Yangfan Group Hull 2181 Order No. 231795

G&O Vibration Compensator
M/V Hull 2181

G&O order no. 231795
Gertsen & Olufsen A/S

Savsvinget 4
DK 2970 Hørsholm
Denmark
Tel: +45 4576 3600
Fax: +45 4576 1773
info@g-o.dk
www.g-o.dk
Manual for G&O
Vibration Compensator
Type C-200V1
Electrical connection diagrams
Setting of compensator
Operators manual / Product specification
Maintenance of compensator
Spareparts
Setting of Compensator

1. Size of compensator force

2. Vertical direction of force

3. Phase angle of compensator force

4. Project data

5. Factory Acceptance Test (FAT)

1. Size of compensator force (Fig. No. 1 & 2)

The size of force “Fc” is adjustable from 0 to 100 % of the design value by changing the imbalance.
The size of force is optimized on basis of vibration records at sea trial.

Relative movement of flyweights changes the imbalance without disassembling the compensator.

The relation between size of force and angle between two flyweights is shown in increments of 5 %
on Fig. No. 2. The angle V° is equal to the value on graduation scale outside the flyweight.

The compensator has two set of flyweights on two horizontal counter rotating shafts. The inner
flyweight on both shafts are adjustable relative to the outer flyweight. Adjustment is undertaken
with compensator stopped and at one set of flyweights at a time. The adjustable flyweights have
quick couplings with connection to the shaft.

With one flyweight locked by M12x90 mm screw in housing and oil pump connected to quick
couplings (see Fig. No. 1) pressure is applied to the shrinkage between shaft and flyweight and the
shafts are moveable by AC‐Servomotor in “MAN” mode. Both set of flyweights to be adjusted to
same value on graduation scale.

To confirm the correct position after adjustment in a more accurate way please check that two
adjustable flyweights pass the center of separate inspection windows simultaneously.

Half the angle V° is called V2° and is the angle between proximity switch point of flyweight and the
resultant of compensator force after adjustment.

1
2. Vertical direction of force (Fig. No. 3)

The vertical direction of force is adjustable without disassembling the compensator. Correct setting
can be carried out as follows:

 Random chosen flyweight to be positioned with edge at red zero point mark in inspection glass
and locked with M12 x 90 screw in the housing.
 Rotafix coupling on small driving shaft on opposite side to be loosened and flyweight to be
turned by hand to similar position as on opposite side.
 Rotafix to be retightened and screws tensioned to 30 Nm.
 M12x90 mm screw to be removed.
 As safety to unforeseen movement between flyweights (incorrect force direction) two proximity
switches (one at each flyweight) are mounted and requires simultaneously activation.

3. Phase angle of compensator force (Fig. No. 4)

The computer and synchronizer module controls the speed and position of flyweights relative to
propeller and main engine. The pulses from proximity switches on propeller shaft and on
Compensator housing are used for timing and position of compensator flyweights.

For timing of the so‐called calibration angle Vc° is calculated and keyed into the computer. Vc° is
always an integral degree between 0 and 359 degrees.

2
4. Project data.
Project no. : 231795

Date of installation :
Compensator type : C-200V1
Part list no. : C400-009 / 70000_7
Base Frame :
Tooth count system : 60437
Opto-coupler : -
Synchronizer Unit : BEC 20-103037-001

Ser. No. : 103037-0017
Build (D/M/Y) : 060212
Hour counter : 1.5 t
Computer : CCS262, No. CX1020 HPS 3.10
Ser. No. : 59044
Host name : CX_0D5142
Software No. : 93-102807-001
6.5” Touch screen : CP6909-0001-0000
Ser. No. : 574220-002
Ref+ (tdc cyl.1) : Balluff, BES M12MG1-PSC60B-S04G

Channel A & B : Balluff, BES M12MG1-PSC60B-S04G
Index pulse compensator : Balluff, BES 516-105-SA5
Gear Ratio i : 9.6

