Marine Monitoring System II Caterpillar

This procedure is used in order to verify that the engine wiring between the junction box and the MECP Enclosure is correct. The following procedure should be performed after all of the wiring has been completed.

Powerup Test

Pre-Powerup Test

1. Visually inspect all of the wiring for loose connections or incorrect connections.

2. Measure the resistance between "1A" and "2" in the control panel. Measure the resistance between "1B" and "2" in the control panel. Measure the resistance between "1C" and "2" in the control panel. Measure the resistance between "1D" and "2" in the control panel. Measure the resistance between "1E" and "2" in the control panel. All of the measurements should be at least 30 ohms.

3. Verify the power supply's polarity. Connect the 24 VDC to "TB-1". Connect the common ground to "TB-2".

4. The Engine Control Switch should be in the OFF/RESET position. The Fuel Control Switch should be in the OFF position. The Prelube/Start Switch should be in the RUN position.

Powerup Test

1. Close circuit breaker 2. The Programmable Logic Controller should power up.

2. Close circuit breaker 4. The flex Input/Output and the engine speed switch should power up.

3. Close circuit breaker 3. The Marine Monitoring System's display should power up.

4. Close circuit breaker 1. The relay logic and miscellaneous circuits should power up.

5. Check the resistance between the following points:
   • "TB-109B" and "TB-109C" (Crankcase Pressure)

   • "TB-105B" and "TB-105C" (Lube Oil Pressure at Low Speed)

   • "TB-102B" and "TB-102C" (Lube Oil Pressure at High Speed)

   • "TB-107B" and "TB-107C" (Customer)

   • "TB-86B" and "TB-86C" (Summary Shutdown)

   • "TB-30A" and "TB-30C" (No Trip Alarm for the Circuit Breaker)

   • "TB-150B" and "TB-150C" (Fuel Control)

   Note: All of the measurements should be very close to zero.

6. Ensure that the display is communicating with the Programmable Logic Controller. The status of the PLC can be checked by selecting the "PLC Status Screen" on the PC display's main menu. The status of the PLC should be displayed.

Prelube Test

Note: This test is only for intermittent prelube.

1. Turn the Engine Control System to the LOCAL position.

2. Temporarily disconnect the wiring to the prelube pump. The wires should be disconnected from terminals "TB-73" and "TB-72".

3. Turn the Prelube/Start Switch to the PRELUBE position.

4. Ensure that there is voltage between "TB-73" and "TB-72".

   Note: The voltage should be 24 VDC.

5. Connect a jumper wire between "TB-72" and "TB-2" in the junction box. The prelube light should be on.

6. Turn the prelube switch to the "Off" position.

7. Reconnect the wires from step 2.

8. Turn the prelube switch to the "Prelube" position.

9. The prelube pump should run, if air is supplied to the pump.

Test for the Local Emergency Stop

1. Push the "E-Stop" button on the control panel.

2. Check the display in order to verify that an emergency stop has been activated. Ensure that the "Summary Shutdown" light has been illuminated.

3. Check the connections at both "TB-85" and "TB-82A" for 24 VDC with respect to terminal strip 2. This is done in order to verify that both the Air Shutoff Solenoid and the fuel control relay have been energized.

4. Turn the Engine Control Switch to the OFF/RESET position. Release the "E-Stop". The shutdown indicator should disappear.

Test for the Remote Emergency Stop

1. Connect a jumper wire between "TB-84" and "TB-2".

2. Check the display in order to verify that an emergency stop has been activated. Ensure that the "Summary Shutdown" light has been illuminated.

3. Check the connections at both "TB-85" and "TB-82A" for 24 VDC with respect to terminal strip 2. This is done in order to verify that both the Air Shutoff Solenoid and the fuel control relay have been energized.

4. Turn the Engine Control Switch to the OFF/RESET position. Remove the jumper wire. The shutdown indicator should disappear.

5. Remove the jumper from step 1. Repeat steps 1 to 4 with a jumper wire between "TB-113" and "TB-2".

Test for the Jacket Water Detector Alarm

1. Connect a jumper wire between "TB-1A" and "TB-90".

2. Turn the Engine Control Switch to the LOCAL position. Turn the Prelube/Start Switch to the RUN position. Turn the Fuel Control Switch to the ON position.

3. Connect a jumper wire between "TB-202" and "TB-2" in the junction box. The RJWDA should energize.

4. Ensure that the display shows the alarm.

5. Ensure that the "Summary Alarm" lamp is on.

6. Turn the FCS to the OFF position. Turn the ECS to the OFF/RESET position.

7. Remove the jumper wire. The light should turn off.

Test for the Oil Mist Detector Alarm

This alarm is optional.

