MAN Diesel

PMI Online 2nd generation

PMI Online 2nd generation - January 2010.

This paper introduces the 2nd generation PMI Online system. It will be used as basis for the release of a
DUN to all licensees in the fall of 2009.
What is new /different compared to PMI Offline and PMI Online 1st generation systems?
What are the additional benefits for customer as well as the engine builders?

Developments:
The PMI system is a reliable high accuracy instrument for measurement of cylinder pressures.
Furthermore for ME engines - the PMI system is required for identification of TDC during shop and sea
trials for correct configuration of the Engine Control System (ECS).
The PMI Offline version was developed in 1992 and has since 2004 been included as ME engine standard.
In 2002 a PMI Online system was developed and offered as an option.
A 2nd generation of the PMI Online System is now being introduced on the market and can be delivered
from January 2010. The 2nd generation PMI Online system hardware and PC software has been completely
redesigned, including new development of sensor chain and controller.
The 2nd generation has been developed with specific attention to simple and easy configuration, installation,
troubleshooting and system maintenance, a.o. by reducing the overall system complexity and at the same
time leading to considerable cost down.
The 2nd generation PMI Online provides online cylinder pressures for both engine monitoring and control
purposes, and as such being an integrated part of the Auto-tuning and ME-GI applications.
It is recommended to upgrade the standard PMI Offline system to PMI Online 2nd generation system for ME
engines. The upgrade is optional and comes with an add-on price, that is expected easily earned back in
cost savings of both the engine building as well as the engine operation in service.

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

1of15

MAN Diesel

PMI Online 2nd generation

This documents includes:

1. System configuration
1.1 PMI Offline (1992 - 2012?)
1.2 PMI Online 1st generation (2002 - 2009)
)
1.3 PMI Online 2nd generation (2010
2. PMI Online 2nd generation benefits
2.1 Benefits to the customer (owner)
2.2 Benefits to the engine builder
3. ECR installations
4. Tables & documentation
- Feature comparison
- Component comparison
- Drawings
5. Appendix
- CoCoS-EDS:

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

2of15

MAN Diesel

PMI Online 2nd generation

1. System Configuration
1.1.

PMI Offline

PMI Offline is as ME standard scope of supply installed and commissioned by the engine builder. The
components included and the cabling that have to be established is shown in the figure below.

Figure 1.1 PMI Offline ME standard

Engine room installation (on or close to the engine):

Cable connections to the PMI junction box include a 24V power supply cable and a cable to the ME
trigger system. On ME engines, instead of using the intermediate boxes, the cable is connected directly
to a tacho amplifier (TSA box) included in the ME scope of supply
When measuring cylinder pressures, the PMI controller with cable (8 or 15m) and pressure transducer
is connected to the junction box, which must be mounted with consideration to the maximum distance to
the cylinder covers.
Engine control room installation:
A serial cable connects the junction box in the engine room with the RS 422/232 converter box and PC
in the engine control room (ECR).
The converter box has a fixed serial cable with a length of 1.5m and must therefore be mounted close
to the PMI / CoCoS-EDS PC. For all ME engines, the PC most have Ethernet / LAN connection to the
ME MOP-B via a Hub, also supplied as part of the ME scope of supply.

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

3of15

MAN Diesel

PMI Online 2nd generation

1.2 PMI Online 1st generation (2002-2009)

The PMI Online System 1st generation is developed based on the PMI Offline system and includes
following additional components:

Fixed sensors / each cylinder

Charge amplifier / each cylinder

Signal conditioner box / every three cylinders

Controllers (Alphacomms) / 1 for 4-6 cylinders and 2 for 7-12 cylinders (master slave configuration)

Cables

The PMI Online 1st generation offers following additional features compared to PMI Offline:
Continuous online display of key values (Pmax, Pcomp, Pi and Pscav)
Simultaneous measuring of all cylinder pressures
Pressures curves retrieval on user demand (average over 10 revolutions)
With PMI online the effect of performance adjustments made on the ME MOP can immediately be viewed
in the PMI program, ensuring that adjustments can be made with high accuracy, reducing the time used on
testbed, sea trials and in service for adjusting and optimizing engine performance.
Commissioning of the PMI Online system is equivalent to the PMI offline system.

Figure 1.2 PMI Online Mk. 1

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

4of15

MAN Diesel

PMI Online 2nd generation

1.3 PMI Online 2nd generation (2010 - )

Reduced system complexity
Comparing to 1st generation PMI Online, the 2nd generation PMI Online features:

Charge amplifiers and signal conditioner omitted (Built into sensor)

Support of engines up to 20 cylinders instead of max. 12

A single controller (PMI DAU Data Acquisition Unit) unit instead of master/slave units

Ethernet (LAN) connection from PMI DAU to PC instead of a serial (RS485/RS232) line.