Gear wheel backlash : 0,2mm
Max. Torque Mmax : 441 Nm
Inertia Jred : 0.305 kgm2
Compensator Force : 84,31 kN (mcr)

Max. Imbalance : 200 kgm
Setting : 125 kgm
Calculated Power : ±8 kW
Deceleration time ( - 0 rpm) : 0 min.54sec. (V = 180°)
Setting angles V° : 102
V 2° : 51
V 3° : 90/270°
Ship :
IMO No. :
Type of Ship :
No. of propeller blades :
Main engine : (CW/CCW)
Main eng. Hour counter : hrs. (Date)
Speed : 124 (mcr)
Application : 2nd Order external couples (1349 kNm)
Distance to Zero Nodes : -
Location : CL in Steering gear room
3
CCS262 computer parameters:
System setup:
1. Compensator type : C-200V1

2. Software number : 93-102807-001
3. Software revision : B02
4. Number of compensators pc : 1
5. Simulation mode On/Off : Off
6. Simulation acceleration rpm/s : 1
7. Angle V4 deg : 0
8. Average factor : 10
9. Teeth on gear wheel :
10. Max. allowed deviation : 1
11. Number of teeth counted : ?
12. Analog torque scaling %/V : 10
13. Automatic Slowturn On/Off :
14. Main engine time hrs :
15. Current date and time : 2012/02/20 13:31:10
16. New date (YYYY/MM/DD) : 2012/02/20
17. New time (HH:MM:SS) : 13:31:10
Compensator setup:
1. Low speed velocity rpm : 50

2. High speed velocity rpm : 127
3. Slow turn velocity rpm : 0
4. Inactive range of max. speed rpm : 5
5. Inactive range of min. speed rpm : 5
6. Speed factor Ks : 2
7. Compensator pulses/revolution (P13051 x i) 1/rev : 3840
8. Compensator speed at 10 V rpm : 279.5
9. Motor surveillance limit min : 50
10. Angle Vc deg : 0
11. Max. deviation error deg : 10
12. Max. deviation time sec : 10
13. Automatic acceleration rpm/s : 20
14. Manual acceleration rpm/s : 1
15. Manual max. speed rpm : 1
16. Torque average limit % : 0
17. Torque average time min : 0
18. Torque peak limit % : 0
19. Compensator speed at 10V rpm : 279.5
20. Compensator speed at 0V rpm : 0
21. Low set point 0.0V rpm : 0
22. High set point 0.0V rpm : 0
23. New speed at (0V, 10V) rpm : 0.0 0.0
24. Deviation deg : 0
4
Regulator setup:
1. Gain factor Kp - : 0.25

2. Integral time Tn - : 4000
3. Automatic Gain factor Kp (L-9400) - : 1
4. Automatic Integral time Tn (L-9400) - : 300
5. Manual Gain factor Kp (L-9400) - : 3
6. Manual Integral time Tn (L-9400) - : 300
7. Slow turn Gain factor Kp (L-9400) - : 3
8. Slow turn Integral time Tn (L-9400) - : 300
9. Regulator - : Disabled/Enabled
10. Deviation gain factor Kp - : 0.2
Password:
Change user level 0-2 : 2
Password level 0 : -
Password level 1 : 1234
Password level 2 : 4321
5
L-9400 single drive
Lenze single drive : E94ASHE0594

