ENGINE AUTOMATION

MAN Diesel SE SaCoS 99

System description

Revision 1.0
 System description
SaCoS 99 GS

Table of Contents
1 System overview ......................................................................................................... 3
2 System description ..................................................................................................... 5
2.1 Safety system ................................................................................................................ 5
2.1.1 Load reduction ........................................................................................................................6
2.1.2 Emergency stop .....................................................................................................................6
2.1.3 Override ..................................................................................................................................6
2.2 Alarm pre-processing ................................................................................................... 6
2.2.1 Alarm initiation ........................................................................................................................6
2.3 Engine control ............................................................................................................... 6
2.3.1 Starting/stopping sequences ..................................................................................................6
2.3.2 Control station switch-over .....................................................................................................6
2.3.3 Speed setting .........................................................................................................................6
2.3.4 Jet-assist ................................................................................................................................7
2.3.5 Pump control ..........................................................................................................................7
2.4 Electronic speed control ............................................................................................... 7
2.4.1 Speed setting .........................................................................................................................7
2.4.2 Operating modes ....................................................................................................................7
2.4.3 Load sharing ...........................................................................................................................7
2.4.4 Interfaces ................................................................................................................................7
2.5 Operation ....................................................................................................................... 8
2.5.1 Local operation .......................................................................................................................8
2.5.2 Indications: .............................................................................................................................8
2.5.3 Remote operation ...................................................................................................................8
3 Interfaces ..................................................................................................................... 9
3.1 Machinery alarm system ............................................................................................... 9
3.2 Propulsion control system ........................................................................................... 9
3.3 Gear box......................................................................................................................... 9
3.4 Pump control ................................................................................................................. 9
3.5 Remote control system ................................................................................................. 9
4 Technical data ........................................................................................................... 10
4.1 Design, environmental conditions ............................................................................. 10
4.2 Installation locations ................................................................................................... 10
4.2.1 Engine room .........................................................................................................................10
4.2.2 Engine control room .............................................................................................................10
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4.3 Weights ........................................................................................................................ 10

4.4 Dimensions, views ...................................................................................................... 11
4.5 Electric consumption .................................................................................................. 11
5 Installation requirements ......................................................................................... 12
5.1 General ......................................................................................................................... 12
5.2 Ambient conditions ..................................................................................................... 12
5.3 Cabling ......................................................................................................................... 12
5.4 Installation works ........................................................................................................ 12

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 System description
SaCoS 99 GS

1 System overview
SaCoS99 is a control and monitoring system for MAN marine main engines. It is available as
application for propulsion engines and as application for generator engines used for electric
propulsion.

To SaCoS99 all sensors of the engine according to MAN sensorlist and engine cabling diagram
are connected. Also the engine control station defined in the MAN engine design is necessary
for use of SaCoS99.

The engine is fully monitored and controlled by SaCoS. Control is normally performed by
means of an operating and indicating panel installed in the engine control room console. Local
control from the engine room is also possible by the engine local operating panel. The
connection between SaCoS and the engine is effected via permanent wiring.
The electronic speed controller is installed inside one of the SaCoS cabinets. The speed
control is subordinate to SaCoS.
The connection between the engine system and the load management, the plant-specific
control system as well as the alarm system are effected via the interfaces of SaCoS.
The auxiliary cabinet supplies and controls all engine-attached electric motors.
The COCOS-EDS engine diagnosis system is a computer-controlled system which is supplied
with data by SaCoS and which is suitable for the connection of up to four engines.

The system consists of the following components:

- Local control station (local on engine)
- SaCoS (switch cabinets in the engine control room or engine room)
- auxiliary cabinet (engine room)
- Uninterrupted power supply (engine control room) (optional)
- Indicating and operating panel (in the engine control room) (optional)
- Media temperature controllers (engine control room) (optional)
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 System description
SaCoS 99 GS

System block diagram

system_description_S99_32_40cn_m_1.0.docx

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 System description
SaCoS 99 GS

2 System description
The Safety and Control System serves for full monitoring and control of an engine.

SaCoS comprises:
- two control cabinets that contain the independent subsystems safety system, engine control
and alarm pre-processing, and that are to be set up in the engine control room or in the
engine room.
- the operating panel for installation in the engine control room.