1. Turn the Engine Control Switch to the LOCAL position. Turn the Fuel Control Switch to the ON position.

2. Disconnect the wire "235" from PLC "Card 3 Input 14".

3. Ensure that the display shows a fault in a sensor.

4. Turn the FCS to the OFF position. Turn the ECS to the OFF/RESET position.

5. Reconnect the wire "235" from PLC "Card 3 Input 14". The alarm for failure in a sensor should turn off.

6. Turn the Engine Control Switch to the LOCAL position. Turn the Fuel Control Switch to the ON position.

7. Connect a jumper wire between "TB-1A" and "TB-236".

8. Ensure that the display shows a shutdown for the oil mist detector.

9. Ensure that the summary lamp is on.

10. Turn the FCS to the OFF position. Turn the ECS to the OFF/RESET position.

11. Remove the jumper wire. The shutdown for the oil mist detector should turn off. The summary lamp should turn off.

Contactors

1. Verify that there are no failures in the contactors' sensors on the display screen. This includes the oil pressure contactors and the crankcase pressure contactor.

2. If any problems occur with the contactors, check all of the wiring from the MECP to the contactor. This check will find the majority of the problems that would exist. The most common problem is the interchanging of leads.

Thermocouples

1. Verify that there are no failures in the thermocouples on the status screen of the display. Valid temperatures should be displayed for each exhaust port on the status screen. Select the button on the bottom right side of the status screen in order to display the exhaust manifold temperature and the stack temperature.

2. Disconnect the exhaust manifold thermocouples one at a time. Verify that this creates a failure for the appropriate sensor. This verifies that the proper thermocouple is wired to the corresponding terminal block.

3. If any problems occur with the thermocouples, check all of the wiring from the MECP to the sensor. This check will find the majority of the problems that would exist. The most common problem is the interchanging of leads.

Use the following checklist in order to check each thermocouple:

• Thermocouple For Exhaust Port 1

• Thermocouple For Exhaust Port 2

• Thermocouple For Exhaust Port 3

• Thermocouple For Exhaust Port 4

• Thermocouple For Exhaust Port 5

• Thermocouple For Exhaust Port 6

• Thermocouple For Exhaust Port 7

• Thermocouple For Exhaust Port 8

• Thermocouple For Exhaust Port 9

• Thermocouple For Exhaust Port 10

• Thermocouple For Exhaust Port 11

• Thermocouple For Exhaust Port 12

• Thermocouple For Exhaust Port 13

• Thermocouple For Exhaust Port 14

• Thermocouple For Exhaust Port 15

• Thermocouple For Exhaust Port 16

• Thermocouple For The Left Exhaust Manifold

• Thermocouple For The Right Exhaust Manifold

• Thermocouple For The Left Exhaust Stack

• Thermocouple For The Right Exhaust Stack

Test for the Resistive Temperature Device

1. Verify that there are no failures in the Resistive Temperature Devices' on the status screen of the display. Valid temperatures should be displayed for each RTD on the appropriate screens. Each RTD that follows should be displayed: Lube Oil Temperature, Inlet Manifold Air Temperature, Jacket Water Coolant Temperature 1, Jacket Water Coolant Temperature 2, Fuel Temperature to the Engine and Aftercooler and Oil Cooler Water Temperature.

2. Disconnect each RTD one at a time. Verify that this creates a failure for the appropriate sensor. This verifies that the proper RTD is wired to the corresponding terminal block.

3. If any problems occur with the thermocouples, check all of the wiring from the control panel to the sensor. This check will find the majority of the problems that would exist. The most common problem is the interchanging of leads.

Use the following checklist in order to check each RTD:

• RTD For The Lube Oil Temperature

• RTD For The Inlet Manifold Air Temperature

• RTD For The Fuel Temperature to the Engine

• RTD For The Jacket Water Coolant Temperature 1

• RTD For The Jacket Water Coolant Temperature 2

• RTD For The Aftercooler and Oil Cooler Water Temperature

Transducers

1. Verify that there are no failures in the transducers on the status screen of the display. Valid pressures and engine speeds will not be displayed when the engine is not running. The pressures and speeds need to be measured while the engine is running. However, small amounts of pressure may be indicated. If a pressure indication is present, it is fairly safe to assume that the transducers are operational. While the engine is running, valid pressures should be indicated on the PC display. Each of the pressures that follow should be verified:
   • Lube Oil To Engine

   • Lube Oil To Filter

   • Fuel To Engine

   • Fuel To Filter

   • Jacket Water

   • Water Pump for the Aftercooler and Oil Cooler

   • Sea Water

   • Starting Air Pressure

2. The pressures should be able to be checked without removing the sensors in order to provide failures. A careful inspection of the transducers should provide a verification of the parameters. The parameters may be checked by looking at the engine overview, the cooling water piping diagram, the lube oil piping diagram, the air gauge, and the fuel gauge.

3. If any problems occur with the transducers, check all of the wiring from the MECP to the sensor. This check will find the majority of the problems that would exist.

Use the following checklist in order to check each transducer:

• Lube Oil To Engine

• Lube Oil To Filter

• Air Inlet Manifold

• Fuel To Engine

• Fuel To Filter

• Jacket Water (Option)

• Aftercooler And Oil Cooler Pump (Option)

• Sea Water (Option)

• Starting Air Pressure (Option)