322270

MAN Diesel PrimeServ Academy
Hydraulic Power Supply, HPS
ME
MEEngine
Enginecontrol
controlsystem
system--Hydraulic
HydraulicPower
PowerSupply
Supply(July
(July2009)
2009) © MAN Diesel 2009/07/01 <1>
Hydraulic Power Supply
1) System
2) Filter Unit
3) Startup Pumps
4) Engine Driven Pumps

Drive System
Pump Principle
5) Valve Block
ME Engine control system - Hydraulic Power Supply (July 2009) © MAN Diesel 2009/07/01 <2>
Lubricating and Cooling Oil System
50 μ filter
Connection to
hydraulic system
Hydraulic Power Supply - HPS
 Contamination of
hydraulic oil must
not exceed:
 ISO 4406: 16/13
or
 NAS Code: 7
Bearings and piston cooling
In 100 ml oil sample the

number of particles with
the size should be within
the range.
16: 32,000 ≤ 6μm ≤ 64,000
13: 4,000 ≤ 14 μm ≤ 8,000
25 μ 6μ
Supply line from cooler and 50 μ filter
Separate Hydraulic System
Separate Hydraulic System
Filter Unit, Schematic
Old plants = 10 µm
New plants = 6 µm
25 µ
HPS Components
Filter and pumps
Auto Filter Backup Filter
Mechanically driven
Hydraulic pumps
Electrically driven
Hydraulic start-up
pumps
ME Engine control system - Hydraulic Power Supply (July 2009) © MAN Diesel 2009/07/01
HPS Components
Filter and pumps
Filter unit
Start-up pumps
High pressure
pumps
Drain pipe
System oil
High pressure pipes
Filter
Single filter cartridge
ME Engine control system - Hydraulic Power Supply (July 2009) © MAN Diesel 2009/07/01 < 10 >
Filter Cartridges
10 µm filter cartridge: 6 µm filter cartridge:

08/06 = production month/year 09/06 = production month/year
1340006 = filter cartridge ID 1341446 = filter cartridge ID
25 = manufacturer's filter mesh code Sintered filter material
Automatic Filter
Filtering process Back flushing process

Automatic Filter, Type 6.64
Backflushing Line to Lube Oil Tank
Start up Pumps, fixed
Safety valve setting

Automatic mode:
175 bar
 Stopped at Finish With Engine.
 Master pump running at engine standby.
(both pumps are running during pressure
build up).
 Stopped via a timer at a specified engine
RPM (default 15 % MCR)
Manual mode:
 Controlled by the operator via the Main
Operating Panel
HPS Components,
Start-up Pumps
Drain Outlet
Drain
Electric Outlet
motor
Inlet
Drain
Pump drain Pressure relief valve,

Pump
setpoint 175 bar
ME Engine control system - Hydraulic Power Supply (July 2009) © MAN Diesel 2009/07/01 16
HPS Components,
Start-up Pumps
Inlet
Electric motor
Pressure relief
valve set point
175 / 225 bar
Pump
Outlet
Valve
Pump drain
Electrically Driven Start-up Pumps
Engine Driven Pumps
Axial Piston Pump – Bosch Rexroth
Axial Piston Pump – A4VSO xxx HS3xxx…. (Bosch-Rexroth)
Axial Piston Pump – Rotating Parts
Pistons
Pressure side Suction side
Swash Plate Principle
 Ahead  Astern
Axial Piston Pump
Pump sizes:
• 125 ccm/rev - 3 pumps
• 500 ccm/rev - 3 to 5 pumps
Design features for
K+S80ME-C9, K98ME-C7
210 Bar  300 Bar
 Working pressure increased from 210 bar to 300 bar resulting in:
HPS:
 Necessary pump size reduced from 355 cc to 250 cc.
 Only 3 pumps needed.
 Same pipe and hose dimensions.
 This is because of the relation between Q’ (flow) and pressure (p) shown by the
equation:
 P=Q’x p, where P is the power generated by the pump, the power consumption is
the same; therefore a higher pressure will result in a lower flow
7S50ME-C Hydraulic Power Supply
Accumulator
Safety and
accumulator block
Three engine driven

axial piston pumps
with flow controlled
by ECS
Generates hydraulic
oil pressure up to
250 bar
Redundancy:
The engine can
operate on two
pumps
Gear Box
7S50ME-C Gear Box for HPS
 Output wheel ………………

 Intermediate wheel……………….
 Connections wheel……………
 Gearwheel on crankshaft…
 Two rows of gears, one is spare.
Spacer………..
 Gear ratio - 12:1
Pump Drive
and Moment Compensator
Pump Drive
Hydraulic Pump
Step Up Gear
Chain wheel for

4” Duplex chain
Pump Shaft Principle
Gear end
High friction disc

Pump end
7S60ME-C
Access to Hydraulic Power Supply
Design of Hydraulic Power Supply
• Mounting of HPS
• Structure of HPS and Framebox
• Design of components
12K98ME
Engine driven Hydraulic Power Supply
10-12K98ME/ME-C
 5 x 500 ccm pumps

