Installation Operational and Maintenance Instructions - MS Wheels RLPS CAS 3600

____________________INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS MS-WHEEL RLPS CAS 3600
Installation, Operation and Maintenance
Instructions
for the
MS-Wheels
RLPS CAS 3600

Edition 05.2007
subject to change without notice
LEHMANN & MICHELS GmbH

Sales & Service Center
Siemenstrasse 9 • D-25462 Rellingen • GERMANY
Tel. +49 4101 5880 0 • Fax +49 4101 5880 129
e-mail: lemag@lemag.de • visit us at www.lemag.de
Contents
1. General system description………………………………………………………………3
2. Installation Instructions…………………………………………………………………...6
2.1 Mounting the Universal-holder………………………………………………………7

2.2 Mounting the Increment-wheel…………………………………………………….10
3. Parts list for the RPLS CAS 001-00…………………………………………………..13
4. Maintenance Instructions……………………..………………………………………...14
5. Trouble shooting…………………………………………………………………………15

Tel. +49 4101 5880 0 • Fax +49 4101 5880 129
e-mail: lemag@lemag.de • visit us at www.lemag.de 2
1. General system description

The crank angle measuring system RPLS CAS3600 was developed for continuous
measurement of the crank shaft angle for slow speed running two stroke engines of
the type Wärtsilä RTA as a retrofit.
It is used for the new cylinder oil lubricating system from Wärtsilä.
The system consists of (see drawing RPLS CAS 001-00) :
• a rotating slotted disk (1,2) mounted on the intermediate shaft close to the engine,
• an optical sensor head (3,4) with mounting brackets (5,6,7),
• a crank angle controller box (8,9).
For security reasons, two fully identical redundant systems are used for every
engine.
The slotted disks (1,2) have two signal traces which are sensed by the optical sensor
head(s) (3,4).
The inner trace has a single slot per revolution giving the signal called TDC.
The outer trace consists of equally wide slots and the slot width is identical to the gap
between two adjacent slots. The slot width is calculated for exactly 360 slots around
the circumference of the trace. For ease of adjustment and software there are in fact
only 359 slots. The 360th slot within the outer trace is missing at position of the TDC
slot of the inner trace. The TDC slot has the same width as the other 359 slots.
The sensor heads are equipped with 3 infrared photoelectric barriers.

One photoelectric barrier detects the inner TDC trace.
There are two photoelectric barriers for the outer 359 slots giving the signal S1 and
S1+.
The photoelectric barriers S1 and S1+ are aligned in such a way that depending on
the rotating direction one of the trace gives a signal first.
For clock wise rotation the signal S1+ is generated first while signal S1 is off.
If the engine is rotating further in a clock wise rotating direction for an amount of time,
both signals S1+ and S1 are generated. Then the signal S1+ disappears followed by
signal S1 if the engine is further rotating in the same direction.
For status information and ease of adjustment the sensor heads are equipped with
status LEDs for TDC (red), S1+(green) and S1(yellow). If the photoelectric barriers
are sensing the slot the LED is alit.
Because the cylinder oil lubricating system uses a standardized synchronous serial
communication bus (SSI) for the transmission of the crank angle, a controller box
(8,9) is used for converting the signals of the optical sensor heads into the actual
crank angle and allows for synchronous serial communication with the cylinder oil
lubricating system.

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At all signal changes inside the optical sensor head a new crank angle position is
calculated inside the controller box giving a physical resolution of 0,5 degree of crank
angle.
The controller box (8,9) is also equipped with status LEDs for TDC (red) and S1+
(green) and S1 (yellow).
The controller box (8,9) is supplied with 24V DC by the cylinder oil lubricating system.
The typical current consumption is 100 mA for each controller box (including optical
sensor head).
The controller boxes contain a galvanic isolation between the 24V DC power supply
and the digital output sensor/clock input signals. The 0V input of the 24V DC power
supply has no galvanic contact to the housing of the controller box
The controller box supplies the optical sensor heads with 5V DC and receives the
digital signals for TDC and S1+ as well S1 from the optical sensor heads. The sensor
heads are connected to the controller box using a cable of 2m length and a cable
plug connector at the sensor head side and fixed cable connection using cable gland
at controller box side.
All sensor heads and controller boxes are interchangeable!
The controller box receives a differential clock signal Clock+ and Clock- with 500 kHz
frequency from the cylinder oil lubricating system. Synchronized to the clock signal,
the controller box generates a differential digital pulse signal DATA+ and DATA-
containing the crank angle. Between two pulse trains of 500 kHz clock pulses, a gap
of at least 30 microseconds has to be inserted. Otherwise the response of the
controller is unpredictable.
In order to suppress any outside noise a screened cable with twisted wire pairs for
clock+/- and data+/- signals as well as the 24V DC/0V supply has to be used. The
cable screen has to be connected to the cable gland of the controller box.
The crank angle is coded inside the controller box as a 12 bit binary output value.
Because there are only 720 different physical sensible crank angle positions the
output data is interpolated to fit best into the 0000 to 4095 code scheme.
It was agreed that for clock wise rotating direction the controller gives a descending
digital output signal from 4095 down to 0000.
For counter clock wise rotating direction the sensor will give an ascending signal from
0000 to 4095 depending on the actual crank angle.
Because the measuring system is based on an incremental measuring principle at