Ser. No. : 13371376 02944664
Operation Modes, Scaling

P11 Motor reference speed : 2088 rpm
P173 Mains voltage : 400/415 V
P1215-1 Seconds : 00 Seconds
P1215-2 Minutes : 33 Minutes
P1215-3 Hours : 13 Hours
P1215-4 Day : 20 Day
P1215-5 Month : 02 Month
P1215-6 Year : 2012 Year
P2732-1 Analog input 1: Dead band : 0.2 %
Current controller
P18 Chopper frequency : 8 (var.) kHz
P22 Maximum current : 118 Amps.
P57-1 Maximum torque : 441.76 Nm
P57-2 Motor reference torque (Analog out: X3.A02 v. X5.DI8=0) : 441.76 Nm
P74 CFeedfwd. Ctrl. - current contr. : Dea. feedfwd. ctrl.
P75 Current controller gain : 4.5 V/A
P76 Current controller reset time : 13 mS
P789 Max. device current (Analog out: X3.A02 v. X5.DI08=1) : 118 Amps.
Speed Controller
P70 Speed controller gain : 1 Nm/rpm
P71 Speed controller reset time : 300 mS
P72 Speed controller D component : 0 mS
P497 Speed act. Val. Time const. : 2 mS
Field Controller / Field Weakening Controller

P77 Field controller gain : 1000 A/Vs
P78 Field controller reset time : 1000 mS
P93 Fieldweaking for SM : Off
P577 Field weakening controller gain : 0 Vs/V
P578 Field weakening controller reset time : 15000 mS
Attached modules
Frequency module (Encoder emulation) : E94AYFLF
EtherCat module : E94AYCET
DIB switch module (MM330) : E94AYM33
SMO module : E94AYAA
6
Motor Parameters
Hoyer motor type (30 kW) : HMC2 200L-4

Ser. No. : SH536922-028
With Space heater : 13338054
P59 Motor - Number of pole : 2
P79 Motor - Mutual inductance : 54.6 mH
P81 Rated motor power : 30 kW
P82 Motor - Rotor resistance : 0.0732 Ohm
P83 Motor - Rotor time constant : 775.61 mS
P84 Motor stator resistance : 0.375 Ohm
P85 Motor stator leakage induction : 2.2 mH
P87 Rated motor speed : 1472 rpm
P88 Rated motor current : 53 Amps.
P89 Rated motor frequency : 50 Hz
P90 Rated motor voltage : 400 V
P91 Motor - Cosine phi : 0.88
P92 Motor - Magnetising current : 11.5 Amps.
P121 Motor temp. warning threshold : 120 °C
P586 Resp. to resolver open circuit : Fault
P596 Threshold max. speed reached : 4500 rpm
P1190 Motor thermal sensor : KTY83-110
Resolver/Incremental Encoder Set-up

P80 Resolver - Number of pole pairs : 1
P495 Motor encoder selection : Resolver on X7
P13051 No. of increments DFOUT : 400
Regenerative power supply module
Lenze regenerative supply unit : E94ARNE0244

Ser. No. : 13378000 02931106 000003
P5 Application selection : 0
P6 Selected control scheme : Open loop
P18 Chopper frequency : 4 (fixed) kHz
P57 Maximum effective power : 55.4 kW
P70 DC bus voltage ctrl. Gain : 0.01 Nm/rpm
P71 DC bus voltage reset time : 50 mS
P75 Current controller gain : 15 V/A
P76 Current controller reset time : 50 mS
P84 Filter resistance : 0.026 Ohm
P85 Filter inductance : 1.57 mH
P121 Filter temp. warning threshold : 135 °C
P122 Heatzink temp. warning threshold : 85 °C
P123 Warning threshold device util. : 90 °C
P126 CPU temp. warning threshold : 70 °C
P173 Mains voltage : 400/415 V
P789 Max. device current (Analog out: X3.A01) : 58.8 Amps.
P4035 Reference value (Analog out: X3.A02) : 40500 W
7
Attached modules
EtherCat module : E94AYCET
DIB switch module (MM330) : E94AYM33
SMO module : E94AYAA
Mains filter
Mains filter type : E94AZMR0474LDB

Part no. : 13242927
Ser. No. : 30000013003757
8
5. Factory Acceptance Test (FAT)
Gertsen & Olufsen A/S carries out a complete function test. Functions are checked on
CCS262, curve recorder and motor drive as follows:
Start (simulator and remote control)
Checklist: Visual check of oil level at inspection glass (Compensator stopped)