Reduced number of cables to be prepared by engine builder

Reduced number of connections/ boxes to be installed on engine

Signal converter (RS422/RS232) omitted

Compared to the ME standard PMI Offline installation, the additional work for installation and
commissioning of PMI Online 2nd generation is limited to the mounting & cabling of the fixed sensors, and
can typically be completed within hours.
Redesigned software:
The PMI Online 2nd generation includes completely redesigned software with following additional features
compared to 1st generation PMI Online:

Real time pressure curves each revolution.

Wizards guiding the user through the process of trouble shooting and setting up the system.

User friendly design, with reduced complexity

Interface to ME-ECS (MOP)

Auto tuning

Easy and fast software upload to controller

Sensors:
Compared to the Kistler sensor of PMI Online 1st generation, the Kistler sensor of PMI Online 2nd
generation is delivered as a single unit, with built in charge amplifier and signal conditioner. This reduces
the overall system complexity, makes it easier and faster to install, configure, troubleshoot and maintain,
and reduces the overall system price.
Furthermore, with PMI Online 2nd generation the customer has the option to choose from either Kistler or
ABB sensors. The sensors are interchangeable and use the same interface (Harting connector) towards
the PMI DAU.
The Kistler sensor (in a sensor adaptor) is mounted on the cylinder cover, with indicator cock mounted on
top of the sensor adaptor.
CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

5of15

MAN Diesel

PMI Online 2nd generation

The ABB sensor is mounted on the end of the indicator pipe, with the indicator cock mounted directly on
the sensor.

Figure 1.3 PMI Online 2.generation

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

6of15

MAN Diesel

PMI Online 2nd generation

2 PMI Online 2nd generation benefits

2.1 Benefits customer/owner/operator
Cost down:. The PMI Online 2nd generation system price has been reduced more than 30% compared to
PMI Online 1st generation system. E.g. for a 6 cylinder engine, the upgrade price from PMI Offline to PMI
Online 2nd generation at ME new buildings is equivalent to the price of PMI Offline *).
The completely revised PMI Online 2nd generation systems features reduced system complexity. This make
the system more reliable, easier to use, troubleshoot and maintain.
With PMI Online 2nd generation comes also the opportunity to utilize the ME-ECS Auto tuning option.
The benefits of Auto-tuning are:
Reduced Fuel oil consumption
Reduced CO2 emissions
Reduced maintenance cost
Reduced workload on chief
Future possibility for easier documenting and ensuring IMO compliance operation
With PMI online, enhanced troubleshooting of the combustion process

2.2 Benefits engine builder / Licensee

Adaption of PMI Online rather than PMI Offline, contributes to reduce the time needed at testbed
providing faster and easier retrieval of higher quality engine performance measurements and offering
opportunity for Auto-tuning of the engine. I.e. the engine can be balanced at a given load from a single
press on the MOP screen, and the engine can continously automatically - keep the correct Pmax level
adjustment.
At a larger number of ME engine testbed installations, the PMI Online Mk. 1 portable equipment is installed.
After the testbed runs, this portable is demounted and PMI Offline is installed for the ships delivery (to be
used at sea-trial).
If an ME engine is equipped with PMI Online 2nd generation ordered by the customer the additional
mounting of the portable equipment and PMI Offline can be omitted.

'
&

Required time and fuel consumption on testbed reduced, easy & fast engine adjustment
utilising the ME Auto-tuning functionality.
- 1 hour engine running saved each time the engine are to be balanced / adjusted.
This corresponds easily to USD 15-20.000 worth of fuel oil as well as total 1-2 man days of
testbed engineer attendance.

&

Additional installation work is required to install the fix mounted sensors compared to PMI
offline, in total incl. cabling, typical one man in one day.
However with PMI online 2nd generation, this work is much less than with PMI online Mk. 1,
minimum 1-2 days saved.

Higher quality cylinder pressure measurements

The PMI online 2nd generation is easier to configure, troubleshoot and use, compared to PMI
offline and PMI online Mk.1 and provide as such more reliable results.

*) estimate assuming Kistler sensor

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

7of15

MAN Diesel

PMI Online 2nd generation

Installation of Licensees own PMI online portable equipment is avoided with customers
ordering PMI online 2nd generation as permanent installation. Save installation and
dismantling work.

No need for engine builder / Licensee to invest in own portable equipment for online cylinder
pressure measurements

&
&
&

Licensees are allowed to sell PMI Online 2nd generation as option to their customers.

These benefits are estimated to a much larger value than the initial time spend to mount the PMI Online 2nd
generation system instead of the PMI Offline system.

