Installation Manual

Installation Manual
Bandak Light Weight Taut Wire
Mk 15B
Kongsberg Part no.: 702788

This document describes the installation of the Light

Weight Taut Wire Mk 15B supplied by Bandak.
The Mk 15B version has an electronic cabinet that is
located indoors, separate from the main unit of the Light
Weight Taut Wire.

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Bandak Light Weight Taut Wire Mk15B

Document revisions
Written by Checked by Approved by
Rev.
Date Sign. Date Sign. Date Sign.
A 23.09.04 SL 25.09.04 HT 25.09.04 SL
B 30.09.05 SL 06.10.05 HT 12.10.05 SL
C 07.02.07 HHO 08.02.07 TH 08.02.07 TF
D 08.06.07 PLB 08.06.07 TH 08.06.07 TH

The original signatures are recorded on the company’s logistic data system.

Document history
Rev. A Initial Issue.
Rev. B New type of Remote Control (RC).
Rev. C Air connection type added in sections 2 and 3.5.4.
Rev D Note added to Electrical specifications in section 2, new drawing 4-0893 Rev. B
added and drawing 3-7728 updated to Rev..B.

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Table of contents
1 INTRODUCTION....................................................................................................5

2 SPECIFICATIONS..................................................................................................6

3 INSTALLATION ...................................................................................................10
3.1 General information.........................................................................................10
3.2 Location of the units ........................................................................................10
3.2.1 Light Weight Taut Wire Unit ......................................................................10
3.2.2 Electrical Cabinet ........................................................................................10
3.2.3 Remote Control Unit (optional)...................................................................11
3.3 Logistics ..........................................................................................................11
3.4 Handling ..........................................................................................................11
3.4.1 Light Weight Taut Wire ..............................................................................11
3.4.2 Electrical Cabinet ........................................................................................11
3.4.3 Remote Control Panel (optional).................................................................12
3.5 Mechanical installation....................................................................................12
3.5.1 Light Weight Taut Wire Unit ......................................................................12
3.5.2 Electrical Cabinet ........................................................................................12
3.5.3 Remote Control Unit (optional)...................................................................12
3.5.3.1 Drop-in Remote Control Unit............................................................. 12
3.5.4 Pressurised air..............................................................................................13
3.6 Electrical installation .......................................................................................13
3.6.1 General ........................................................................................................13
3.6.1.1 PG-glands ........................................................................................... 13
3.6.1.2 Tension relief...................................................................................... 13
3.6.1.3 Recommended cables ......................................................................... 14
3.6.1.4 Cable clamping and screen/earth connections.................................... 14
3.6.1.5 Cable terminations.............................................................................. 15
3.6.2 Light Weight Taut Wire Unit ......................................................................15
3.6.2.1 Servo Motor Junction Box.................................................................. 15
3.6.2.2 Hydraulic Motor Junction Box ........................................................... 15
3.6.2.3 Taut Wire Control Unit ...................................................................... 15
3.6.3 Electrical Cabinet ........................................................................................16
3.6.4 Remote Control Unit (optional)...................................................................16
3.6.4.1 Drop-in Remote Control Unit............................................................. 16

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Bandak Light Weight Taut Wire Mk15B

4 INSTALLATION DRAWINGS............................................................................17

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1 INTRODUCTION
The Light Weight Taut Wire Mk 15B is a position reference
system designed for use in a deck-mounted port or starboard
position on surface vessels. The purpose of the Light Weight
Taut Wire system is to provide accurate data of the vessel's
movements, relative to a known point, in the fore/aft (along-
ship) and port/starboard (athwart-ships) directions.
WARNING The equipment includes high voltages, which means that the
possibility for getting an electrical shock is present. Before
commencing any installation work, read the guidelines for
First Aid treatment of personnel with electrical shock.

Cables between Taut Wire Unit and Electrical Cabinet must

not exceed 50 m. Signal cables must not be located with
cables whose charging magnetic field may induce voltage.
Caution The Light Weight Taut Wire Mk 15B is delivered with
sufficient hydraulic fluid inside. No refilling or topping of
hydraulic fluid should be done by yard/customer during
installation or before setting to work.
Note Unless stated otherwise, all mounting equipment referred to
within this document is to be supplied by yard/customer.

