Marine Monitoring System II Caterpillar

Control Panel

Illustration 1	g00749565

The control panel contains the following items:

• Gauges

• Indicator lamps

• Switches

Gauges

Illustration 2 shows the arrangement of the following gauges:

• "ENGINE SPEED"

• "STARTING AIR PRESSURE"

• "ENGINE HOURS"

The gauges are a backup to the programmable logic controller.

In the event of a failure in the PLC, the redundant relay backup system will maintain minimum engine protection. The gauges are used for essential engine operation.

Note: The "ENGINE SPEED" gauge, "STARTING AIR PRESSURE" gauge, and "ENGINE HOURS" meter are provided as a backup to the monitoring system. The gauges may be used for basic engine operation that is independent of the programmable logic control and the display screen. Also, the switches and the "EMERGENCY STOP" button on the control panel operate independently, if necessary. However, power must be supplied to the control panel in order for the components to operate.

Illustration 2	g00749543

"ENGINE SPEED" Gauge

The "ENGINE SPEED" gauge has a digital display. The gauge displays the rotational speed of the crankshaft.

The signal for this gauge is provided by an engine speed sensor that is mounted in the flywheel housing. The signal is also used by the Engine Speed Switch. The engine RPM is displayed on the gauge regardless of the status of the PLC.

Illustration 3	g00749551

"STARTING AIR PRESSURE" Gauge

The gauge indicates the air pressure for the starting motor and the shutoffs regardless of the status of the PLC.

The start air pressure must be a minimum of 482 kPa (70 psi) and a maximum of 1550 kPa (225 psi). Starting air pressure above 1550 kPa (225 psi) is abnormal. Stop the engine and diagnose the cause. Running the engine during abnormal conditions may cause engine damage.

Illustration 4	g00562723

"ENGINE HOURS" Meter

The "ENGINE HOURS" meter indicates the total hours on the engine. The hour meter is driven off the contacts of the crank terminate relay. The meter is operating after crank terminate speed is reached.

Use the hour meter in order to schedule engine service. Do not use the hour meter on the PLC in order to determine regular service intervals.

Illustration 5	g00562726

Indicator Lamps

The indicator lamps provide the following status information:

• "SUMMARY SHUTDOWN"

• "SUMMARY ALARM"

• "CONTROL FAILURE"

• "SPEED SWITCH FAILURE"

• "ENGINE PRELUBE"

The lamps activate when the "HORN SILENCE/LAMP TEST" switch is placed in the LAMP TEST.

Illustration 6	g00749556

"SUMMARY SHUTDOWN" Indicator Lamp

The "SUMMARY SHUTDOWN" lamp displays the status of the engine protection shutdown system.

An OFF lamp indicates that no engine protection shutdowns exist within the system.

A flashing "SUMMARY SHUTDOWN" lamp indicates that an engine protection shutdown has occurred and that the shutdown has not been acknowledged. A description of the shutdowns that are active is displayed on an alarm banner of the operator interface and on the alarm status screens. Shutdowns can be acknowledged on the operator interface by selecting a specific shutdown on the screen and pressing the "Acknowledge" button. The "Acknowledge All" button may be used. Use caution because the button will acknowledge all alarms that have not been acknowledged.

A solid "SUMMARY SHUTDOWN" lamp indicates that active shutdowns exist and the shutdowns have been acknowledged at the operator interface. The "SUMMARY ALARM" lamp will remain illuminated until the situation is resolved. When a shutdown occurs, the "Air Shut-Off" damper closes and the engine will stop unless the "Shutdown Over-Ride" is active. If the "Shutdown Over-Ride" is enabled, the engine will be shut down when an "Engine Overspeed" or "Emergency Stop" occurs. All other shutdowns will have no effect on machine operation. The status of the shutdowns will continue to be annunciated on the operator interface. The status of the shutdowns will continue to be indicated by the "SUMMARY SHUTDOWN" lamp. The following conditions must be met before the machine can be restarted:

• The shutdown condition must be cleared.

• The "Engine Control Switch" must be placed in the "Off/Reset" position.

• The "Air Shutoff Damper" must be reset.

