Operator - MWM

Seminar program 

2013 

Customer and Operator 

1 

www.mwm.net

Content. 

Customer Training by MWM 3 

Welcome to the MWM Training Centre - our team 4 

The Way to a qualified and competent Customer/Operator 5 

Competence classes an technical content 6 

Product-related Engine Technology 

for Gas Engines 

Basic Knowledge Gas Engine Technology 8 

TCG 2016 series KK1 / CG 132 KK1 9 



Product-related System Technology 


Operator Seminar TEM EVO 

Total Electronic Management 

Customer Dongle Level 100 

General Comprehensive System Technology 14 

General Comprehensive System Technology 

Basic Knowledge Electrical Engineering 


Practice Seminar on Control Engineering 

Electrical Instructed Person regarding 

BGV A1 and BGV A3 

Advanced course Electrical Engineering 

“Electrical drive /3- Phase Asynchronous motors“ 

Advanced course Electrical Part I 

“Synchronous motors /Generator operation” 

Advanced course Electrical Part II 

Practice oriented generator operation 

and recurring testing... 

Workshop for Diesel Engines 21 

Diesel Workshop 22 

Condition and Terms for the Participation in Seminars - Part 1 23 

Condition and Terms for the Participation in Seminars - Part 2 24 

Seminar Fees 2013 25 

Notes Concerning Registration 26 

2 

7 

12 

13 

15 

16 

17 

18 

19 

20

Customer Training by MWM – 

a worthwhile investment 

Training and Qualification of 

Customer- and Operator 

Availability, reliability and durability of equipment 

and power units are highly dependent on proper 

operation and service by qualified and experienced 

operating and service personnel. For this purpose 

MWM offers, apart from the training of in-house 

personnel and service staff of MWM Service 

Organisation, also for customers and operators staff 

service–related seminars on MWM products. 

Cross-System Information 

Through the comprehensive competence of MWM in 

the engine technology, the contents of the individual 

training courses are always holistically oriented and 

provide sound, easily comprehensible know-how with 

cross-system information. 

3 

Centralised and Decentralised Trainings 

The courses are held at the Training Center. If required 

basic training and further training can also be 

organised regionally. In terms of content, it is possible 

to choose between ongoing courses that built on each 

other and compact, topic-related individual seminars.

Welcome to the MWM Training Center 

Mannheim – Your team for success 

Jürgen Bauer 

Senior Manager Training Center 

Special branch Electrical Engineering 

Control and Feedback Control Systems 

Bernd Koch 

Trainer 

Fundamentals Electrical 

Engineering & Gas Engine Technology 

Günter Tomiczek 

Trainer 

Diesel and Gas Engine Technology 

Inquiries an application 

please send to 

training@mwm.net 

Tel. +49 621 384 84 12 

Fax +49 621 384 84 11 

4 

Silke Schenk 

Administration 

Training Center 

Werner Seitz 

Trainer 

Gas Engine Technology 

Werner Schlenker 

Trainer 

Gas Engine Technology

The Way to a qualified and 

competent Customer/ Operator 

Engine Technology for Gas Engines 

Series TCG 2016 / CG 132 

Competence class 1 

E 20 / 30 / 40 

Basic Knowledge Gas Engine Technology 

Series TCG 2020 / CG170 


E 20 / 30 / 40 

Customer Seminar TEM EVO, Total Electronic Management - Customerdongle - Level 100 

Trainings in all Systems 

The contents of the MWM trainings used to impart 

the knowledge of assembling and function of engines. 

Comprehensive skills to operating of engines and 

plants provide additional security for later practice. 

General Comprehensive and Product-related System Technology for Gas 

Advanced Course Electrical Engineering „Electrical drive / 

3-Phase Asynchronous Motors“ 


Electrical Instructed Person regarding BGV A1 and BGV A3 


5 

Series TCG 2032 / CG 260 


E 20 / 30 / 40 

Problem cases can be dealt within targeted fashion 

single-handed system-checking and fault correction by 

means of measuring technique. 