The guidelines for installation presented here must be regarded

as a base for detailed plans prepared by the installation
shipyard. These plans must include drawings, instructions and
procedures specific to the ship in which the equipment is to be
installed. These drawings must be approved by the local
maritime classification society.

Unless stated otherwise, all installation work described in this

document is to be performed by yard/customer personnel.
It is the responsibility of the yard/customer to assure that their
installation personnel are sufficiently qualified, and that proper
caution is taken to avoid injuries or damage to life, health,
environment, equipment and property.
Kongsberg Maritime AS accepts no responsibility for any
damage or injury to the system, ship or personnel caused by
drawings, instructions or procedures not prepared by Kongsberg
Maritime.

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Bandak Light Weight Taut Wire Mk15B

2 SPECIFICATIONS

Mechanical specifications
Light Weight Taut Wire Mk 15B:
Height: .....................3550 mm (Parked), 1665 mm (Operational)
Width: ............................................................................ 1400 mm
Depth (Length): .......1700 mm (Parked), 5115 mm (Operational)
Weight (excluding Depressor weight): .............................2200 kg
Electrical Cabinet:
Height: ........................................................................... 1900 mm
Width: .............................................................................. 800 mm
Depth: .............................................................................. 510 mm
Weight.................................................................................250 kg
Depressor:
Volume: ............................................................................. 50 dm3
Weight: ...............................................................................360 kg
Depressor (optional):
Volume: ............................................................................. 65 dm3
Weight: ...............................................................................460 kg
Drop-in Remote Control Unit (optional):
Height: ............................................................................. 102 mm
Width: .............................................................................. 202 mm
Depth (exclusive cable gland): .......................................... 50 mm
Weight: ...................................................................................2 kg

Electrical specifications
Input voltage:
440 VAC, +20%, -27%, 3-phase, 50 to 60 Hz (50 A fuses)
Note The input voltage must be supplied from a standard Terra
Neutral net (TN-net). A 3-phase isolation transformer is
optional for an Isolated Terra net (IT-net) supply. For further
information, please contact Bandak AS.
220 VAC, single phase, 50 to 60 Hz

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Power consumption:
440 VAC: 18 kW / 37 A continuous load
220 VAC: 500 W
Batteries: ......................................PLC; lithium size ½ AA, 3.6 V

Cable specifications
See Table 1 on page 14.

Air specifications
Pressure:............................. 10 bar (maximum), 6 bar (minimum)
Flow: ............................................................. 5 Nm3/h (minimum)
Purity: ..................................................... according to ISO8573-1
Solid contamination:....................................................class 5
Maximum particle size..................................... 40 μm
Maximum concentration ............................. 10 mg/m3
Water: ..........................................................................class 3
Dew point......................................................... -20 °C
Oil: ...............................................................................class 5
Maximum concentration:............................ 25 mg/m3
Connection:...............................................................GE12LR 3/8"

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Bandak Light Weight Taut Wire Mk15B

Environmental specification
Light Weight Taut Wire Mk 15B:
Enclosure material: ....................Surface treated and painted steel
Enclosure protection (located on open deck): ....................... IP56
Operational temperature range: ................-15 to +65 °C, no icing
Operational humidity:........... 20 to 100 % RH with condensation
Operational Wind Strength .......................................0 to 80 knots
Storage temperature range: ......................................-25 to +70 °C
Storage humidity: .............0 to 100 % RH, sealed aluminium foil

Electrical Cabinet:
Mounting plates: ..........................................................Zinc plated
Enclosure protection (indoor location): ................................. IP22
Operational temperature range (indoor location): ...... 0 to +55 °C
Operational humidity:........... 20 to 93% RH (none condensation)
Storage temperature range: ......................................... 0 to +65 °C
Storage Humidity:................. 20 to 80% RH (none condensation)

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Remote Control Unit

Enclosure protection (indoor location): ................................. IP56
Operational temperature range (indoor location): ...... 0 to +65 °C
Operational humidity:........... 20 to 93% RH (none condensation)
Storage temperature range: ......................................... 0 to +65 °C
Storage Humidity:................. 20 to 80% RH (none condensation)

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Bandak Light Weight Taut Wire Mk15B

3 INSTALLATION
This chapter presents the procedures for installation of the Light
Weight Taut Wire Mk 15B supplied by Bandak AS.