The shutdown should also be acknowledged at the customer interface. This will clear the status of the shutdown. The "SUMMARY SHUTDOWN" lamp is reset. The shutdown should be acknowledged before the "Engine Control Switch" is placed in the "Off/Reset" position. This will ensure that a time stamp is present and that a date stamp is present. If the communication from the PLC to the operator interface fails, an "Acknowledge All" command can be executed by placing the "Horn Silence" switch in the "ON" position.

"SUMMARY ALARM" Indicator Lamp

The "SUMMARY ALARM" lamp displays the status of the alarm system for the engine and for the failure of sensors.

An Off "SUMMARY ALARM" lamp indicates that no engine protection alarms or failures in sensors exist within the system.

A flashing "SUMMARY ALARM" lamp indicates that an engine protection alarm or a failure in a sensor has occurred and that the alarm has not been acknowledged. A description of the alarms that are active or failures in sensors is displayed on an alarm banner of the operator interface and on the alarm status screens. Alarms and failures in sensors can be acknowledged on the operator interface. Select a specific alarm or shutdown on the screen and press the "Acknowledge" button. The "Acknowledge All" button may be used. Use caution because the button will acknowledge all alarms that have not been acknowledged. A solid "SUMMARY ALARM" lamp indicates that alarms that are active or failures in sensors exist and the conditions have been acknowledged at the operator interface. The "SUMMARY ALARM" lamp will remain illuminated until the condition is resolved. Alarms can be reset in two ways:

• Clearing the fault and acknowledging the alarm

• Placing the "Engine Control Switch" in the "Off/Reset" position after the engine has reached 0 RPM.

Failures in sensors can be cleared in two ways:

• Placing the "Engine Control Switch" in the "Off/Reset" position after the engine has reached 0 RPM.

• Hold the "Horn Silence" switch in the "ON" position for five seconds.

"CONTROL FAILURE" Indicator Lamp

The "CONTROL FAILURE" lamp indicates the health of the PLC. When the PLC is correct, the output signal to the "PLC Functioning Alarm Relay" is "ON". The "CONTROL FAILURE" lamp is "OFF".

If the "CONTROL FAILURE" lamp is "ON", the PLC is in one of the following conditions:

• The PLC is in "Program Mode".

• The PLC has a fault.

• The PLC has no power.

During a failure in the control, the PLC is providing no protection for the engine. The data that is being displayed on the operator interface is not accurate. Refer to the gauges on the panel for information that is accurate. The redundant logic provides minimal protection during a failure in the control. The failure should be corrected as soon as possible. This will prevent damage to the engine.

In the event of a failure in the PLC, the redundant relay logic shutdown system will provide minimum protection. The failure in the PLC should be corrected as soon as possible. While the "PLC FAILURE" lamp is illuminated the PC display may not be correct. Use the backup gauges for accurate information. If the programmable logic control is inoperative, the redundant shutdown system will provide minimum protection.

"SPEED SWITCH FAILURE" Indicator Lamp

The "SPEED SWITCH FAILURE" lamp indicates the status of the engine speed switch. A yellow lamp that is ON indicates that the engine speed switch is not functioning properly. An OFF "SPEED SWITCH FAILURE" lamp indicates that the engine speed switch is operating properly.

"ENGINE PRELUBE" Indicator Lamp

The "ENGINE PRELUBE" lamp provides the status of engine lubrication.

A green "ENGINE PRELUBE" lamp indicates that the engine is prelubed and that the engine is ready to start. Place the "PRELUBE-RUN-START" switch in the START position. If the "ENGINE PRELUBE" lamp is illuminated the engine will immediately begin cranking. The "ENGINE PRELUBE" lamp is not illuminated when the engine is running.

Switches

Illustration 7 shows the arrangement of the control switches. The switches operate independently of the PLC. The switches will function in the event of a failure in the PLC.

Illustration 7	g00749559

"EMERGENCY STOP"Button

Do not use the button for normal stopping.

An Operator can press the red "EMERGENCY STOP" button in order to initiate an emergency stop. The button is enabled only when the panel is energized by 24 volt DC power. The emergency stop button is in the OUT position for normal engine operation. Press the button for an emergency stop. This shuts off the fuel supply and the inlet air to the engine. The button will lock in position.

The push button includes a mechanical latch. The button must be twisted clockwise in order to release. The "EMERGENCY STOP" button must be released before the Marine Monitoring System can be reset.

