Daihatsu MD-SX Instruction Manual
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Daihatsu MD-SX Instruction Manual

Daihatsu MD-SX Instruction Manual

Oil mist detector
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JULY. 2015
INB000044D
OIL MIST DETECTOR
INSTRUCTION MANUAL
MD-SX
(Sensor type)
Issued to HORIZON TANKERS LIMITED S.A.

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  • Page 1 JULY. 2015 INB000044D OIL MIST DETECTOR INSTRUCTION MANUAL MD-SX (Sensor type) Issued to HORIZON TANKERS LIMITED S.A.
  • Page 2 Safety Precautions on Operation of Oil Mist Detector This Manual describes cautionary items for installation and operation of the oil mist detector for sake of safe use. Please operate the equipment adequately while following the cautionary items. The degree of hazard and damage likely to result from wrong use, neglecting the indicated cautions, is explained in this Manual using symbol marks shown below.

  • Page 3: Table Of Contents

    CONTENTS 1. OVERVIEW ......................... 1 2. FEATURES .......................... 1 3. CONSTITUTION......................... 2 4. OUTLINE ..........................4 5. SPECIFICATIONS......................8 Sensor unit ........................8 Controller .......................... 9 DISPLAY AND FUNCTIONS OF SENSOR UNIT ............10 Description of function ....................10 “POWER” LED ......................10 “ALARM”...

  • Page 4: Overview

    1. OVERVIEW This equipment consists of “sensor units” that are directly mounted through the wall on the crankcase side of a diesel engine or gas engine (or EGR system : option) that collectively controls the units by communication means and “controller”. This equipment was developed by applying new techniques and ideas based on our long-term accumulated techniques related to detection of oil mist density.

  • Page 5: Constitution

    RELAY OUTPUTS（to Alarm Marine cable Monitoring System） （shielded） Fig. 1 Install MD-SX system on one engine (2) In case of install MD-SX system for two engines. (For land or ship use without classification approved) DIESEL ENGINE MD-SX SENOSR JUNCTION BOX MD-SX CONTROLLER...
  • Page 6  Limit the total length of the telecommunication cable from the sensor of an end to a controller is less than 150 m (for use of Daihatsu option cables). In case of the total wire length exceed 150 m, please ask the wiring method to Daihatsu.

  • Page 7: Outline

    4. OUTLINE (1) DOWN WARD SENSOR UNIT STANDARD TYPE (CONNECTOR TYPE) CABLE GLAND TYPE FLYING-LEAD TYPE Fig. 3 MD-SX OUTLINE OF DOWN WARD SENSOR UNIT Issued to HORIZON TANKERS LIMITED S.A.
  • Page 8 (2)HORIZONTAL CABLE SENSOR UNIT STANDARD TYPE (CONNECTOR TYPE) FLYING-LEAD TYPE Fig. 4 OUTLINE OF HORIZONTAL CABLE SENSOR UNIT． Issued to HORIZON TANKERS LIMITED S.A.
  • Page 9 (2) CONTROLLER Wall mount type(with cable gland) Wall mount type(with cable comb) Fig. 5 Controller outside Issued to HORIZON TANKERS LIMITED S.A.
  • Page 10 Flush mount type PANEL CUT Fig. 6 Controller outside Issued to HORIZON TANKERS LIMITED S.A.

  • Page 11: Specifications

    Rotary switch : Communication node (16CH) “0” - “F” Initial-setting operation Dip switch : Terminator “ON”/“OFF Sensor line : MD-SX option cables (Daisy chain) Total length: 150 m max. External connection (10) Connection method : Connector (Standard type) (Sensor unit - Controller)

  • Page 12: Controller

    (Sensor units and external unit) Sensor line : Daihatsu option cables or specified cable for ships (To install a junction box: AWG15  4 cables) Contact output line : Cable outer dia. = 18 mm or less (for one engine)

  • Page 13: Display And Functions Of Sensor Unit

    DISPLAY AND FUNCTIONS OF SENSOR UNIT Connector ground “FAILURE” DISPLAY “FAILURE” DISPLAY “ALARM” DISPLAY “ALARM” DISPLAY “ OWER”DISPLAY “ OWER”DISPLAY Slide cover Screw of cover Fixed Screw of slide cover Slide cover Connector ground Fig. 7 Sensor unit Each sensor unit has three status indicating lamps (LEDs); POWER (green), ALARM (red), and FAILURE (yellow).

  • Page 14: Display And Functions Of Controller

    DISPLAY AND FUNCTIONS OF CONTROLLER LCD DISPLAY MIST INDICATOR [INITIAL SET] (LED) [TEST] “HIGH ALARM” [MODE] DISPLAY (LED) Fastener “PRE ALARM ” DISPLAY (LED) [STEP] “RUN” DISPLAY (LED) “SYSTEM FAILURE” [ENTER] DISPLAY Cable gland (LED) Fig. 8 Controller face of a board The controller has not only operation key switches and an LCD indicator for displaying the status, but also 16-ch mist indicators that show the oil mist density level with 16 LEDs in three colors, green, orange and red.