Stand by status (CCS262)
Parameter setting of computer according to list in section 4
Parameter setting of motor drive according to list in section 4
Parameter setting of regenerative module according to list in section 4
Manual start from green button 9S7 (Stand by to Low speed + 17P10)
Automatic start at min. speed setting (Compensator setup 1)
Automatic start at max. speed setting (Compensator setup 2)
Simulator acceleration according to setting (System setup 5)
Synchronizing (simulator, remote control and curve recorder)
Checklist : Relation between speed of simulator and compensator (Ks)

Performance curve of acceleration (rpm at recorder)
Performance curve of torque (torque at recorder)
Stop (simulator, remote control and curve recorder)
Checklist: Automatic stop at max. speed + inactive range (Compensator setup 2+4)
Automatic stop at min. speed - inactive range (Compensator setup 1-5)
Manual stop from red stop button 9S5.2 (17P10)
Performance curve of controlled deceleration (recorder)
Manual operation (remote control)
Checklist : Manual turning in both directions

Setting of manual speed (Compensator setup 14)
Teeth count operation
Checklist : Check of signals (A+, B+ & Ref+) on DI test page

Reading of counted teeth from “System setup”
9
Safety functions.
Checklist: Index interval

High vibration
Oil flow
Deviation error
Index count error
Speed surveillance error
Torque overload
Sense 1, 2 or 3 (Status message)

G&O Project No. : 231795
Approved Date Signature
Customer
Mr. Jakob Heidicke 12-02-2012 Jakob Heidicke

Service Manager
10
Calculation Data for Vibration Compensator.
Project No. : 231795
Compensator speed (rpm) : 248
Compensator max. Imbalance (kgm) : 200,000
Angle V° Angle V2° U kgm Force in kN %
0,0 0,0 200,000 134,9 100
36,4 18,2 190,000 128,1 95
51,7 25,8 180,000 121,4 90
63,6 31,8 170,000 114,7 85
73,7 36,9 160,000 107,9 80
82,8 41,4 150,000 101,2 75
91,1 45,6 140,000 94,4 70
98,9 49,5 130,000 87,7 65
106,3 53,1 120,000 80,9 60
113,3 56,6 110,000 74,2 55
120,0 60,0 100,000 67,4 50
126,5 63,3 90,000 60,7 45
132,8 66,4 80,000 54,0 40
139,0 69,5 70,000 47,2 35
145,1 72,5 60,000 40,5 30
151,0 75,5 50,000 33,7 25
156,9 78,5 40,000 27,0 20
162,7 81,4 30,000 20,2 15
168,5 84,3 20,000 13,5 10
174,3 87,1 10,000 6,7 5
Fig. No. 2

AUTOMATIC COMPENSATOR
OPERATOR MANUAL
Rev. No. B02

99‐102804 HU‐B03

Table of contents

1 Introduction .............................................................................................................................................. 3
2 Operational principles ............................................................................................................................... 3
3 Controller user interface ............................................................................................................................ 4
3.1 Overview of the pages ............................................................................................................................... 5
3.2 Main Menu ................................................................................................................................................. 6
4 Status pages .............................................................................................................................................. 7
4.1 Status 1/2 ................................................................................................................................................... 7
4.2 Status 2/2 ................................................................................................................................................... 8
4.3 System states ............................................................................................................................................. 9
4.3.1 STANDBY: .............................................................................................................................................. 9
4.3.2 LOW SPEED: ........................................................................................................................................... 9
4.3.3 HIGH SPEED: .......................................................................................................................................... 9
4.3.4 SLOW TURN: ........................................................................................................................................ 10
4.3.5 ACCELERATING: ................................................................................................................................... 10
4.3.6 RUNNING: ............................................................................................................................................ 10
4.3.7 DECELERATING: ................................................................................................................................... 11
4.3.8 ALARM: ................................................................................................................................................ 11
4.3.9 SENSOR INPUT: .................................................................................................................................... 11
5 Alarm ...................................................................................................................................................... 12
5.1 How to reset alarms ................................................................................................................................. 12
6 Password / user levels ............................................................................................................................. 13
6.1 How to change user level ......................................................................................................................... 14
6.2 How to change password ......................................................................................................................... 14
99-102804 HU-B03 2 / 14
1 Introduction
This document is the Operator manual for the controller unit of the Gertsen & Olufsen A/S
Vibration Compensator.