The "EMERGENCY STOP" button secures the fuel and the button secures the air via the relay logic. An emergency stop is annunciated by the PLC.

Note: When a shutdown occurs the air damper closes. This secures the intake air. The air damper must be reset in order to start the engine.

"OFF/RESET-LOCAL-REMOTE"Switch

Do not use the switch for normal stopping.

Note: The speed of the engine must be less than 10 RPM in order to restart the engine.

The three-position keyswitch determines the control mode of the engine.

In the "OFF/RESET" position, the engine may not be started. The "OFF/RESET" position secures the engine. Placing the switch in the "OFF/RESET" position will reset all active shutdowns.

The "LOCAL" position shifts engine control to the control panel. When the switch is in the "LOCAL" position the engine may only be started at the control panel.

The "REMOTE" position shifts engine control to the bridge. When the switch is in the "REMOTE" position the engine may only be started at the bridge.

"PRELUBE-RUN-START"Switch

The "PRELUBE-RUN-START" switch is only active when the following conditions are met:

• The "OFF/RESET-LOCAL-REMOTE" switch is in the "LOCAL" position.

• The engine is not running.

• No engine faults are present.

The engine must be stopped with no active engine faults. Turn the switch to the "PRELUBE" position in order to activate the prelube pump prior to starting. The starting motors will not engage if the engine is not prelubed.

The green "ENGINE PRELUBE" indicator will illuminate when an oil pressure of 10 kPa (1.5 psi) is achieved for intermittent prelube. For continuous prelube, the presence of oil is detected. The engine can be started when the "ENGINE PRELUBE" indicator is illuminated.

To start the engine, turn the switch to the "START" position. The starting motors will engage and the engine will crank. The starting motors will disengage after the engine reaches 170 rpm. When the switch is released, the spring-loaded switch will move to the "RUN" position. This is the normal position for the switch during engine operation.

"FUEL CONTROL" Switch

This is the normal procedure for stopping the engine.

The two-position "FUEL CONTROL" switch controls the engine fuel system.

The ON position allows fuel to the engine for running. The OFF position secures the fuel to the engine. The OFF position may also be used for rolling the engine with the air starters.

Note: The engine may start when the "FUEL CONTROL" switch is in the OFF position. This may happen if the starter is activated. In order to use the starter to roll the engine, you must first depress the "EMERGENCY STOP" button.

"SPEED CONTROL" Potentiometer

The "SPEED CONTROL" potentiometer provides local adjustment of engine speed. The adjustment is on a variable range.

"SPEED CONTROL" Switch

The "SPEED CONTROL" switch provides local adjustment of engine speed. The switch is a three-position switch:

• OFF

• Increase

• Decrease

The "SPEED CONTROL" potentiometer is used in order to increase the engine speed when the "SPEED CONTROL" switch is in the "increase" position. The "SPEED CONTROL" potentiometer is used in order to decrease the engine speed when the "SPEED CONTROL" switch is in the "decrease" position.

"GOVERNOR CONTROL" Switch

The "GOVERNOR CONTROL" switch has two positions:

• Idle

• Rated

The idle position sets the governor to the idle speed setting for the engine. The rated position sets the governor to the rated speed setting for the engine.

Note: The rated speed setting in the 723+ governors should be set for the engine idle speed for marine applications. Refer to, RENR 228-01 for more information.

"HORN SILENCE" and "Lamp Test" Switch

The switch acknowledges the detected alarms and the switch tests the indicator lamps. The switch will also test the horn and the beacon, if a horn and a beacon are installed.

To acknowledge an alarm condition, turn this switch to the "HORN SILENCE" position. The flashing of the alarm indicator will stop and the annunciator (if equipped) will be silenced. To check the indicator lamps on the control panel, turn the switch to the "LAMP TEST" position. This will also test the alarm annunciator (if equipped). The spring-loaded switch will return to the middle position after the switch is released.

A sensor failure can be reset by holding the switch in "RESET" for a minimum of five seconds.

Shutdown Override Mode

Use the shutdown override mode in critical situations only. When it is absolutely necessary to prevent engine shutdown the override may be used. The override disables all shutdowns except for the "Overspeed" and the "Remote/Local Emergency Stop".