  • Page 15: System Failure" Led

    7.3 “SYSTEM FAILURE” LED When a controller CPU trouble occurs, a hardware trouble is detected by the self-diagnostic function of any sensor unit or a communication trouble between the controller and a sensor, the LED will be turn on, and the “SYSTEM FAILURE”...

  • Page 16: Step] Keys And [Enter] Key

    7.5 [STEP] keys and [ENTER] key Use the arrow keys to move the cursor on the LCD or to increase or decrease the set values. Use the ENTER key to reset the alarm to the normal mode. In the setting status of each mode, also use the ENTER key to determine the set data at the cursor position. 7.6 [INITIAL SET] key switch The [INITIAL SET] key switch is to (store the mist density data under the maximum load in the controller) when setting the full load.

  • Page 17: Mode] Key Switch

    7.8 [MODE] key switch You can select the mode change screen for the modes of ｢1. STATUS｣, ｢2. INITIAL RESET｣, and ｢3. CONFFIGURE｣ by pressing the [MODE] key switch. 1. STATUS 1) CONTROLLER : To display the controller data on the LCD screen in a batch 2) SENSOR : To display the current status of the connected sensor 3) MIST/ALARM LEVEL...

  • Page 18: Installation

    Please install it by a recommended method. The recommended installation position of the MD-SX sensors is upper place from clank shaft and side of figure below.
  • Page 19 (2) Mounting conditions 1) Horizontal or downward (front declined) within 15° Fig. 10 Tilt tolerance for horizontal direction 2) Rotation direction within ±5° Fig. 11 Tilt tolerance for the rotation direction (3) Insert the hood of the sensor unit into the crankcase through the threaded portion (thread size: G3/4) of the engine frame, screw in the hood to the specified length (threaded portion length of 15 mm: 10 turns or more) after winding a sealing tape, and secure the hood with the lock nut through the supplied sealing washer.
  • Page 20 - There is the structure like oil pool, and the sensor hood sinks. In case the sensor is installed such a place, mist inlet holes of the hood may be blocked by oil and MD-SX may not detect mist density surely. Then, oil comes into mist detection area in hood from the mist inlet holes. As a result it may cause sensitivity abnormal or miss-alarms (HIGH and/or PRE- ALARM).

  • Page 21: Controller

    8.2 Controller (1) Use the controller under environmental conditions meeting the following specifications. The vibration acceleration applied to the mounting place shall be 1G or less. If the acceleration exceeds 1G, mount the controller using the separately supplied antivibration bracket or equivalent brackets through the specified rubber vibration insulators. Install the IACS M10 at a safe place far away from the engine room.

  • Page 22: Wiring

     Wire the sensors in daisy chain system (connection-in-a-row system) for each engine.  Use the Daihatsu option cables for the wiring between sensors and a controller. For one engine, limit the total length of the wires within 150 m from the end sensor and the controller. Even if two engines are used, the total length of the cable should be within 150 m for each engine.

  • Page 23: Cable

    (2) A general cable for ships (batch shielded cable with 4 or more cores) can be used between the junction box (terminal box) and controller when the junction box is installed on the engine body. But use a Daihatsu option cable for the wiring between sensor units, and between a sensor unit and a junction box.
  • Page 24 The color of cable jacket of Daihatsu optional cables are shown at this table. When you connect the Daihatsu optional cable to the general cable for ships, distinguish the power supply lines and the communication lines with a color of cable jacket, and connect it without wrong.

  • Page 25: Wiring Of The Sensor

    Wiring of the sensor (1) Cable for connection : Daihatsu option cables [Cable with both-ends connector] or [Cable with single-sided connector] (2) Connection topology : Daisy chain (3) Connection method : Connector - Connector <Before connection> <After connection> (The terminal in the sensor)

  • Page 26: Wiring Of The Controller

     Power supply (24 V DC) : 1.5 mm (AWG14) 1 wire  Communication line: (Between the sensor units and controller) Daihatsu option cable ( 4  0.5mm ２ ) 4 lines (When a junction box is installed) 1.5 mm (AWG15) ...
  • Page 27 * Ground wire must * The drain wire of Power supply Wiring Contact be installed to the shielded cable must be line for sensors Outputs ground terminal installed to the grounding bar. Fig.25 Schematic drawing of the controller external wiring connections (for one engine) ...
  • Page 28 (3) Cable gland and selection of the correct type gland Cable gland (2) Inlet for power supply cable (15c) (1) Inlet for sensor cables (3) Inlet for contact outputs (15c) cable (25a) Fig. 28Controller cable inlet hole 15c  2 sets Cable gland : For sensor units Cable gland 15c ...