3.1 General information

The overall dimensions of the Light Weight Taut Wire Unit are
shown in Figure 1 to Figure 3.

3.2 Location of the units

3.2.1 Light Weight Taut Wire Unit
The Light Weight Taut Wire Unit must be installed at the side of
the vessel and as close to the water surface as possible. The
reason for this is to obtain the maximum possible inboard angle,
see Figure 4 for the operational area of the wire. This will also
result in the minimum pendulum movement of the depressor
weight when clearing the water surface. Excessive pendulum
movement stresses the wire and is often the main reason for wire
breakage.
The unit should not be installed above the thrusters because the
water movement from the thrusters (when they are running) may
affect the wire and cause the sensor head to send false
information to the data processing system.
It is important to ensure that the deck supports are sufficiently
strong to avoid unwanted mechanical deflection in the deck and
foundations, which can affect the measured results.
The location on the deck where the Light Weight Taut Wire
Unit is to be positioned must have a maximum elasticity of
1.5 mm.

3.2.2 Electrical Cabinet

The Electrical Cabinet should be located in an indoor
environment, satisfying Environmental Specifications in
section 2.
WARNING Cables between Taut Wire Cabinet and the Electrical
Cabinet must not exceed 50 m. Signal cables must not be
located with cables whose charging magnetic field may
induce voltage in the signal cables.
Note Ensure that the electrical cabinet has sufficient space both for
mounting and for service area, see Figure 5.

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3.2.3 Remote Control Unit (optional)

The Remote Control Unit should be located in an indoor
environment, satisfying the Environmental Specifications given
in section 2. For space required, see drawing S-03205 (drop-in
unit).

3.3 Logistics
Safety:
Personnel qualifications:
Min. no. of personnel:
Ship location:
Special tools required:
General safety precautions should
be followed when working
on/with Light Weight Taut Wire
Mk 15B
Two trained mechanical workers,
and one trained electrical workers.
Three.
No recommendations.
None.

3.4 Handling
WARNING Never, ever pass or stay, complete or partly, under any lifted
object.

3.4.1 Light Weight Taut Wire

The Light Weight Taut Wire Unit has three points for the
attachment of lifting slings. When the unit is to be lifted, the
boom must be lowered down into the operational position and
all three slings attachment points must be used.
Use three nylon slings. Two are passed through openings in the
main structure whilst the third is passed around the foremost
upper part of the weight-basket (see Figure 10). All three slings
shall have a length from lifting point to the hook of 2 m.

3.4.2 Electrical Cabinet

The Electrical Cabinet includes delicate electronic components
and should be handled accordingly.
Appropriate lifting equipment should be used and care must be
taken when handling the Electrical Cabinet. Use the eyebolts
(DIN 580) on top of the cabinet for attaching lifting slings (see
Figure 6). Minimum angle of the lifting sling at the base is 60°.

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Bandak Light Weight Taut Wire Mk15B

3.4.3 Remote Control Panel (optional)

The Remote Control Unit includes delicate electronic
components and should be handled accordingly. The Remote
Control Unit can be lifted by hand.

3.5 Mechanical installation

3.5.1 Light Weight Taut Wire Unit
A base frame (see Figure 8) serves as the foundation for the
Light Weight Taut Wire Unit. It is constructed of HEB-120
section girders and steel plates that are welded together.
It is recommended that the base frame is welded to the deck.
In the top of the base frame there are twelve (12) 18.5 mm holes
for securing the Light Weight Taut Wire Unit to the base frame
with M16 type A4 80 bolts, torque to 214.5 Nm.
For the calculated maximum load acting on these 12 attachment
bolts, see Figure 9.
Note The frame shall be mounted in such a way that the Light Weight
Taut Wire Unit be standing horizontally levelled and 90° on the
along-ship axis.

3.5.2 Electrical Cabinet

Note Prior to installation the Electrical Cabinet, ensure that
necessary service area is available. For details on service area
and general space requirements, see Figure 5.
The Electrical Cabinet is attached to a yard/customer supplied
base frame that is attached to the floor through welding The
Electrical Cabinet is attached to the base frame by use of four
M8 bolts (bolts to be supplied by yard/customer).
The base frame has to fit the footprint of the Electrical Cabinet,
see Figure 8.