Advanced Course Electrical Engineering „Electrical drive / 

3-Phase Asynchronous Motors“

Competence classes of Customer/ Operator 

Target groups 

Customer/ 

Operator 

Prerequisite Training Objectives Acquirement of various Competence classes 

• Basics about gas / diesel engines 

• Knowledge in technical training 

language 

• KK1 E 20 / 30 / 40 Operation and Maintenance 

Technical Content of the Competence classes 

Competence classes 

• KK1 E 20 / 30 / 40 

Operation and maintenance 

Technical Content 

• Job card B 

• Maintenance activities corresponding to the maintenance schedule contained in the 

operation manual 

• Visual inspections, cleaning, checking and change of maintenance parts and operating 

materials, easy repair and overhaul workings with standard tools, subsequent test run 

and checking of functions 

6

Product-related Engine Technology 


7

Basic Knowledge Gas Engine Technology 

Note 

Target group Customer and Operator 

Duration 1 day 

No. of participants max. 8 

Content 

The seminar serves for lead-in for a better comprehension with special 

MWM Gas Engines 

History of the Gas Engine Inventions and developments 

Events in the Gas Engine 

MWM Gas Engines 

Design and Function of 

Basic Engine 

Process, charge changing, strokes, change of different conditions, degree 

of efficiency, ignition and burning sequence 

Explanation of MWM Gas Engines types, engine designation, characteristic 

data, application and use, engine mappings, power spectrum, power 

reduction diagrams 

Crankcase, cylinder head, piston, cylinder, bearings, valves and valve 

seats, exhaust turbo charger 

8

TCG 2016 series KK1 / CG 132 KK1 

Note 

Requirements 


Duration 4 days 


Content 

Introduction Service documentation 


Assembly Groups and 

Systems 

The seminar deals exclusively with the engine and includes the 

maintenance intervals E10 up to E40. 

Corresponding to the work content must worn safety shoes 

according to the operational safety! 

The attendance at lead-in “Basic Knowledge Gas Engine Technology” or 

in-depth knowledge in Gas Engine Technology are advantageous. 

Lubrication- and cooling system, crankcase and oil pan, gear train and 

timing, ignition system, gas regulating line 

Operation Starting and shutdown, operating media (lube oil, fuel, coolant) 

Maintenance according to 

the Competence Class KK1 

Operation of the TEM- 

System 

Terms (serving, inspection, repair), service instructions, tolerances, wear, 

limits, valuation of coolant and lube oil, di- and assembling of components 

and units 

Display and operation menu, manual- and automatic mode, required 

signals, required adjustments, calibration and diagnostics, test mode 

auxiliaries, speed governor, ignition system, anti knock control, histories, 

log book 

9


Note 

Requirements 




Content 




Systems 













System 



and units 




log book 

10


Note 

Requirements 




Content 




Systems 













System 



and units 




log book 

11

Product-related System Technology 


12

Operator Seminar TEM EVO 

Total Electronic Management 

Customer Dongle Level 100 

Note 

Requirements 




Content 

Introduction 

Structure and function of 

components and systems 

Operation of TEM System 

Error processing 

Practical demonstration 

with simulator 

This customer dongle contains all the legal regulations to ensure a 

necessary operation of access. For prices and fees for the customer 

dongle look at your offer. A review of the current software of the system is 

required. An update is carried out to ensure safe access, it neccessary. 

Participation in a Product-related Engine Technology 

for gas engines course is a requirement for participation in this course. 

After a successfull achievement test can be performed the key 

authorization, if required. 

Combustion control, exhaust emissions, lambda operation, setpoint 

selections, power reduction, fuel gas characteristics, classification of 

combustion gases, combustion knock, ignition temperature 

Gas regulation line, gas air mixture, ignition systems, Sensors (PT100, 

thermo couple, pickup, etc.), cooling / heatcircle / emergency cooling 

circle, PI flow diagram to read and understand, components, security 

chain, plant control, TEM cabinet, PLC, TEM touch screen operation 

terminal. 

Screen menus, manual- / automatic operation, calibration and diagnostic, 

auxiliary-test mode, speed governor, ignition system, history, operation 

logbook 

Checklist for sytematically failure diagnosis, trouble shooting diagnostic, 

assessment of characteristic curves with operation by means of log and 

data recording 

Manual- /automatic operation, changing the ramps, knocking, history 

curves select and record 

13


14



Note 




Content 

Introduction 

Components 

Wiring diagram 

Systematically trouble 

shouting 

The seminar imparts elementary knowledge in the field of electrical 

engineering for non-electricians with concrete examples. 

After successfull test you may attend continuing courses. 

Elementary of electrical engineering, charging, current, potential, voltage, 

resistance, electric conductance, resistivity. 