  • Page 29: Setting Of Resistance For Detecting Disconnection

    Setting of resistance for detecting disconnection The setting of the resistance for detecting disconnection of the controller safety circuit (High-alarm) can be changed by changing the specified jumper positions on the board. The jumper has been normally fitted to the pins 1 and 2 (open) before shipment. Fig.

  • Page 30: Wiring Of The Gland Type Sensors

    Wiring of the gland type sensors Using the sensor of “gland type”, connection work for “Terminal Block” is necessary. The connection and method of wiring work for Terminal Block, please refer to [9.6 Cautions in wiring]. (1) Loose screw fastening the slide cover and slide the slide cover to reveal the terminal block. (2) Wiring connection refer to Figure 26 [SENSOR TERMINAL BLOCK LAYOUT].
  • Page 31 (2) Wiring procedure Use the supplied special tool or 2.5 to 3.5 mm wide flat tip screwdriver. Insert the screwdriver at an angle Straighten up and insert the If properly inserted, the screw- in the setting slot (square hole). screwdriver to the full depth. driver can stay straight in the slot when hand is take off.

  • Page 32: Initial Setup

    10. INITIAL SETUP 10.1 Initial setup of sensor units After fitting the sensor units on the engine, initialize the units while the controller power is off. Remove the lid of the sensor unit case, and operate the internal setting switches. How to take off the cover : for slide type Slide the cover to downward.

  • Page 33: Initial Setup Of Controller

    10.2 Initial setup of controller After the completion of the initial setup of the sensor units, initialize the controller with power on the controller. Refer to [11. OPERATION] for the operation procedure of the controller from initial setup to run. Initial setting menu is displayed interactively on the Liquid Crystal Display (LCD).

  • Page 34: Operation

    Described in this item are steps from the first power ON, initial setting, and full load setting to the actual operation. For the other operation functions and details, refer to the "MD-SX OPERATION MANUAL" (Q7LT333380F). 11.1 Checks before turning the power on Always check the followings before turning the power on for the first time.
  • Page 35 (1) Power ON Unlock the snap type lock or the knurled lock on the right side of the controller, and then open the panel front side toward the left side. Turn the power switch on. The power is supplied to the system and the controller begins the self-diagnosis after the power switch is turned on.

  • Page 36: Full Load (Mist Density Level) Setting

    (6) Full load setting is yet to be carried out and the system is in the trial operating condition. The MD-SX detector can properly operate only when [full load setting] is carried out for the mist density under the full load. If the screen as shown below is displayed, it indicates [full load setting] is yet to be carried out and the system is operating with the alarm setting-off value set as the initial value.

  • Page 37: Initial Reset

    11.4 Initial reset This is the function to repeat the initial setting carried out when the MD-SX is turned on for the first time. For instance, when the initial setting is improperly carried out, the number of sensors or of engines must be changed, or the computed average value must be changed, you can carry out the initial setting again from the beginning with this function.
  • Page 38 (2) Select a sensor to temporarily lower the setting value by scrolling the screen with the upward and downward arrow keys. Select the sensor and press the [ENTER] key to define the selection. (3) Set the HIGH ALARM level for the selected sensor. The value currently detected is displayed (5 is displayed as an example here), and the value of about 10 above the currently displayed value (15 as an example here) is automatically set as the HIGH ALARM level.

  • Page 39: Test Method And Operation Check (For Iacs M10.13)

    12. TEST METHOD AND OPERATION CHECK (FOR IACS M10.13) To check the HIGH ALARM and PRE ALARM functions or to check operation of sensors, refer to Section [11 OPERATION]. Sensors are calibrated before delivery from our plant. So the scales will not be changed. At starting and stopping the engine during daily operation, check whether the mist levels indicated by the controller are increased.

  • Page 40: Approximate Value Of Mist Density

    13. APPROXIMATE VALUE OF MIST DENSITY (1) Mist density 1) The oil mist density is expressed as the weight (mg) of oil contained in 1 liter of air. It has been experimentally verified that 50 mg/L is the lower explosion limit of oil mist. 2) The oil mist density of an engine considerably varies depending on the engine type and operating conditions.

  • Page 41: Maintenance

    Since the sensor unit is the maintenance-free type. After installing and starting operation of the sensor unit, it is not necessary to provide maintenance services for 3 years basically. MD-SX sensor does not need the renewal parts. Regarding the contamination of the lens surface, it is necessary to be cleaned the sensor hood section when the error code 17 which means the sensitivity decreased occurred and daily operation check.
  • Page 42 Note) When use of the MD-SX oil mist detecting system becomes it over eight years, you should ask DAIHATSU for system operation check and maintenance by Daihatsu engineer.