3.5.3 Remote Control Unit (optional)

The optional Remote Control Unit is supplied as a Drop-in type
see drawing 3-7728, where the Remote Control Panel is
connected to the electrical cabinet (cable #2) TB 31.

3.5.3.1 Drop-in Remote Control Unit

The Drop-in Remote Control Panel protrudes 80 mm below the
cabinet front. Before commencing any mechanical installation,
ensure that sufficient space is available inside the cabinet.

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The cut out and overall dimensions of the Drop-in Remote

Control Unit are shown in drawing S-03205.
The Drop-in Remote Control Panel is mounted to the panel by
four (4) bolts with nuts on the opposite side.

3.5.4 Pressurised air

Pressurised air, usually from the vessel's working air supply, is
used to set and regulate wire tension.
The pressure connection point is located just underneath the
Servo Motor, see Figure 11.
The connection for the air supply is GE12LR 3/8".

3.6 Electrical installation

3.6.1 General
Throughout all electrical installation, see drawings 3-7728 and
3-7543.

3.6.1.1 PG-glands
For PG-glands recommended at the Electrical Cabinet, see Table
1.
For PG-glands recommended at the Light Weight Taut Wire
Unit, see Figure 11.
The following PG-glands are pre-mounted at delivery:
• PG-gland for cable number 6 which is going into the
junction box of the Hydraulic Motor at the Light Wire Taut
Wire.
• PG-glands for cable number 7 and 8 which are going into the
junction box of the Servo Motor at the Light Wire Taut Wire
Unit.
Note PG-glands that are not pre-mounted at delivery are not included
(Customer/Yard supply).

3.6.1.2 Tension relief

All cables to and from the Electrical Cabinet or the junction
boxes of the Taut Wire Unit or Remote Control Unit must be
equipped with tension relief just outside their entrance, leaving
no tension to the PG-glands.

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Bandak Light Weight Taut Wire Mk15B

3.6.1.3 Recommended cables

For recommended cable types, see Table 1. For identification of
cable numbers, see drawings 3-7543 and 3-7728.

Cable Cable Type Proposed

No. PG-gland at
Electrical
Cabinet
1 Delivered by Bandak AS N/A
2
2 Signal cable, 2x2x0.5mm screened PG-16
2
3 Power cable, 2x1.5mm screened, 24VDC PG-16
4 Signal cable, twisted pairs 12x2x0,75mm2 or 24x0,75 mm2 screened PG-21
2
5 Signal cable, 12x1.5 mm screened PG-21
2
6 Power cable, 4x1.5mm (3 phases 440VAC plus earth) screened PG-16
2
7 *Power cable, 4x16mm (3 phases 440VAC plus earth) screened PG-21
Delivered by Bandak AS
8 *Signal cable, 2x4x0.5mm2. Each pair screened PG-21
Delivered by Bandak AS
9 Signal cable, 2x2x0.5mm2 screened PG-16
10 Power cable, 3x1.5mm2 (2 phase 230VAC plus earth) screened PG-16
11 Power cable, 4x10mm2 (3 phases 440VAC plus earth) screened PG-21
2 2
12 Signal cable, 16x1.5mm or 2x8x1.5mm twisted pairs, screened PG-21
2
13 Power cable, 4x1,5 mm (3 phases 440VAC plus earth) screened PG-16

Table 1 Cable Types and PG-Gland

Note * Cables and PG-gland delivered by vendor

All cables are with screen.

All cables must be certified for vessel/offshore use.

3.6.1.4 Cable clamping and screen/earth connections

All cables entering the Electrical Cabinet, except Cable
number 7, shall have their outer screens connected to an Earth
Bar just inside their entries. The cable ends must be stripped
back, and all screens and earth continuity conductors connected
to the earth terminal. Loose cores from the stripped cable ends
must be bundled and secured inside the cabinet.
All cables entering the junction boxes shall have their outer
screens connected to an Earth Point just inside their entries.
Caution The screen of Cable number 7 shall be terminated at a clamp
outside servo controller (see Figure 13). Do not terminate the
screen of the Servo Power Cable at its entrance into the
Electrical Cabinet.
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Caution The additional pair wise inner screens of Cable number 8 shall
be connected together at the dedicated Earth point at its
termination rack (see drawing 3-7728). The outer screen of
Cable number 8 shall as normal be terminated at its entrance
into the Electrical Cabinet.

