Hcu Dump

Examining HCU Events
HCU events from a-z …
Allan Juul Larsen, MDT LEO9

Copenhagen 2018-12
© MAN Diesel & Turbo

Content to cover…
• Basics
• What is a “HCU event” (data stored and saved in case of fault, thus FIVA
Basic understanding
• FIVA Internal parts.
• FIVA Flow diagram.
• Examining using LDE plot
• Signals
• Which signals are stored
• Examples from service
• Selected cases from service
• Don’t waste time on bad data…
• (jitter profile, engine not running)
MAN Diesel & Turbo Allan Juul Larsen LOE9 Examining HCU events 2018-12 < 2 >
HCU Events - Basics
What is a HCU event
• Hydraulic Control Unit Event
• Tells us what is going on in the FIVA control loop

• VERY important for troubleshooting Fuel and Exhaust valve problems!
• Many names: “HCU Event” “HCU Dump” “Log Dump” “Burst Log”
• Electrical signals related to exhaust valve and fuel booster

• Continuously sampled by each CCU
• In case of an critical alarm the data is send to the MOP and stored
• Both data before and after alarm is stored
• Stores a few seconds of data sampled at 2 kHz (2000 times pr. sec.).
• FIVA Setpoint, position, Fuel plunger and exhaust valve position
• Data size: 124 kb each. (~50 kb zipped)
HCU Events - Basics
What is a HCU event
• HCU Event retrieved

from the MOP GUI one by one
• Select one and export to
USB
• If more dumps are needed they

may be copied using explorer:
D:\MANDiesel\MAD
HCU Events - Basics
When is a HCU event stored
• HCU events are store either manually or triggered by a specific alarm.

• Information about the reason is stored in the HCU event.
• Header is composed of:

• MPC type.
• Date and time for event
• Trigger reason, actual alarm or manual dump.
• Make manual dumps from all cylinders for reference.

• The specific list of alarms triggering alarms is shown later.
HCU Events - FIVA
Internal part MDB FIVA
A T P
Main spool
P = Hydraulic high pressure supply

CFI = Fuel booster
TFI = Fuel booster to tank
CVA = Exhaust actuator
TVA = Exhaust actuator to tank
TFI CFI P CVA TVA
HCU Events - FIVA
FIVA main spool
Main spool
TFI CFI P CVA TVA
P = Hydraulic high pressure supply
CFI = Fuel booster

TFI = Fuel booster to tank
CVA = Exhaust actuator

TVA = Exhaust actuator to tank
HCU Events - FIVA
Opening diagram
x-axis position [mm]

y-axis flow area [mm2]
-6mm 0 mm2
Pressurize port to
exhaust valve actuator
- 2
Fuel plunger drained

to tank
HCU Events - Basics
FIVA Set Point – For ME-C engine one engine revolution
Fuel injection
Levels found in
Flow diagram for
valve type.
“Preparation” return plunger and
close exhaust valve Red area
“dangerous” only
allowed here
near TDC!
Position Exhaust valve opening
mm.
HCU Events - Signals
FIVA Feedback CH30 – Setpoint
Feedback follows
set point nicely.
Small time delay

seen at fast
changes.
FIVA Feedback CH30 – Fuel profile
Nice step at prep.
No overshoot
Fuel profile
Prepare for Offset is a
fuel injection few ms.
Flow diagram – Fuel injection
Flow towards fuel injection

start between -0.5 and 0.75 mm
Lets just say 0 mm
Plunger position CH31 – Fuel profile start
Flow to
plunger
Mechanical system Start of fuel
with some reaction time profile
Feedback passes
0.0 mm
Plunger position CH31 – Fuel profile shape
Start of fuel
profile
Profile shape determines
plunger acceleration
Plunger position CH31 – Fuel profile end
After small time delay

Flow to plunger plunger is stationary
stops
Top dead point of
fuel plunger
movement.
Feedback passes
0.0 mm
Plunger position CH31 – Fuel plunger return
Final
position
Fuel plunger
Flow from plunger to Increases return movement.
tank will allow tank flow and
plunger to return. plunger return
speed
Main spool in More negative

negative position position.
Plunger position CH31 – Different loads
Engine running
10% load
Engine running
25% load
Engine running
40% load
Engine running
50% load
Engine running
75% load
Engine running
90% load
Engine running
100% load
Flow diagram – Exhaust valve opening
Flow towards exhaust valve

opening start
between -4 and -6 mm
Lets just say -5 mm
Exhaust valve Position CH34 – Exhaust valve opening
Flow to Exhaust
valve actuator
Feedback passes
-5.0 mm
Exhaust valve Position CH34 – Exhaust valve
Opening speed determined

by constant flow rate.
Constant main spool position
Exhaust valve Position CH34 – Exhaust valve close
Exh.v. closing will start.
Speed determined by
flow rate to tank
Feedback passes
-5.0 mm
Exhaust valve Position CH34 – Exhaust valve damp
Final close speed is