  • Page 43: Troubleshooting

    15. TROUBLESHOOTING 15.1 TROUBLESHOOTING by controller indicate Issued to HORIZON TANKERS LIMITED S.A.
  • Page 44 Issued to HORIZON TANKERS LIMITED S.A.
  • Page 45 “ＳＥＮＳＯＲ ＣＬＥＡＮ 17” Issued to HORIZON TANKERS LIMITED S.A.

  • Page 46: Sensor Fail Code At Lcd On The Controller

    “SENSOR FAIL” occurs only Arrange the loop cable on certain rotation range 15.2 Sensor fail code at LCD on the controller The abnormalities Check the cable condition and connecting condition between sensor and In communication cable. Of sensor unit In case sensor fail occurs only on certain rotation range. Arrange the loop cable.

  • Page 47: Troubleshooting By Sensor Unit Indicate

    15.4TROUBLESHOOTING by sensor unit indicate Issued to HORIZON TANKERS LIMITED S.A.

  • Page 48: Appendix

    ASSY: MD-SX: SENSOR UNIT (GRAND TYPE) DOWN WARD CABLE SENSOR UNIT (Fling - lead type) Number Parts Number Name of Parts Quantity NN00465007B ASSY: MD-SX: SENSOR UNIT (FLYING LEAD TYPE) 2) HORIZONTAL CABLE SENSOR UNIT (Standard：Connector type) Number Parts Number Name of Parts Quantity ※...
  • Page 49 +MACHINE SCREW ASSY M6×1.0×10 Wiring material (Specification article: Option) Number Parts Number Name of Parts Qty. NN00646001A CABLE.: MD-SX:BOTH SIDES CONNECTOR 1M NN00646002A CABLE.: MD-SX:BOTH SIDES CONNECTOR 2M NN00646003A CABLE.: MD-SX:BOTH SIDES CONNECTOR 3M NN00646004A CABLE.: MD-SX:BOTH SIDES CONNECTOR 4M NN00646005A CABLE.: MD-SX:BOTH SIDES CONNECTOR 5M...
  • Page 50 Parts Number Name of Parts Quantity NN00465022A PCHS：MD-SX：SENSOR CHECKER 10)MD-SX SENSOR CLEANER (OPTION) Number Parts Number Name of Parts Quantity 9VB2002005Z CLEANING LIQUID KIT 1L SC-1000(FOR MD-SX) 9VB2580002Z YUNISOL H 4L(CLEANING LIQUID FOR MD-SX SENSOR) Issued to HORIZON TANKERS LIMITED S.A.

  • Page 51: Anti-Vibration Bracket Mounting Drawing (Option)

    16.2 Anti-vibration bracket mounting drawing (OPTION) Fig.38 Anti-vibration bracket OUTLINE Parts No. Name of parts Qty. NN00272001A BRACKET: 1: MD-SX NN00272002A BRACKET: 2: MD-SX ISORATION RUBBER: 1M: AE01166003A SPRING WASHER M6 (Accessory) NUT M6 × 1.0 (Accessory) X249006010ZZ +MACHINE SCREW ASSY M6 × 1.0 × 10 ATTACHMENT BOLT M8 16.3 Sensor cleaning procedure...
  • Page 52 Sensor cleaning procedure by Yunisol H １．SAFETY AND HANDLING Ａ) This cleaning method will be applied to oil mist sensor on the 2or4 cycle engine with heavy contamination of lubricant oil Ｂ) The cleaning agent is used with the stock solution. Please note that the effect decreases when diluting it with the washing oil and water.
  • Page 53 This cleaning method will be applied to oil mist sensor on the 2cycle engine, with less contamination of lubricant oil Issued to HORIZON TANKERS LIMITED S.A.
  • Page 54 How to confirm the good sensitivity of sensor. Check the indication”Good!”,“LV1”,”LV2” by connecting optional sensor. It confirms it by the following methods when there is no checker. (ABOUT 5mm) Issued to HORIZON TANKERS LIMITED S.A.
  • Page 55 “ＳＥＮＳＯＲ ＣＬＥＡＮ １７” “Ｓ ＥＮＳＯＲ ＣＬＥＡ Ｎ １７” 1) When there is a difference of the digital value when the organization stops and it drives in one or less. Issued to HORIZON TANKERS LIMITED S.A.

  • Page 56: Attention Of Using Loop Wiring For Sensor Cable Routing

    (communicate through other connected line) (e) In case of disconnection circuits point two or more , MD-SX can detect a wiring defectiveness and show warning as “Sensor Fail 20”. but to identify disconnection points might be slightly difficult.
  • Page 57  All information contained in this Manual is corrected at the time of printing, but will be subject to change without notice. Issued to HORIZON TANKERS LIMITED S.A.

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