3.6.1.5 Cable terminations

For identification of signal and power cable terminations see
drawing 3-7728.

3.6.2 Light Weight Taut Wire Unit

The signal and power cable connection overview is shown in
drawing 3-7543.
WARNING Remember to remove the two (2) transport bolts from the
gimbal head before starting up the Light Weight Taut Wire
Mk 15B for the first time.

3.6.2.1 Servo Motor Junction Box

The Servo Motor Junction Box is located on top of the Servo
Motor (see Figure 11).
Cables number 7 and 8 are pulled through the pre-mounted PG-
glands into the Servo Motor Junction Box and terminated inside
this box according to drawing 3-7728.

3.6.2.2 Hydraulic Motor Junction Box

The Hydraulic Motor Junction Box is located on top of the
Hydraulic Motor, which is mounted inside the Hydraulic Motor
Cabinet underneath the Taut Wire Control Unit.
Cable number 6 is pulled into the Hydraulic Motor Cabinet
through a customer/yard supplied PG-gland (see Figure 11)
Cable number 6 is then pulled in through the pre-mounted PG-
gland into the Hydraulic Motor Junction Box and terminated
inside this box according to drawing 3-7728.

3.6.2.3 Taut Wire Control Unit

Cables number 4, 5 and 9 are pulled into the Hydraulic Motor
Cabinet through customer/yard supplied PG-glands (see
Figure 11) and terminated according to drawing 3-7728.

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Bandak Light Weight Taut Wire Mk15B

3.6.3 Electrical Cabinet

Cables, number 2 to 12 are pulled into the Electrical Cabinet
through customer/yard supplied PG-glands. The cables are then
terminated according to drawing 3-7728. For identification of
the termination locations, see Figure 13.

3.6.4 Remote Control Unit (optional)

The signal and power cable connections are shown in Figure 13.

3.6.4.1 Drop-in Remote Control Unit

Cables number 2 and 3 are at the one end terminated in the
Electrical Cabinet. At the other end cable number 2 and 3 are
terminated according to drawing 3-7728.

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4 INSTALLATION DRAWINGS
The following figures and drawings are included after this page:

Title Fig./Dwg. No. Rev. Sheets

Light Weight Taut Wire Mk 15B - Side View (Deployed Position) Figure 1 N/A ½
Light Weight Taut Wire Mk 15B - Plan View (Deployed Position) Figure 2 N/A ½
Light Weight Taut Wire Mk 15B - Side View (Stowed Position) Figure 3 N/A 1
Operational Area and Angles of the Wire Figure 4 N/A 1
Electrical Cabinet with Service Area - Top View Figure 5 N/A ½
Electrical Cabinet - Lifting Arrangement Figure 6 N/A ½
Electrical Cabinet Attachment Holes Figure 7 N/A 1
Base Frame Details - Top View Figure 8 N/A ½
Calculated Loads, Base Frame Bolts Figure 9 N/A ½
Light Weight Taut Wire Mk 15B - Lifting Arrangement Figure 10 N/A 1
Taut Wire Cable Entries Figure 11 N/A 1
Taut Wire Control Unit, Location of Terminals Figure 12 N/A 1
Electrical Cabinet Part Locations Figure 13 N/A 1
Electrical Cabinet Parts List Figure 14 NA 1
Wiring Diagram, Computer Signal, LTW Mk 15B 4-0893 B 1
Cable Layout Drawing, LTW Mk 15B 3-7543 B 1
Cable Details Drawing, LTW Mk 15B 3-7728 B 1

Options
Remote Control Unit, Outline Drawing S-03205 NA 1
Remote Control Unit, Power Supply Unit S-03660 NA 1

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Bandak Light Weight Taut Wire Mk15B

Figure 1 Light Weight Taut Wire Mk 15B - Side View (Deployed Position)

Figure 2 Light Weight Taut Wire Mk 15B - Plan View (Deployed Position)

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Figure 3 Light Weight Taut Wire Mk 15B - Side View (Stowed Position)

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Bandak Light Weight Taut Wire Mk15B

Wire

Operational
Area

Vessel side

Plan view
Taut Wire
Gimbal Head

Vessel side

max. max.
23o 23o

Inboard Outboard angle

angle

(Limited by
the horizontal
distance of the
gimbal head
from the
vessel side) Wire