The Operator manual describes the most common issues when working with the Compensator
system.

Please see to the document “95‐102805 DS Product Specification” for a more detailed
description of the Compensator system and specification of the setup parameters.

The controller unit synchronizes the speed and position of a number (max. 2) of compensators
relative to the speed and position of a main engine.
2 Operational principles
The controller regulates the Compensator speed and position relative to the speed and position
of the Main engine. The Compensator speed (Ks) can be selected in steps from 1 to 12 times
the Main engine speed.

When Main engine exceeds a given speed the Compensator starts to accelerate. When required
speed is reached (1 ‐ 12 times Main engine speed), the controller synchronizes the
Compensator position relative to the Main engine position (tdc 1).

The Compensator stops at following situations:

1. If the Main engine speed exceeds a given limit, the Compensator stops and waits for the
Main engine speed to decrease.
2. If the Main engine speed gets below a given limit, the Compensator stops and waits for
the Main engine speed to increase.
3. If an error/alarm occurs.
4. If one of the “Sense inputs” are activated.
5. If the operator press the stop button.

The controller contains a facility to simulate the Main engine speed, used for function test of
the Compensator and for exciter test during commissioning.

In addition the controller contains facilities to operate the Compensator in “Man” mode used
for setting of imbalance at the Vertical type.

99-102804 HU-B03 3 / 14

3 Controller user interface

The interaction between the operator and the controller is done by a 6.5” touch display.

99-102804 HU-B03 4 / 14
3.1 Overview of the pages
Parts of the user interface are present on all pages. These will be explained as follows:

Picture 3.1 Alarm status

1. This field shows the name of the present viewed page.
2. If an alarm is raised this field will flash “ALARM”.
3. This button is used to select between Compensator 1 and 2.
4. This part of the page will change according to selection.
5. This button moves one step back if a series of pages are shown (i.e. if “Status 2/2” is
shown it will select page “Status 1/2”).
6. This button always selects the Main menu.
7. This button moves one step forward if a series of pages are shown (i.e. if “Status 1/2” is
shown page “Status 2/2” will be selected).
99-102804 HU-B03 5 / 14
3.2 Main Menu
When the system starts up following page is shown:

Picture 3.2 Main menu

This page states the different menu items to change in between.

 Status ‐ Enters the “Status 1/2” page.
 Setup ‐ Enters the “Setup menu” page.
 Alarm ‐ Enters the “Alarm menu” page.
 Password / User level ‐ Enters the “Password / user level” page.
99-102804 HU-B03 6 / 14
4 Status pages
Status pages shows information from the system.
4.1 Status 1/2

Picture 4.1 Status page ½

 Status ‐ Shows the current state of the Compensator.
 Main engine velocity ‐ Shows the actual measured velocity of the Main engine.
 Compensator velocity ‐ Shows the actual measured velocity of the Compensator.
 Deviation ‐ The deviation angle is only valid if the Compensator is in system state
“Running”. The deviation angle is calculated when the Main engine angle is at 0 deg.
(Ref+).

99-102804 HU-B03 7 / 14

4.2 Status 2/2

Picture 4.2 Status page 2/2

 Status ‐ Shows the current state of the Compensator.
 Main engine velocity ‐ Shows the actual velocity of the Main engine.
 Main engine position ‐ Shows the actual position of the Main engine in deg.
 Compensator velocity ‐ Shows the actual velocity of the Compensator.
 Compensator position ‐ Shows the actual position of the Compensator in deg.
 Torque ‐ Shows the current torque of the Compensator.