The subsystems safety system, engine control and alarm pre-processing work completely
independently from one another; however, the exchange of information is effected via a
common system bus (Ethernet).
Each of the subsystems is connected with its appertaining signal-processing modules.

The SaCoS control cabinets contain all interfaces to the other system components and to
external systems, i.e.:
- Alarm system/remote control
- Pump control
- Gear box
- Propulsion control system

2.1 Safety system

The safety system monitors all required operating data of the engine and initiates the required
actions, i.e. load reduction or engine shut-down in case the limit values are exceeded. The
system is designed to ensure that the functions are achieved in accordance with the
classification societies’ requirements for marine propulsion engines.
The safety system directly monitors emergency shut-down, speed control and the engine
control.
In addition to the provisions made to permit the internal initiation of demands, binary and
analogue channels have been provided for the initiation of safety functions by external
systems:
- Emergency stop by manual emergency shut-down device
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- Emergency stop by gear box parameters.

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 System description
SaCoS 99 GS

2.1.1Load reduction
For controllable pitch propeller the load reduction has to be realised by the propulsion control
system. Load reductions are only implemented after preceding alarm initiation by the
subsystem alarm pre-processing, and are requested by the safety system.
For fix propeller systems the load reduction by the safety system results direct in a speed
reduction of the engine.

2.1.2Emergency stop
If an emergency stop is triggered by the safety system, the emergency stop signal has an
immediate effect on the emergency shut-down device and the speed control. At the same time
the emergency stop is triggered, SaCoS issues a signal for zero pitch (for CPP-applications).

2.1.3Override
Safety actions can be suppressed by the override function for various parameters. The override
has to be selected before a safety action is actuated. The scope of parameters prepared for
override are different and depend to the chosen classification society.

2.2 Alarm pre-processing

The subsystem alarm pre-processing works independently from the safety system. It monitors
all operating parameters and signals alarms in case impermissible deviations occur.

2.2.1Alarm initiation
All impermissible deviations from operating parameters as well as malfunctions cause alarm
signals to be issued and transmitted to the alarm systems via a serial bus interface.

2.3 Engine control

The engine control system controls and monitors all engine functions, the speed control and
the auxiliary drive cabinet.
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2.3.1Starting/stopping sequences
Demands regarding lube oil and cooling water pumps, monitoring of the prelubrication and
post-cooling period, monitoring of the acceleration period.

2.3.2Control station switch-over

Switch-over from local operation in the engine room to remote control from the engine control
room (SaCoS operating panel) and to the propulsion control system (only in case of CPP
application).

2.3.3Speed setting
Local and manual speed setting is realised by the SaCoS operating panels. Automatic remote
speed setting is carried out by the propulsion control system while remote control is selected

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 System description
SaCoS 99 GS

2.3.4Jet-assist
To improve the response of the engine in case of a load up request, starting air is supplied to
the turbocharger via a solenoid valve when load is applied.

2.3.5Pump control
The demands regarding the electric pumps for lubricating oil and cooling water are issued by
SaCoS. SaCoS also supplies the request signals for standby start of the lube oil and HT
cooling water pumps. The standby and pump logics are to be realised in an external pump
control system.

2.4 Electronic speed control

The electronic speed governing system includes the control and regulating devices for the fuel
rack actuator.
The speed governing system effects the exchange of all data required for safe and reliable
operation with the Safety and Control System. This data exchange is carried out via hardware
connections. There is no direct connection between the speed control and the superior plant-
specific control system. Communication with the plant-specific control system takes place via
SaCoS exclusively.