power up the actual crank angle is unknown to the system. As long as there is no
valid crank angle information it was agreed that the system send the crank angle
value of 0000.
As soon as the optical sensor head has detected the rotating direction (depending on
the lighting scheme of S1+ and S1) and has reached the TDC slot it will give true
crank angle signals.

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The sensor heads as well as the controller boxes contain no serviceable parts. The
cable connection inside the controller boxes are made by using spring-loaded cage
clamp terminals. There is no need to fasten the cable connection if properly installed
during commissioning.
The controller boxes use self re-settable fuses in case of excessive current
consumption (trip current of 300 mA).
The controller boxes use reverse voltage protection and over-voltage protection for
voltages above 36V DC.
Instant reverse voltage or instant over-voltage can destroy the protection circuit in the
controller boxes!

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2. Installation Instructions ( Increment-wheel )

1. Locate place for optimal installation
Criteria for the optimal placement location:
¾ As close to the flywheel as possible (in front of any elastic connections or

couplings)
¾ Possibility of injury from moving parts are to be taken into consideration
¾ Access to the installation area (enough room to move around)
¾ A vibration free area to mount the universal-holder of the sensors.
¾ A route for the cabling from the sensors to the connection box, which will
be connected to the cylinder-station.
¾ Please see attached data sheet for installation/connection of the universal-
holder.
2. Clean the installation area on the shaft of any grease and dirt. A clean, flat
surface is necessary for proper installation.
3. Lay the increment-wheel (2) on the shaft (6). Insert tension-screw (4) (R-L
thread) in the clamping-nut (3) and turn the tension-screw in approximately
one turn. Ensure that both sides of the tension screws turn into their
respectable clamping-nuts at the same time. Tighten all 4 clamping-nuts (3)
until the incremental wheel is only just turn-able by hand on the shaft (6).
Ensure that the tension belt (5) is even with the holders (7) and that all holders
are laying full and flat (no gap) on the shaft.

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4. Insert M6 screws (9) in the holder as seen in previous diagram.
5. Insert the 4 slightly tapered brass set-up aids (8) into the 4 overlapping sensor-
wheel slits to guarantee an exact concentric installation between shaft (6) and
sensor-wheel (6). The slits are tapered in a wedge-form in the direction of the
shaft middle. The set-up aids can therefore only be inserted in one direction.
If the variations in the shaft-diameter are too large, the M6 Screws may
have to be loosened.
ONLY LOOSEN THE M6 SCREWS SO FAR UNTIL ADJUSTMENTS CAN BE

MADE BY LIGHTY TAPPING THE SENSOR-WHEEL WITH A PLASTIC
HAMMER.
6. Tighten the M6 screws (9) in the holder to a torque of 15 Nm.
7. Remove the 4 brass set-up aids (8).
8. Install the universal-holder.
9. Install the sensor-heads and ensure that each opening is in the middle of the
sensor wheel.
10. Measure the concentricity of the sensor-wheel with an indicator gauge and
adjust if necessary.
Deviation allowance: Axial true run <= 1,0 mm; radial true run <= 0,5mm
11. Tighten the tension screws (3,4) and holder screws (9) to a torque of 15 Nm.
12. Secure all M5 Screws on the sensor-head (1) with Loctite.
13. Install connection box and connect the sensor-head cable.
14. Connect the connection box to the engine system.
2.1 Mounting the Universal-holder
The scope of delivery for the universal holders of the sensor heads includes two
angle brackets and a perforated plate. The following picture shows the assembly. It is
vital that the sides marked with „Engine“ are attached in the direction of the engine.
The system, without sensor-heads, must now be attached in a suitable manner to the
ships structure. Two holes are drilled in the middle of the perforated plate for this
purpose. An angle bracket should be used as support. The bracket should be
attached to a fixed object on the ships structure, close to the motor.