Ohm's law, series- and parallel connection, magnetic field, inductance 

and coils 

Various cables, terminal raw, fuses, fault current breaker, power switch, 

relays, contactor, transformer, accumulator, generator, start facilities 

Symbols and signs, designation of electrical, equipment and devices 

Circuit diagrams, read and comprehension of connection diagrams 

Examples at practical models and exhibits 

15



Note 


Duration 1,5 days 


Content 

Basic Knowledge 

Experimental 

Determination of 

Controlled Systems 

Closed Control Loops 

Practical Exercise with 

The seminar serves for lead-in to assess Control Engineering Processes in 

connection with analoge / digital speed cantroller, temperature govenor 

and general TEM-EVO control unit. 

Single - and multi control loop, P- I-DT1 two-position –and multi point 

governor, analog- and digital governor, loops with and without offset 

Control of: Position, level, temperature, flow rate, mixture and proportions 

Advanced control loops systems, cascade control. disturbance variable 

compensation, classical PID, control loops 

Set-point sensor, comparator, PID-Controller, actuator, motor – generator 

module set 

16

Electrical Instructed Person regarding 

BGV A1 and BGV A3 

Note 




Content 

Introduction 

Laws and Prescriptions 

Protection Measure and 

Protective Devices 

Practical Measurements 

In compliance with the BGV A1 the instruction of employees by the 

business employer in the perils of their job and the prevention of it is 

compulsory. Particularly the instruction of non-professionals regarding 

Electrical Engineering in a safety conform conduct according to BGV A3. 

Certifikation of participants with specified schedule of the import subjects. 


Basic knowledge electrical engineering, perils of electricity 

Ohm's law, simple electric circuit, single phase current 

Effect of electrical current to the persons, electrical current - related 

accidents 

General measurement 

General electrical terms, accident prevention regulation 

Operational safety, accident prevention regulation regarding BGV A1 

"General rules" and BGV A2 "Electrical installation and equipment“ 

Selective VDE-regulations, activities of "Electrical instructed persons" 

The 5 safety rules 

Classification of protection measures, 

protection class and protective devices 

Three phase current, net systems and net configuration 

General method for VDE reasonable checking. 

General measurement of : 

current, voltage, power, resistance, insulation check 

17

Advanced course Electrical Engineering 

“Electrical drive /3- Phase Asynchronous 

motors“ 

Note 

Requirements 




Content 

Basics 

Electrical mains 

Transducer 

3- Phase Asynchronous 

motors 

Safety Regulation 

Practice Demonstration 

With emphasis on this seminar, the mode of operation and the operating 

behaviour of the relevant machines are described. 

The attendance at the lead-in "Basic Knowledge Electrical Engineering" / 

"Electrical Instructed Person" or in–depth knowledge in Electrical 

Engineering is necessary. 


Current, voltage, resistance, magnetic field, inductions / Lenzsche law, 

Three-Phase current, rotary field, 

Power category (apparent,- effective- and reactive power), 

power factor cos Phi, efficiency factor 

Different voltage levels, assembly of electrical supply networks, main 

parallel- and island operation, circuit-breaker 

Fundamentals transformer 

Assembly and function of transducers 

Types (voltage / current), transformation, connection diagram 

Design features, star-/ delta connection 

Excitation stator and rotor 

Operating behaviour, characteristics of torque and current, 

starting behaviour, slip-ring motors, pole changing motors 

Soft starter, frequency converter, voltage- and frequency controlled drives 

Safety regulation in view of the electrical equipment of motors according 

EN 60204 

Control possibilities by means of simulation facilities 

Measuring of starting- and load curves 

18

Advanced course Electrical Part I 

“Synchronous motors /Generator operation” 

Note 

Requirements 




Content 

Basics 

Electrical and mechanical 

design 

Characteristics and 

Operating performance 

Practical exercises 

With emphasis on this seminar, the mode of operation and the operating 

behaviour of the relevant machines are described. 

The attendance at the lead-in "Basic Knowledge Electrical Engineering" / 

"Electrical Instructed Person" or in –depth knowledge in Electrical 

Engineering is necessary. 


Technical characteristics 

Power- and speed range, power factor, voltages, frequency, 

Protection class, cooling methods and heat class 

General design, stator, rotor 

Junction box and connections, terminal sequence and sense of rotation 

Excitation system 

Degree of efficiency, voltage level, adjusting range of voltage 

Voltage characteristic, V/f-control, parallel mode 

Start synchronization, net parallel mode, self-excitation, de-excitation, 

Electrical surge protection, behaviour at low revolutions 

Real- and reactive power control 

Control system design at the simulator 

Synchronisation with synchronizers e.g. Woodward or DEIF 

19


Practice oriented generator operation 

and recurring testing... 