Operational Area

Depressor Weight

(Cd2596a) Side view

Figure 4 Operational Area and Angles of the Wire

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800

5
1 Cabinet
0

1
3
Service 1
Area 0

(CD2685) All dimensions in mm

Figure 5 Electrical Cabinet with Service Area - Top View

Figure 6 Electrical Cabinet - Lifting Arrangement

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Bandak Light Weight Taut Wire Mk15B

800 mm

31 mm

4 ea. Ø 10 mm
(max.) holes
500
mm

39
mm

Cabinet Height: 1700 mm (exclusive lifting eyes)

Figure 7 Electrical Cabinet Attachment Holes

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0 25 555 1160 1675

625

25

(CD2600) 12 x 18.5 25

Figure 8 Base Frame Details - Top View

Note The Base Frame is Customer/Yard supply

3 x 18.3kN 3 x 5kN 3 x 10kN 3 x 23kN

(CD2619)

Figure 9 Calculated Loads, Base Frame Bolts

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Bandak Light Weight Taut Wire Mk15B

Between arms,
around shaft

Figure 10 Light Weight Taut Wire Mk 15B - Lifting Arrangement

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Cable Entrances.
PG-29 (used when cable no. 4, Recommended
5, 6 and 9 are bundled together. Cable Sequence
(top-down): 6, 4, 9,
5. Recommended
PG-gland (top-
down): 21, 21, 16,
16.
Cable no.
13

Entrance cable no. 8 Entrance cable no. 7

Figure 11 Taut Wire Cable Entries

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Bandak Light Weight Taut Wire Mk15B

X42 X12 – TSXSCA62

Termination Termination Junction Box
Rack Rack Terminal Rack
Cable no. 5 Cable no. 4 Cable no. 9

Cable Entrances (inside

duct)
Recommended Cable
Sequence (left-right)
5, 4 and 9
Recommended PG-
gland (left-right):
2xPG-21 and 1x PG-16

Figure 12 Taut Wire Control Unit, Location of Terminals

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Figure 13 Electrical Cabinet Part Locations

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Pos Part List Qty Item Art.no. Manufacturer

Name
1 1 Power EMB 9343-E Lenze
2 1 Controller EVS 9828-ES Lenze
3 KM 1 Contactor LC1D65P7 Telemecanique
4 F1 1 Element automatic C60H/C50-3 Merlingerin
5 F6K6 1 Thermic relay GV2 ME08+GVAN 20 Telemecanique
6 F7 1 Thermic relay GV2 ME02+GVAN 20 Telemecanique
7 K6 1 Contactor LC1D 12P7 Telemecanique
8 K7 1 Contactor LC1D 09P7 Telemecanique
9 F12 1 Fuses automatic GB2-CD12 Telemecanique
10 1 PLC Display EMZ 9371 BB Lenze

11 1 Earth SZ 2364 Rital

12 X 49+24 Terminal point M 4/6D2 Entralec
13 PSU3 1 Power 9522 24V Mascot
14 1 Terminal box TSX PA CC01 Telemecanique
15 X71 1 Card keeper SKB 164/C64
16 K11 1 Contactor CA2KN40M7+LA1KN11 Telemecanique
17 K10 1 Contactor CA2KN40M7+LA1KN11 Telemecanique
18 K9 1 Contactor CA2KN40M7+LA1KN11 Telemecanique
19 K8 1 Contactor CA2KN40M7+LA1KN11 Telemecanique
20 KR 1 Relay module ABR2E111M Telemecanique
21 K102 1 Relay RM111 12VDC Entralec
22 K101 1 Relay RM111 12VDC Entralec
23 Z1 1 Drossel ELN3 0075H045 Lenze
24 1 Battery TSX PL P01 Telemecanique
25 06 1 PLC module TSX ASZ 200 Telemecanique
Analogue out 0-10 v
26 05 1 PLC module TSX AEZ 801 Telemecanique
Analogue in 0-10 v
27 01-02 1 16 in / 12 out TSX DMZ 28 DR Telemecanique
28 00 1 PLC TSX Micro TSX 372110 Y Telemecanique

Figure 14 Electrical Cabinet Parts List

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 LCD
Contrast

+5V DC

RS-422 RS-232