 Fore side
 Aft side
Engine Driven Pumps
P2
P1
1204
Sensors for suction pressure.
Low pressure = shut down
Engine Driven Pumps
Automatic mode:
 The pressure set point is depending on the engine load.
 The pumps have two running modes, 1 in pressure control mode [Ctrl]
(selected via the MOP screen), 2 in follow mode [Folw].
 The [Ctrl] pump is running 50% and compensates immediately for deviations
between actual pressure and set point. Over time the [Folw] pumps will take
over the compensation while the [Ctrl] pump goes back to 50 %.
 In case the pressure controlling pump faces a failure, one of the other pumps
will take over pressure control.
Manual mode:
 The pressure set point is set by the operator
Engine Driven Pumps - Summary
In case of control failure of a pump, the swash plate will be forced to
maximum capacity in AHEAD direction.
Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.
Pump Nos. 1, 2, and 3 have their own sensor for system pressure,
connected to their controlling ACU
Pump Nos. 4 and 5 are controlled by a binary signal, either max

capacity AHEAD or ASTERN. No. 4 is controlled from ECU A, and No.
5 from ECU B.
All pumps have sensors for suction pressure. If the pressure is to low,
or all sensors are failing, a SHUT DOWN will be activated.
Leak Detection
Shut down level
Alarm level
Leak Detection
Box for hydraulic pumps
Drainpipe
Sensor LS 1235 & LS 1236, ”vibrating fork” type.

LS 1235 = Alarm LS 1236 = Cancelable Shut Down
Leak Connections
Pump Drive with Accumulator Block
Located on aft end

of the engine
(7S50ME-C).
7S50ME-C
Sensors for Suction Pressure
Engine Driven Pumps,
Nordic Brasilia – 6S70ME-C
Feed back, swash plate
Feed back, pilot valve
Pilot valve for swash plate

control
12K98ME, Different Mark Versions
ME-Mark 1 ME-Mark 2 ME-Mark 3 ME-Mark 4
12K98ME, ME-Mark 4
2 3
Safety blocks mounted on base plates
Accumulator blocks mounted on HPS
4 5 6
12K98ME Mark 4,
Complete HPS with Accumulator Blocks
 Gearbox unchanged
 Hoses from pumps to accumulator blocks
 Pumps turned for easy piping and
mounting of low pressure pipe
 Improved access of valves
 Common drain pipe on both sides of HPS
 Drain valve on low pressure pipes
Galleries and Shielding
12K98ME ME-Mark 4
 Inclined floor plates inside HPS with rubber matting
HPS Unit complete
HPS unit ready

for installation
on the engine.
12K98ME, ME-Mark 4
New H.P connection between acc.block and safety block based on service experience
Pumps and Valve Block,
K98ME/-C – Mark 3
 Modulated valve block
 Divided into fore and aft section
 Pump mounted N2_Accumulator

(Pump depent)
Valve Block
1233 1201-1,2,3 Oil Sample Point, 340
P2 pressure
To hydraulic cylinder
unit (HCU) from pumps
230 bar
311 Safety valve.
(10 – 12 cyl. 90 – 98 bore
have 2 valves, one on
each valve block)
250 bar
Safety system for leaking

high pressure inner pipe
LPS From filter unit

315 311 310
Valve Block K98ME/-C, Mark 3
 Modulated valve block
 Top mounted Fore section
 Top mounted Aft section
Valve Block, Fore Section, Mark 3
 Adaption flange
(Engine depent)
 Primary block,
(Basic for all engines 60-98ME/-C)
 Inlet block
(Pump-depent: 2 or 3 ports)
Valve Block, Aft Section, Mark 3
 Adaption flange
(Engine depent)
 Slave block, (Basic for all

engines with middle chain
drive 80-98ME/-C)
 Inlet block
(Pump-depent: 2 or 3 ports)

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MAN Diesel PrimeServ Academy

Hydraulic Power Supply, HPS

4) Engine Driven Pumps

In 100 ml oil sample the

Supply line from cooler and 50 μ filter

Auto Filter Backup Filter

Single filter cartridge

10 µm filter cartridge: 6 µm filter cartridge:

Filtering process Back flushing process

Safety valve setting

Pump drain Pressure relief valve,

Axial Piston Pump – A4VSO xxx HS3xxx…. (Bosch-Rexroth)

Pressure side Suction side

210 Bar  300 Bar

Three engine driven

 Output wheel ………………

 Gear ratio - 12:1

Chain wheel for

High friction disc

 5 x 500 ccm pumps

Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.

Pump Nos. 4 and 5 are controlled by a binary signal, either max

Shut down level

Box for hydraulic pumps

Sensor LS 1235 & LS 1236, ”vibrating fork” type.

Located on aft end

Feed back, swash plate

Feed back, pilot valve

Pilot valve for swash plate

ME-Mark 1 ME-Mark 2 ME-Mark 3 ME-Mark 4

Accumulator blocks mounted on HPS

 Inclined floor plates inside HPS with rubber matting

HPS unit ready

 Modulated valve block

 Divided into fore and aft section

 Pump mounted N2_Accumulator

Safety system for leaking

LPS From filter unit

 Modulated valve block

 Top mounted Fore section

 Top mounted Aft section

 Slave block, (Basic for all

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