controlled by exh.v. damper
step one and step two.
Exhaust valve Position CH34 – High force Exhaust valve
Good ability to
Dampened
stay open
opening
Highforce
Step 1 damper
exhaust valve
Step 2 damper Different opening
profile with
overshoot
Exhaust valve Position CH34 – High force Exhaust valve
Slow open and close slopes
Highforce
exhaust valve
Different opening
profile with
overshoot
Exhaust valve Position CH34 – Low force Exhaust valve
Fast open and close slopes
Lowforce
exhaust valve
Different opening
profile with
overshoot
Exhaust valve Position CH34 – Low force Exhaust valve
Overshoot at Slowly closes

open stroke due to leakage
Lowforce
exhaust valve
Different opening
profile with
overshoot
HCU Events - FIVA
Opening diagram
HCU Events - FIVA
Opening diagram
HCU Events - FIVA
Opening diagram
ME-V feedback. 1 – Digital “position” signal
The up wards flank is Return flank is

“preparing” the ME-V critical.
Timing is not critical. Time is adusted
to get accurate
timing of exh.v. Activation is not
close time critical, and
will change with
load.
Return stroke
timing is
important. Will
control
Pcomp/Pscav
ratio
HCU Events - Basics
How are axis scaled
• X-axis shows time in ms.

• Resolution is in 500µs (½ms)
• Resolution locked to MPC CPU clock of 2 kHz.
• Y-axis is scaled according to the signals being displayed:

• The resolution is 1 and the span is ±32767 (16 bit values).
• FIVA Set Point / Feedback are shown in mm * 1000
• Electrical current is shown in A/D Counts
• Electrical voltage is shown in A/D Counts
• Exhaust valve position in mm but must be scaled according to parameter
• Tacho angle is shown in deg.
HCU Events - Basics
Amount of data stored
• Time stored dependents on the number of signals.

• Number of signals depend on engine type:
• ME-C 6 signals = 5.250 sec.
• ME-B DOT3 5 signals = 6.300 sec.
• ME-B 4 signals = 7.875 sec.
• ME-B (2 cyl. pr. MPC) 7 signals = 4.500 sec.
• In total 31500 samples are stored.
• Marker line indicated the time where the HCU event was triggered.
• ECS Parameters determine the time before and after Marker line.
HCU Events - Basics
Examining using LDE plot
• Windows application to examine HCU Events at office.

• Intuitive user interface and proper screen resolution.
• Sort multiple events based on:
• Dump cause.
• CCU number.
• Data / Time.
• Change colors and line width.
• Export and print to improve documentation.
• Show short DEMO
HCU events from service
Exhaust valve stroke low.
HCU Events from service
Exhaust valve
stroke is reduced
for each
revolution.
At the marker the
fuel is stopped.
Exhaust valve
activation
continues.
Reason:
SW related?
Exh.v. Mech?
Hydraulic?
Sensor?
Manual dump - Feed back not following well.
Manual dump
troubleshoot.
Fuel plunger OK
Exh.v. OK
Feed back not following well.
Closer look at
feedback.
Unable to follow
set point.
Large Control
signal amplitude.
Reason:
Worn out FIVA.
Illegal FIVA Position
Exhaust valve open to avoid

Cover lifting. Feedback cross
zero when prep.
Is made!
Control signal is
set to safe.
Note that set
point keeps
“going” only
intern signal.
Illegal FIVA Position – zommed
A bit closer
FIVA is reacting
and following
control signal
safe position
Illegal FIVA Position – zoomed more..
Even closer!
At first sample
crossing zero
control signal is
set to safe.
Exhaust valve closed position changed
Large control
signal tells that
FIVA is not
reacting!
Exhaust valve closed position changed – compare revolutions
Note the “short”

fuel injection
FIVA Pilot spool
is stuck at exh.v.
open position.
Unable to control
FIVA.
Exhaust valve closed position changed- The good
After fuel
injection control
signal settles as
FIVA stopes at
desired position.
Exhaust valve closed position changed – and the bad
Control signal
keeps going
positive to stop
FIVA movement.
FIVA is NOT
following control
signal.
May be caused
by particle in oil.
Why is control
signal still
running???
Should be
compression
pressure limiter!!
And safe position
on control signal?
• WHY did the control signal NOT go to safe position?
ECS SW 1304-1 ECS SW 1008-6

Load reduction introduced in this ECS
Exhaust valve stroke low– OR what is going on?
Something is
very wrong here.
But what?
electrical signal
error
CH30?
CH70?
Exhaust valve stroke low– OR what is going on?
Electrical fault!
Fault on
Which signal?
MPC output: CH70 or
FIVA input
Is Feedback
correct CH30?
Exhaust close position change – OR what is going on?
Look like
previous
situation.
Dependent on
other alarms and
conditions the
controller might
be active and try
to control the
error.
Could also be
CH70 error.
But why is the

control signal
active NOW?
= 20 RPM
= ? Load
= ? Pscav
Below 0.9 bar!!
Update for self-controlling FIVA ME-C
A safe safe-position
• IMPORTANT update for Bosch-Rexroth FIVA
• Self controlling type