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Sensor heads with angle brackets and universal-holder
The correct positioning of the holder has to be carried out with great care. The blue
sensor-heads must point to the centre of the ships shaft with as little deviation as
possible.
It can help to mark the angle bracket. To do so, remove a sensor head from the
angle bracket. Then mark a line 11mm from the upper edge of the angle bracket.
Marking the angle bracket
Remove the second sensor head and replace with the marked angle bracket.

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To determine the correct distance of the perforated plate to the ships shaft; measure
the height of the increment-wheel from the inner edge of the tension-belt to the outer
edge of the sensor-wheel.
Measure the height of the increment wheel. (Reading=S)

In this example, S=134 mm
Add 90mm to the height (S) (134+90=224mm).

This sum is used to mark the angle bracket, as shown below.
Outlay positioning
Screw all parts together before welding them to the ships structure. Everything will be
brought into the final position and the marking positioned on the ships shaft.

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The prepared parts should touch the ships shaft. The following pictures show correct
and incorrect positions.
too low correct position too high
Weld the angle bracket in the correct position to the ships structure. The perforated
plate can be removed before installing the increment wheel.
2.2 Mounting the Increment-wheel
Ensure that the sensor heads are installed with the markings „Engine“ in the direction
of the engine.

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The rotating sensor wheels should be covered after installation to ensure that no
involuntary contact is made, which could cause injuries.
The following pictures show the mounting of the sensor-heads below a ceiling. The
angle brackets with the universal-holder could in this case be kept very short.

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Alignment of the increment wheels
The sensor connection box is supplied with 24V from the engine management
system. Once the system has been switched on, test the sensors by turning the
shaft. To begin the process, turn the shaft/motor until all control-LED’s are dark.
When the shaft is turning clockwise, as seen when looking at the flywheel, S1 and
S1+ should cause S1+ to light first. Then both S1 and S1+ should light at the same
time. Then S1+ should now go out, leaving S1 on. S1 then should also go out and
the procedure repeats itself through every gap on the sensor-wheel. The TDC diode
should light only once per revolution. The S1 and S1+ LED’s should be dark when
the TDC diode is alight.

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3. Parts list for the RPLS CAS 001-00

(Please see attached schematic)
1. RPLS wheel one

2. RPLS wheel two
3. RPLS sensor one
4. RPLS sensor two
5. RPLS sensor bracket one
6. RPLS sensor bracket two
7. Double bracket
8. Controller one
9. Controller two

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4. Maintenance Instructions (Increment-wheel)
¾ Periodically check the sensor lenses in the RPLS CAS 3600 sensors
(part numbers 3 and 4). If they are contaminated, dusty or an oil film from the
surrounding engine area has appeared on the lenses, clean the lenses with a
clean and dust/dirt-free rag. DO NOT use any corrosive or petroleum based
chemicals on the lenses. The lenses are fastened with silicon-based glue and
the lenses will fall out of the housing if treated with the above mentioned
chemicals. Leaving the built in sensors open to contamination which will lead
to false/incorrect readings. Please ensure that the propeller shaft is kept as
clean as possible to avoid contamination of the lenses which are in close
proximity of the shaft.
¾ Ensure that all sensor and electrical cables are properly fastened and that the
cables are not subjected to moisture or oil impregnation. If the cables become
dirty or oily, clean them with a rag and ensure that the insulation is not
damaged. Also ensure that the cables are not subject to being walked on and
are not installed where they may be in a heavy traffic area and subject to
abuse. If the cables are subjected to periodical traffic (because of
circumstances beyond the control of the installation area), or if the cables
become parched and show signs of heat stress, wear and cracking; ensure
that the cables are appropriately inspected and cared and maintained for and
replace if necessary with original LEHMANN AND MICHELS GMBH approved
cables.
¾ Ensure that the sensors (part numbers 3 and 4) DO NOT come into
operational contact with the RPLS wheels (Part numbers 1 and 2). Contact of
the sensors from the wheel will scratch/damage the housing and the lenses
and sensors contained within and the sensors will have to be replaced.
¾ RPLS wheels one and two should periodically be checked for contamination in
the 360 slits. If the slits are filled with dirt and/or contaminated with oil and dirt;
the sensors will not be able to take a proper reading. Gently clean out any
contaminated slits with a small flat object (for example: a small screwdriver)
and if possible with a clean rag afterwards to remove any contamination that
could contribute to the slit being contaminated again in the future. If the
wheels and/or sensors are subject to open contamination and oil spray; it is
highly recommended that a barrier be built/set-up between the contamination
source and the RPLS CAS 001-00.