Subject 

Note 

Target group 

Duration 1 day 


Content 

General 

Preliminary operation test 

/ troubleshooting 

Voltage regulator – 

Functional test 

Power factor regulator / 

Cos Phi – Functional test 

Practical exercise / 

Measuring practice 


Practice oriented generator operation and recurring testing of 

electrical plant equipment in the low voltage range 

The participants learn the procedure based on first commissioning of the 

generator set and receive indispensable working aid and ideas for effective 

completion of the required preliminary operation test. 

The participants may bring their company‘s own measuring equipment to 

the seminar. 

Qualified electricians, qualified personnel and electrically skilled person 

for defined activities 

Safety precautions, marking and working method 

Mounting- and alignment instructions 

Installation and connecting requirements 

Generator grounding, insulation resistance measurement 

Rotation- and vibration measurement 

Verifying of the generator via external excitation 

Testing of generator windings an rotation diodes 

Adjustment of synchronizing facilities 

Explanation of various wiring diagrams 

Voltage-, low frequency- and stability adjustment 

Reactive power control (voltage matching / static control) 

Explanation of various wiring diagrams 

Adjustment of voltage matching and stability 

Presettings and reactive Power VAR / power factor Cos Phi 

Mechanical and electrical set up based at the synchronous generator 

Type STAMFORD UC 274 F23 

With integration of the power cabinet for net-parallel operation 

Measuring practice at Marelli MJB 350 

20

Workshop for Diesel Engines 

21

Diesel Workshop 

Note 


maintenance intervals E10 up to E60. Corresponding to the work content 

must worn safety shoes according to the operational safety! 

Requirements In-depth knowledge in view of diesel engine technology. 

Targat group Customer and Operator 

Duration min. 3 days / max. 5 days 


Selection of topics 

Documentation Introducing of documentation of old engines, Service Library MWM 

Electronic analoge engine 

speed governor GAC and 

digital speed governor 

EMR 2 

Electronic digital engine 

speed governor 

Heinzmann Helinos and 

MKS engine monitoring 

Recap prinziple of Diesel 

engine TCD 2016 / 2020 

Injection pumps 

Practical training on the 

engine TCD 2016 / 2020 

Fundamentals and basic knowledge, functionalities and governor control, 

introducing of various components, practical demonstration with 

simulation units 

Fundamentals and basic knowledge, functionalities and governor control, 

introducing of various components, practical demonstration with 

simulation units 

Intake air system with turbo charger, effects of delivery time according to 

ignition pressure, temperature and fuel consumption, various fuel typs e. 

g. heavy oil, destillate fuel and their effects, wear and tear of parts in view 

of the injection system, single and dopple-walled injection pipes 

Introducing of various injections pumps 

TBD 616 RP 21u. RP 25, TBD 620 P9 u. P10 

Diassambling of the injection pump with pump drive, basic adjustment of 

gear drive (measuring of valve timing), checking and adjustment of the 

delivery time, (prestroke methode), maintenance of injection valve 

22

Condition and Terms for the 

Participation in Seminars 

The participation on seminars and courses shown 

in this program are keyed to the product and service 

related training and further education exclusively for 

staff members of MWM GmbH and of the affiliated 

service partners. 

For the personnel of installation customers and operators 

separate meetings are offered, which are to be 

found in the “Seminar program 2012 for customers”. 

Seminar are ordered and organized 

at the terms and conditions stipulated 

below: 

The publication of this seminar program invalidates 

any previously published programs. The conditions 

and seminar fees in this document, which are based 

on the relevant price level of calculation rates for 

engineers in accordance with point 1.c. of the MWM 

GmbH price list, apply for the ordering and running 

of the respective seminars. 

We reserve the right to change prices. All prices listed 

are without VAT. 

23 

• For the events run in the Training Centers in 

Mannheim, the seminar costs include a copy of the 

participation documents, the provision of work 

overalls and writing materials, a choice of cold and 

hot drinks during the seminar breaks, lunch in the 

company restaurant and a participation certificate 

on successful completion on the event. 

• Participation in the seminar is only possible after 

prior and confirmed application and only for the 

chosen seminar(s). People attending without confirmed 

applications cannot be considered. 