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

8of15

PMI Online 2nd generation

MAN Diesel

3. ECR installations:
PMI / CoCoS-EDS PC
The PMI and CoCoS-EDS applications are installed and executed on the same PC.
Installing PMI Offline, it is highly recommended that the PC is supplied by MAN Diesel (as part of the ME
scope of supply) or supplied by the Engine builder from MAN Diesel specification. Applying PMI Online,
this is a mandatory requirement.
It is highly recommended to mount the PMI/CoCoS-EDS PC in the ECR panel, adjacent to MOP-B, as
outlined in drawing 5135476-3 (attached).
The PMI / CoCoS-EDS PC must always be connected via the Hub (Ethernet) to the MOP-B no matter if the
ME engine is equipped with PMI Offline or PMI Online.
The LAN connecting the PMI DAU, the PMI/CoCoS-EDS PC and the MOP-B via the Hub is named MAN
LAN.
Engine Control
Room PMI/CoCoSMOP B

Engine Room

EDS PC
PMI DAU
Data Aqusition Unit

MAN LAN

Firewall/
switch/
router

*Optional
AMS PC

Ships LAN

The data measured by the PMI Online and PMI Offline are transferred to the CoCoS-EDS ME basic for
logging and trending purposes. The CoCoS-EDS ME Basic will furthermore acquire data from the ME-ECS
for the same purposes, transferring data from MOP-B via the Hub.
The CoCoS-EDS ME basic has been included in the ME standard scope of supply since autumn 2007.
The CoCoS-EDS full version is optional and require in addition a connection to the Alarm & Monitoring
system.
For security reasons, the MAN LAN may not be connected directly to the Ships LAN, unless a hardware
firewall is installed in between. With such connection (optional), recorded data can be transferred e.g. to
CoCoS-EDS installed in the CEO or transferred via internet for remote monitoring, troubleshooting and
reporting purposes.
A combined firewall and switch can be supplied within the ME scope of supply, replacing the Hub, allowing
for a secured remote connection.
CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4
9of15

MAN Diesel
4 Tables

PMI Online 2nd generation

& Documentation

Comparison tables:

PMI
software features
Portable measuring unit
Calculated value chart
Balance chart
CoCoS-EDS interface
Auto-tuning option

Offline

Online 1st
generation

Online 2nd
generation

9
9
9
9

9
9
9
9

8
8

9
9
9
9
9
9
9
9
9
9
9
9
9

Filtered pressure curves

9
9

Real time pressure curves

8
8
8
8

8
8
8
8

Angle triggered sampling

Time triggered sampling

0-load commissioning

9
9

9
9

Simultaneuos sampling

Continuous curve storage

Maintenance wizard
Commissioning wizard

E-load commissioning
Tabel 4.1

8
9

PMI software feature comparison

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

10of15

MAN Diesel

PMI Online 2nd generation

Offline

Online 1st
generation

Online 2nd
generation

Handheld Transducer

Handheld Measurement
Box

Connection cable for

Handheld Meas. Box

Intermediate Box

Tacho System (from ME

System)

Scavenge air measurement

(12 ) / 1

12 / 2

20 / 1

Junction Box

Controller

8
8
8
8
8
-

Alphacomm (2)

DAU (1)

9
9

8
8

Kistler

Kistler or ABB

Handheld meas. chain

PMI Hardware

No. of cylinders/controller

On controller status
indication
Signal Conditioner Box

Fixed meas. chain

Charge Amplifier Box

Fixed Pressure Sensor

Fixed sensor type

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

11of15

MAN Diesel

PMI Online 2nd generation

RS422/232 Converter

PC supply

PC communication

Download calibration to
controller
Tabel 4.2

Owner

Owner

MAN/Builder

Serial RS232

Serial RS232

Ethernet

minutes

seconds

PMI hardware comparison

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

12of15

MAN Diesel

PMI Online 2nd generation

List of drawings attached to this document:

Please note that some of the below listed drawings are still to be regarded as preliminary - but close to be
released.