2.4.1Speed setting
An influence on speed is exerted by SaCoS. In case of remote control, a set-point input by the
plant-specific control system is possible either by means of binary contacts (e.g. for
synchronisation) or alternatively by an active 4-20mA analogue signal via SaCoS.
In the case of local control, speed alteration is only possible at the local engine control stand.

2.4.2Operating modes
The following operating modes are available as a standard:
- Isochronous
- Droop (with a 5-percent speed increase when reducing load from nominal load to no load,
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as a standard).

The operating mode is preselected via the SaCoS interface and has to be defined during the
application period.
Details regarding special operating modes on request.

2.4.3Load sharing
In the case of multi-engine plants, load sharing is effected by a droop function.

2.4.4Interfaces
The speed governing system is supplied with electric power of the required voltage from the
power supply cabinet. Cabling is to be done by the yard.

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 System description
SaCoS 99 GS

The connection of the speed control cabinet with the actuators on the engine is to be carried
out by the yard. The restrictions with regard to the length of these connecting lines mentioned
under item 2 are to be observed.
The connection to SaCoS is realised by means of a prefabricated cable set.

2.5 Operation

2.5.1Local operation
Local operation is carried out via an operating panel which is directly installed at the engine.
Visualisation of relevant operating data is realised by gauges. The following operational
functions are possible:
- Starting
- Stopping
- Adjustment of the desired speed value
- Local control/remote control switch-over
- Reset for stops and alarms
- Engine emergency stop.

2.5.2Indications
- Engine speed
- Cylinder cooling water pressure
- Charge air cooling water pressure
- Injection valve cooling water pressure
- Turbocharger lube oil pressure
- Fuel oil pressure
- Engine lube oil pressure
- Control air pressure
- Charge air pressure
- Starting air pressure.
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2.5.3Remote operation
An operating panel for installation at the controlling console of the engine control room will be
delivered for remote control.
The panel is equipped with an interactive display for visualisation of all engine parameters,
status and fault indications.
The following operational functions are possible:
- Starting
- Stopping
- Control station switch-over (local/remote control) to remote control system
- Reset for stops and alarms
- Engine emergency stop.

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 System description
SaCoS 99 GS

3 Interfaces
The automation and control system consists of several interfaces to external systems.
- Machinery alarm system
- Propulsion control system
- Gear box
- Pump control
- Remote control system

3.1 Machinery alarm system

Hardware
The main connection between SaCoS and the machinery alarm system is implemented as
serial interface RS232 or RS422/RS485
RS422/RS485 - Standard 5 wire with electrical isolation (cable length <= 100m)
RS232 - Standard, no electrical isolation (cable length < 10m)

Software
The software interface is realised with a MODBUS RTU protocol whereby the SACOS-system
acts as MODBUS Slave.
All measured values of the engine are provided as floating-point data words in a fixed register.
All pre-alarms, load reduction, shutdown and status information from the SACOS system are
also available as single bits in this register.

3.2 Propulsion control system

The interface to the propeller system is carried out as hardwired interface. Signals for safety
actions and control function as well as clutch control functions are exchanged.

3.3 Gear box

The interface includes all necessary signals for gear box control by the main engine. Alarm
indications of the gear box have to be realised by the machinery alarm system directly.
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3.4 Pump control

SaCoS sends request signal for oil and cooling water pumps to the pump control panel.

3.5 Remote control system

For various applications free programmable signals can be used at a separate interface.

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 System description
SaCoS 99 GS

4 Technical data

4.1 Design, environmental conditions

All switch boards are designed as cabinets to be placed on the floor with cable entry from
below, through the base.
The cabinets are accessible through doors provided at the front. All doors are equipped with
locking devices, the opening angle is 90°.
All switch cabinets are supplied in the standard colour light grey, RAL 7035. The cabinets’
degree of protection is IP54.