• Feedback CH30 used by valve itself.
• In case a FIVA fault is detected the ECS orders FIVA to safe position
• Safe position must be OPEN Exhaust valve to avoid compression cover lift
• Safe position is a constant output on CH70
• Default is -30 %
Update for self-controlling FIVA
A safe safe-position
• Explained on flow diagram
• Controlled (regular) FIVA

• -30% pilot valve position
• -30% sets return speed
• Return to end stop
• Self-Controlling FIVA
• -30% main spool position
• Not opening exh. valve!
Update for self-controlling FIVA
• Observation in service
• Missing Exh. valve close may lead to cover lifting !
MPC failure
MPC failure but

which channel?
MPC failure
CH30 matches
exhaust valve
and plunger.
Fault is on CH70
CH30 is not
changing abrupt
(one sample to
the next)
MPC failure
Same ship
different MPC.
Which signal?
MPC failure
CH30 changes
~14mm in ONE
sample.
This is not
possible.
Electrical fault on
CH30 signal
MPC failure
SAME SHIP!!
MPC replaced
and fault
removed!
Which signal?
MPC failure
Fault seen on 3
signals AT ONCE
• exh.v. pos
• Fuel plng. Pos
• FIVA feedback
Almost same
value.
Common
electrical fault on
MPC affecting all
analogue inputs.
MPC failure
Affected MPC have Serial Numbers starting with OT

And date code before 1515:
OT1515….
ELFI Fluctuation G95
• G95 ELFI Drain kit

• Including long plug
• Check HCU events or send to

LEO9
Things not to look at….
• Use your time on the real problems

• Many HCU events are triggered by unimportant events.
• Start / stop
• Remove / apply connections
• Electrical noise
• Follow alarms to other alarms
• Some examples.
Dither function – Zoomed to show feedback
One sine
One square
Avoid that FIVA is

sticking
May give a idea

about the FIVA
condition.
Dither function – Situation 1
All OK
Feedback is
“dead”
Control signal is
running
Missing hydraulic
pressure.
Set point is
“running”
No control
signal?
No feedback?
FIVA in safe
position, Control
signal forced to
exh.v. open
Know what is NOT important look at
This HCU event

should not give
raise to much
concern?
Zooming in on
Tacho signal.
Engine is not
running.
May be
interesting but
not related to
engine running.
Connector on/off
Burst and Prep

Sync missed!!
Tacho?
After TDC it will jump to 0 deg.

normal
Tacho is jumping
Indicates that the
engine direction
have just
changed!
Tacho angle is
always counting
positive.
New angle
Migth setup exh.v. open and then this is “missed”
due to the tacho suddenly jumping to a new position. = 360-old
What is wrong?
Electrical noise is
on channel not in
HCU event.
No information in
this event.
HPS pressure
drops.
Connector
removed.
Engine not
running.
SOMETHING CLEVER
• I hope this lecture have given you a :

• Practical ways to look at HCU Events.
• Better understanding of the signals presented in HCU Events
• Understanding that not all HCU Event contain important information
• Gained some idea of the complexity of looking at HCU Events
• If you have funny looking HCU Events or get some. Let me know and I will
comment on them.
• Question…..

Hcu Dump

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Examining HCU Events

HCU events from a-z …

Allan Juul Larsen, MDT LEO9

© MAN Diesel & Turbo

• Hydraulic Control Unit Event

• Tells us what is going on in the FIVA control loop

• Electrical signals related to exhaust valve and fuel booster

• Data size: 124 kb each. (~50 kb zipped)

• HCU Event retrieved

• If more dumps are needed they

• HCU events are store either manually or triggered by a specific alarm.

• Header is composed of:

• Make manual dumps from all cylinders for reference.

P = Hydraulic high pressure supply

TFI CFI P CVA TVA

P = Hydraulic high pressure supply

CFI = Fuel booster

CVA = Exhaust actuator

x-axis position [mm]

Fuel plunger drained

Small time delay

Nice step at prep.

Flow towards fuel injection

Lets just say 0 mm

After small time delay

Main spool in More negative

Flow towards exhaust valve

Lets just say -5 mm

Opening speed determined

Constant main spool position

Exh.v. closing will start.

Final close speed is

Slow open and close slopes

Fast open and close slopes

Overshoot at Slowly closes

The up wards flank is Return flank is

• X-axis shows time in ms.

• Y-axis is scaled according to the signals being displayed:

• Time stored dependents on the number of signals.

• In total 31500 samples are stored.

• Windows application to examine HCU Events at office.

• Show short DEMO

HCU Events from service

Exhaust valve open to avoid

Note the “short”

• WHY did the control signal NOT go to safe position?

ECS SW 1304-1 ECS SW 1008-6

But why is the

• IMPORTANT update for Bosch-Rexroth FIVA

• Self controlling type

• Explained on flow diagram

• Controlled (regular) FIVA

MPC failure but

Affected MPC have Serial Numbers starting with OT

• G95 ELFI Drain kit

• Check HCU events or send to

• Use your time on the real problems

Avoid that FIVA is

May give a idea

This HCU event

Burst and Prep

After TDC it will jump to 0 deg.

• I hope this lecture have given you a :