5170204-6 El. diagram, PMI Online 2nd generation

5170807-4 Socket for ABB Cylmate & Kistler pressure transducers
5170822-8 Bracket for socket
5170852-7 Extension for ABB Cylmate pressure transducers
5171115-3 Indicator Valve, f. ABB Cylmate
5170722-2 Pressure Transducer, Kistler
5171020-5 Pressure Transducer, ABB Cylmate
5182867-5 Data Acquisition Unit in cabinet, PMI-DAU
5135476-3 Arrangement of control equipment (ME / ME-C)
5135766-3 Arrangement of control equipment (ME-B)

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

13of15

MAN Diesel

PMI Online 2nd generation

Appendix A: CoCoS-EDS: ME basic vs. Full versions

The CoCoS-EDS is - like PMI - mandatory on all ME engines.
The CoCoS-EDS can be supplied in two versions:
o

CoCoS-EDS ME Basic: Mandatory for ME, ME-C and ME-B engines

CoCoS-EDS (full version): Optional for any MAN Diesel two-stroke engine

The two versions shares the same system software, hence the only difference is configuration of the
software and interfaces towards other systems, like the AMS (Alarm & monitoring System).
The CoCoS-EDS ME Basic has only interfaces toward MAN Diesel systems (MOP and PMI) and do not
require any dedicated commissioning (plugnplay).
This version is for condition monitoring and manual troubleshooting of the ME engine
The CoCoS-EDS full version interfaces the AMS and is to be configured with a set of reference curves,
recorded typically at the sea-trial. Additional sensors must be applied for continuous engine performance
evaluation. The reference curves are obtained typically at Sea-trial by a MAN Diesel service engineer, at
the same time configurring the software accordingly.
This version is for condition monitoring, troubleshooting, performance evaluation, reporting and diagnostics.

CoCoS-EDS ME Basic:
The CoCoS-EDS ME Basic will log and display data from the PMI and the ME ECS via MOP-B. The
software makes monitoring, adjustment and troubleshooting of the ME engine much more efficient.

ME-ECS data:
All data that appears on the MOP are stored in CoCoS-EDS, allowing to monitor trends of these as
well as tracing parameter changes. The CoCoS-EDS ME Basic is the history log of the ME-ECS and
as such form the basis for monitoring and troubleshooting an ME engine in operation.

PMI data:
With PMI online adapted, the Pmax, Pcomp and Pi is continuously (automatically) acquired by the
CoCoS-EDS ME basic for logging, trending, troubleshooting and engine running in / adjustment
purposes.

The CoCoS-EDS ME Basic is used from the very first engine start at test bed, at shop trial, sea-trial and in
service. The software is used by MAN Diesel developers and engineers, Licensee engineers as well as
crew/chiefs.
Data from the CoCoS-EDS ME Basic can furthermore in a dedicated data analyser tool for MAN
engineers be combined with the alarm log of the MOP for enhanced troubleshooting.
Installation:

LAN connection to MOP-B via a hub or switch/firewall

Optional connection to ships LAN via hub and firewall (for e.g. remote access or additional CoCoSEDS installation in CEO)

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

14of15

MAN Diesel

PMI Online 2nd generation

CoCoS-EDS software Installed and executed on the (dedicated) PC for PMI (common CoCoSEDS/PMI PC)

Where to place the PC?, see recommendation, drawing 5135476-3

Type af PC? If PMI offline applied, PC can be owner supply. If PMI online applied, the PC must be
according to MAN Diesel specification and preferably supplied by MAN Diesel or Licensee. See
drawing 1881804-9 (HP Compac dc7900)

The CoCoS-EDS ME Basic software can be installed directly from a CD (or memory-stick) and
recquires none additional configuration, as the interfaces towards the ME-ECS (MOP-B) and PMI is
pre-configured to specific standard settings.

CoCoS-EDS full version

The CoCoS-EDS full version is intended for enhanced data logging, monitoring, trending, continuous
performance analysis, diagnostics and performance reporting for engines in service. The full version is
optional, can be adapted for any MAN Diesel Two-stroke engine and includes all of the ME Basic as well
as:
The full version includes the features of the ME Basic version and in addition:

Interface to the AMS in order to log e.g. cylinder exhaust gas temperatures

Reference meaurements (model curves) for enhanced troubleshooting, performance analysis and
diagnostics

Needs additional sensors installed for a full, continuous engine performance evaluation (see project
guides for sensor list) e.g. sensor for turbine back pressure.
(Alternatively, values can also be manually keyed in by the user, however reducing the benefits of
the full version. Performance analysis, diagnostics etc. will then only be done when entering data
and not continuously / online.)

Requires commissioning by MAN Diesel service enginneer, typically done at sea-trial.

(Alternatively, the crew can make performance measurements and forward these to MAN Diesel for
configuration into the CoCoS-EDS full version. The quality of the performance measurements is in
this case owner responsibility. If not correct, the CoCoS-EDS can in some cases be lead to
conclude incorrectly, evaluating the performance of the engine)

Sold as a software package from MAN Diesel. The customer (owner) must ensure that cabling,
sensor mounting, AMS interface preparation is arranged, e.g. via the engine builder / licencee.
Included up front in the plant spec, the engine builder will include the necessary preparations,
sensor mounting etc.

CopyrightMANDiesel.ConfidentialInternaluse/TOMLDE4

15of15