance with the available Scavenge Air alleviates this problem.

Figure 3.2.5:Fuel Index Limiters in the EGS2200-STD.

Figure 3.2.5 shows a typical Scavenge Air Limit curve. The values on the x-axis and y-axis are pro-grammed either by PC equipment or via the front panel of the EGS2200-STD Operating Panel duringcommissioning.

The EGS2200-STD contains an Engine Torque Limitation function, which purpose is to protect the engineagainst torque overload. The maximum allowable Fuel Index as a function of RPM is shown in figure 3.2.5.

The values determining the limit curves may be altered by privileged user access.


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3.2.6 Engine Limit Prewarnings (Option)

EGS2200-STD may optionally include two additional curves, normally chosen in parallel with the Scaven-ge Air Limit curve and the torque limit curve, but with lower index-values.

This first curve is referred to as the Scavenge Air Pre-warning Curve. When this curve is exceeded by thesystem, a contact in the EGS2200-STD Control Cabinet is opened. This contact is used by external sys-tems to indicate the condition scavenge air pressure limit pre-warning.

The second curve is referred to as the torque limit pre-warning curve. When this curve is exceeded by thesystem, a contact in the EGS2200-STD Control Cabinet is opened. This contact may be used by externalsystems to indicate the condition torque limit pre-warning.

3.2.7 The Minimum Selector

The MINIMUM Selector limits the Actuator Index Demand (from the Optimal Controller) before passing on

the final value of the Actuator Index Demand to the Actuator via the actuator power circuits.

The Actuator Index Demand is limited by three signals:

1) Scavenge Air Limit

2) Engine Torque Limit

3) Index MAX (The maximum index set from the Control Panel by use of theIndex MAX function).

If the Actuator Index Demand is limited for any of the above reasons then the condition will be indicated onthe LCD display of the EGS2200-STD Operating Panel.

The index will be limited to zero whenever a STOP or SHUTDOWN signal is active.

3.2.8 Control Mode

There are different control modes available to operate the propulsion plant:- Automatic EGS2200-STD Control from the Bridge (Automatic Bridge Control)- Automatic EGS2200-STD Control from the ECR (Automatic ECR Control)- Manual ECR Speed Control from ECR- Local Control from the Local Control Station

If more than exactly one of the three binary inputs for the selection of Control mode are activated at a time,then an is released after a timedelay and the actual control placechanges to the one with the highest priority (highest priority first):

- Local Control at the Local Control Station- ECR Manual Control- Automatic Bridge/ECR Control Mode

If none of the three binary inputs for the selection of Control mode are activated, then anis released after a timedelay and the actual control place remainsunchanged.

If no control place is selected during Power up / Reset Gamma CPU, then Local Control is selected, the

actuator remains blocked and is released after a timedelay.


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3.2.9 Alignment of Bridge- and Manual Engine Control Room setpoints.

When changing the control position from the Bridge to the Manual ECR control mode or vice versa, if thetwo SPEED-SETTING handles are in different positions, then the transfer will be "BUMPY", i.e. the engineRPM will suffer a step-wise change.

In order to avoid this, it is advisable to ensure that both speed-setting handles are in the same position be-fore transferring control from one location to the other. This is monitored in the Basic Mode overview dis-play at the Operating Panel:

ACTUAL RPM xxx.x CTRL MODE GOV. SETPOINT xxx.x STATUS REM. SETPOINT xxx.x MANUAL SETP xxx.x

Figure 3.2.9: Basic Mode Overview Display obtained when pressing [ESC] key repeatedly.

Indications for Main Engine include:

ACTUAL RPM xxx.x RPM Main Engine RPM from the tacho system MAN. CTRL Manual Speed Control mode

REMOTE Bridge Manoeuvring System in controlLOCAL Local Control from Local Control Station

GOV. SETPOINT xxx.x RPM EGS2200-STD resulting Rpm Setpointafter slope and other setpoint limitations.This value must be close to that of the setpoint source selected.

REM. SETPOINT xxx.x RPM EGS2200 Rpm Setpoint from DMS is usedin Remote Control

MANUAL SETP xxx.x RPM EGS2200 Rpm Setpoint from the speed-

setting handle used in Manual Control

3.2.10 Start / Stop System

The EGS2200-STD START/STOP system controls the index during start and stop of the diesel engine.

When a STOP or SHUTDOWN signal is received, the EGS2200-STD will immediately give an index zerodemand to the actuator. When a START request is received, the EGS2200-STD causes the actuator tomove to a pre-determined index value. This value will be maintained for a length of time (unless the actualRPM exceeds the desired RPM, in which case the index will be controlled by the Optimal Controller).When this time expires, the actuator index control will go on-line if the RPM has not reached the orderedvalue.

If the EGS2200-STD is started up after a mains supply failure, and the engine is already running at a RPMvalue above start level RPM, then this function will automatically be by-passed. The function is also by-passed if the Cancel Limits function is in operation for instance during a repeated start situation.

At the Operating Panel or by an external signal from the Remote Control System a higher value of startlevel index can be selected, e.g. if the first start attempt was not successful. This function is effectuated bythe Load Limit Cancel signal described in chapter 4.4.


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3.2.11 Failure Detection Module

The following categories of failure detection exist:

1. Cable failure for all analog input signals.

2. Pick-up errors for the Tacho System.

3. System supervision including Remote Control System, Tacho System, Operating Panel, Ac-tuator P

EGS2200 Std Manual

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