• If a seminar application confirmed by the Training 

Center will not be taken up, the estimated cancellation 

fees, see page 22 are to be applied (Excepting 

on presentation of a doctors’ certificate in case of 

unforeseen illness). Sending a replacement participant 

is possible without additional costs. 

For special seminars a cancellation fee is shown separately 

as well. In addition, for special seminars in 

external locations transport costs for seminar equipment 

already incurred as well as any costs incurred 

for flight or hotel cancellations will be charged.

Condition and Terms for the 

Participation in Seminars 

• For participants from foreign service partners, it is 

the responsibility of the customer to ensure that the 

participant has valid and adequate health and accident 

insurance for the stay in Germany, which at 

the request of the customer can be verified by 

relevant proof. Costs incurred by MWM GmbH as 

a result of lack of or insufficient insurance are to be 

refunded by the customer. 

• The particular seminars are provided and carried 

out by state-of-the-art. All given advice or the use of 

acquired knowledge we assume no liability. 

• Kindly take care of the hotel reservation for accommodation 

for participants with our authorized 

hotels at agreed preferential prices yourself. Hotel 

contact details are to be found on the registration 

form. 

• The Training Center reserves the right to cancel 

seminar dates for important reasons e.g. insufficient 

number of participants, illness of the seminar 

leader. The customer will be informed about this 

within an appropriate amount of time and about a 

proposed new date. 

• With the application to the seminar the customer 

accepts the binding nature of the conditions set 

down in this document. 

24 

• The customer is hereby informed that personal 

details will be stored in accordance with the Federal 

data protection law. 

• In view of the computer processing technology, 

queries and applications to seminars are exclusively 

to be made to the relevant Training Center running 

the event using the forms in this program. For this 

the necessary details are to be entered into the given 

sections in full and in clear block capitals. 

Note: Queries and applications, which do not correspond 

to the required format because of illegible 

or incomplete details, will be disregarded.

Seminar Fees 2013 

1. For the Courses contained in the Schedule: 

for each seminar day and participant *) 450,00 € 

The fees listed under *) above for seminars held in the Training Centers includes cold / hot drinks, lunch at the company’s restaurant, 

provisions of working clothes. 

Hotel expenses are not included, these have to be settled by the attendee / ordering party with the hotel directly. 

2. For Seminars to be held externally: 

for each trainer assignment and course day 1850,00 € 

plus travel expenses: 

travelling time of the trainer, for every part-period of 4 hours 650,00 € 

upon travelling by car per driven km 0,70 € 

upon travelling by service van per driven km 

incidental travelling expenses like flight and/or rail ticket, toll, 

0,85 € 

taxi, custom duties, visa etc at actual 

board and lodging 

1) 2) + 

shipment costs, for engines, special tools, custom duties etc. at actual 

1) per diem flat rate acc. to rates set out in the guidelines for travel variously applicable of MWM GmbH 

2) plus any additional costs for board and/or lodging, if any 

3. Cancellation Fees: 

For the courses contained in the schedule for each participants and external and special seminars. 

until 21 day before seminar beginning 30 % of the seminar fee 

from 20. day until 11. day before seminar beginning 40 % of the seminar fee 

from 10. day until 7. day before seminar beginning 60 % of the seminar fee 

from 6. day until 1 day before seminar beginning 80 % of the seminar fee 

one travel day and no attendance without cancellation 

plus additional costs arising from flight and hotel accommodation cancellation 

100 % of the seminar fee 

and costs potentially arising from dispatch of seminar equipment at actual 

4. Additional Seminar Documentation: 

The documentation is limited to one copy per participant respectively in the case 

of special seminars to the max. number of participants indicated in the seminar 

description, for each additional set 

The above prices do not include VAT. 

25 

at actual

Notes Concerning Registration 

Please only use the forms prepared in the attachment 

for the registration of participation in training courses 

offered by the Training Center Mannheim. This is 

necessary as the incoming registration is directly 

processed by our EDP system. 

The registration form consists of 1 pages, the cover 

sheet including data of the applicant and about 

the relevant seminar; as well as the data about the 

participant(s). 

Please fill in the columns of the both forms completely 

and send it to the e-mail address or fax number, 

which are on the registration by forms. 

Please note registrations that are received by us 

with incomplete and/or illegible information or 

do not so comply with the specified form cannot 

be adopted by the system and will not be taken 

into consideration. 

26

Operator - MWM

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