Environmental conditions for all cabinets:

- Ambient temperature: +10°C to +45°C
- Relative humidity: <60%
- Vibrations <0,7g

4.2 Installation locations

4.2.1Engine room
SaCoS control cabinets
Arrangement in the engine control room. The cabinets do not have to be attended for daily
operation. Location in engine room is alternatively to location in engine control room.
Installation depends on available space and ambient temperature conditions.

4.2.2Engine control room

SaCoS control cabinets
Arrangement in the engine control room. The cabinets do not have to be attended for daily
operation
SaCoS operating panel
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Installation in the engine-control-room consol for permanent attendance.

4.3 Weights
device weight
SaCoS safety system cabinet app. 300 kg
SaCoS control cabinet app. 300 kg
Operating panel in the engine control room 15 kg

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 System description
SaCoS 99 GS

4.4 Dimensions, views

Auxiliary cabinet: depending to type of speed governor
from 600 x 600 x 350 mm1* (wall mounted),
800 x 2100 x 400 mm* (height including base),

Common rail speed control cabinet: 1200 x 2100 x 400 mm* (height including base),

SaCoS safety system cabinet: 1200 x 2100 x 400 mm* (height including base),

SaCoS control cabinet: 1200 x 2100 x 400 mm* (height including base),

SaCoS operating panel: 400 x 600 x 100 mm*, (for control desk installation)

4.5 Electric consumption

Consumer Supply system Remarks

Pn Ub F Phase Fuse/starter
[kVA] [V] [Hz] By yard
SaCoS safety system 0,3 24V DC +/- 16A Power supply from ship battery
distribution
(two line redundant power supply)
SaCoS engine control and alarm 0,3 24V DC +/- 16A Power supply from ship battery
preprocessing system distribution
(two line redundant power supply)
SaCoS safety system 0,25 230 50 / 60 2≈ 10A Cabinet illumination, socket, anti
condensation heater
SaCoS engine control and alarm 0,25 230 50 / 60 2≈ 10A Cabinet illumination, socket, anti
preprocessing system condensation heater
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*
Width x height x depth
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 System description
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5 Installation requirements

5.1 General
The cabinets for engine control and safety system are designed for installation in engine rooms
and engine control rooms. Both cabinets should be located side by side.
The cabinets must be installed at a location suitable for service inspection.
In case of bulkhead mounting, a distance of at least 100mm is required between cabinet and
wall in order to allow for air convection. When installed in engine rooms, the cabinets should be
supplied with fresh air by the engine room ventilation.
The cabinet for engine-attached auxiliaries is designed for engine room installation and has to
be located near the engine.

5.2 Ambient conditions

For restrictions of ambient conditions please refer to the chapter “Technical data”

5.3 Cabling
The interconnection cables between the engine and the SaCoS cabinets have to be installed
according to the rules of electromagnetic compatibility. Control cables and power cables must
be routed in seperate cable ducts.
The maximum cable length between the engine and the interface cabinets is 60m.
The minimum bending radius for the installation of the premanufactured SaCoS cables is 180
mm.
Shielded cables have to be used for the cabling of sensors. The shielding must be connected
with the clamp. Keep unshielded cables as short as possible.
Each cabinet must be earthed by the vessel’s earth connection or by the potential equalization
by the customer.
The cabinets are equipped with spring loaded terminal clamps. All wiring to external systems
system_description_S99_32_40cn_m_1.0.docx

should be carried out without conductor sleeves.

5.4 Installation works

Make sure the ambient conditions are met during installation as well.
During the installation period the cabinets must be protected against water, dust and fire. It is
not allowed to do any welding works near the cabinets. The cabinets need to be screwed onto
the floor or the walls.
If it is inevitable to do welding works near the cabinet, the cabinets and panels must be
protected against heat, electric current and electromagnetic influences. To protect them against
current, all cabling has to be disconnected from the affected components.
The installation of additional components inside the cabinets is only allowed upon approval by
the responsible project manager of MAN Diesel.

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