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5. Trouble shooting
Symptom Indications Tests _________
1. No SSI communication all LEDs are dark measure DC power supply

on controller box X1:3= +18...30V, X1:4=0V
2. 24V fuse in cylinder oil Reverse and over-voltage

lubr. control system is protection circuit might be
blown when connecting destroyed in controller box
controller box
3. No SSI communication all LEDs are alight check wires X1:5,6,8,9

on controller box in controller box
4. No valid crank angle all LEDs are alight check wires X1:5,6,8,9
on controller box and in controller box
optical sensor head
5. No valid crank angle LEDs TDC,S1 and S1+ check cable plug in optical
are dark on controller sensor head, check
box and optical sensor sensor adjustment
head
6. No valid crank angle a single LED (TDC,S1 check sensor adjustment,

and or S1+) is dark clean optical sensor
windows
7. Sometimes wrong check sensor adjustment,

crank angle
check cable plug, clean
sensor and slotted disk,
check vibration of sensor
head, check alignment of
slotted disk

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Gültige Toleranzen für offene Masse und offene Winkel
Für diese Zeichnung behalten wir uns alle Rechte

nach ISO 2768 - m.
Alle Masse in mm.
vor, auch für den Fall der Patenterteilung oder

Diese Zeichnung
wurde mit CAD
erstellt. Alle
Änderungen müssen
am Computer
erfolgen
Gebrauchsmustereintragung.
Gültige Toleranzen für offene Masse und offene Winkel
Für diese Zeichnung behalten wir uns alle Rechte
nach ISO 2768 - m.

Alle Masse in mm.
vor, auch für den Fall der Patenterteilung oder
Diese Zeichnung
wurde mit CAD
erstellt. Alle
Änderungen müssen
am Computer
erfolgen
Gebrauchsmustereintragung.

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____________________INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS MS-WHEEL RLPS CAS 3600

Installation, Operation and Maintenance

RLPS CAS 3600

subject to change without notice

LEHMANN & MICHELS GmbH

1. General system description………………………………………………………………3

2.1 Mounting the Universal-holder………………………………………………………7

3. Parts list for the RPLS CAS 001-00…………………………………………………..13

LEHMANN & MICHELS GmbH

1. General system description

The system consists of (see drawing RPLS CAS 001-00) :

The sensor heads are equipped with 3 infrared photoelectric barriers.

LEHMANN & MICHELS GmbH

All sensor heads and controller boxes are interchangeable!

Because the measuring system is based on an incremental measuring principle at

LEHMANN & MICHELS GmbH

LEHMANN & MICHELS GmbH

2. Installation Instructions ( Increment-wheel )

Criteria for the optimal placement location:

¾ As close to the flywheel as possible (in front of any elastic connections or

LEHMANN & MICHELS GmbH

4. Insert M6 screws (9) in the holder as seen in previous diagram.

ONLY LOOSEN THE M6 SCREWS SO FAR UNTIL ADJUSTMENTS CAN BE

6. Tighten the M6 screws (9) in the holder to a torque of 15 Nm.

7. Remove the 4 brass set-up aids (8).

8. Install the universal-holder.

12. Secure all M5 Screws on the sensor-head (1) with Loctite.

13. Install connection box and connect the sensor-head cable.

14. Connect the connection box to the engine system.

2.1 Mounting the Universal-holder

LEHMANN & MICHELS GmbH

Sensor heads with angle brackets and universal-holder

Marking the angle bracket

LEHMANN & MICHELS GmbH

Measure the height of the increment wheel. (Reading=S)

Add 90mm to the height (S) (134+90=224mm).

LEHMANN & MICHELS GmbH

too low correct position too high

2.2 Mounting the Increment-wheel

LEHMANN & MICHELS GmbH

LEHMANN & MICHELS GmbH

Alignment of the increment wheels

LEHMANN & MICHELS GmbH

3. Parts list for the RPLS CAS 001-00

1. RPLS wheel one

LEHMANN & MICHELS GmbH

4. Maintenance Instructions (Increment-wheel)

LEHMANN & MICHELS GmbH

Symptom Indications Tests _________

1. No SSI communication all LEDs are dark measure DC power supply

2. 24V fuse in cylinder oil Reverse and over-voltage

3. No SSI communication all LEDs are alight check wires X1:5,6,8,9

6. No valid crank angle a single LED (TDC,S1 check sensor adjustment,

7. Sometimes wrong check sensor adjustment,

LEHMANN & MICHELS GmbH

Für diese Zeichnung behalten wir uns alle Rechte

vor, auch für den Fall der Patenterteilung oder

nach ISO 2768 - m.

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