99-102804 HU-B03 8 / 14
4.3 System states
4.3.1 STANDBY:

The main power is switched on to the Synchronizer cabinet, waiting for the start signal. In
this state the Compensator motor is stopped and without torque.
4.3.2 LOW SPEED:

When Main engine speed is below the minimum setting value the “Status” will show
“LOW SPEED”. This “Status” will release the “RF” signal and the Compensator are
stopped. The Compensator will restart when the Main engine speed exceeds the low
speed limit setting.
In “LOW SPEED” state the motor is without torque.
4.3.3 HIGH SPEED:

When Main engine speed exceeds maximum setting value, the “Status” first enters
“DECELERATING”. “RF” signal is off and the Compensator will stop. If the Main engine
speed still exceeds the maximum value the state “HIGH SPEED” is shown. The
Compensator will restart when the Main engine speed gets below the high speed limit
setting. In “HIGH SPEED” state the motor is without torque.

99-102804 HU-B03 9 / 14

4.3.4 SLOW TURN:

The Compensator is rotated with a given “Slow turn velocity”. The Compensator will start
automatically, when Main engine velocity is within the programmed limits.
“SLOW TURN” can be disabled in “Setup” by entering the value 0 in “Slow turn velocity”.
4.3.5 ACCELERATING:

The Compensator is accelerating to obtain the required speed. The actual speed is given
by Main engine speed * Ks.
4.3.6 RUNNING:

The Compensator and Main engine speed and position are synchronized according to
setting of Ks (Speed factor) and Vc (Calibration angle).
99-102804 HU-B03 10 / 14
4.3.7 DECELERATING:

The Compensator is decreasing speed until stopped. In this state the motor is running
free without torque.
4.3.8 ALARM:

An alarm situation has occurred. The Compensator will not start until the alarm situation
has been resolved and the alarm is reset from the controller panel.
4.3.9 SENSOR INPUT:

The “Sensor input” signals is a feature used for external control of the system by remote
potential free contacts. The Compensator will enter decelerating state if one or more of
the inputs should be inactive. If a slow turn speed is programmed, the Compensator will
decelerate and stop before entering into “Slow turn” mode, otherwise the Compensator
will stop. When all inputs are reactivated, the Compensator will automatically start again.
99-102804 HU-B03 11 / 14
5 Alarm
5.1 How to reset alarms
In order to reset alarms first select the alarm menu by pressing the “Alarm” button in the main
menu.

Then press the “Alarm status” button.

In the “Alarm status” page the currently raised alarms will be shown in a list.

99-102804 HU-B03 12 / 14

When the button “Reset alarm” is pressed the alarm listed topmost of the list will be reset. If
the conditions to raise the alarm still exist, the alarm will reappear in the bottom of the list.
Note that system alarms always will be inserted in the top of the list.
Please refer to the product specification for a detailed description of the alarms.
6 Password / user levels
To protect vital setup values a password system is implemented in the controller.
This password system is based on user levels.
User level 0 is reserved for Gertsen & Olufsen service personnel.
User level 1 is used for supervisors / technicians ‐ gives access to all setup changes.
User level 2 is used for normal users. Some setup values are not accessible.

Picture 6.1 Password / User level
99-102804 HU-B03 13 / 14
6.1 How to change user level
Pressing “Change user level” button (1) will show a dialog that enables change of user level. In
order to change user level one must know the password for the specific user level.

Leaving this dialog by pressing the “OK” button will change to the wanted user level, provided
that the entered password is correct.

6.2 How to change password
Referring to illustration “Picture 6.1 Password / User level” pressing “Change password” button
(2) will show a dialog that makes it possible to change passwords. In order to change password
one must know the current password for the specific user level.

Leaving this dialog by pressing the “OK” button will change to the password for the current user
level, provided that the entered password is correct.
99-102804 HU-B03 14 / 14

AUTOMATIC COMPENSATOR
PRODUCT SPECIFICATION
Rev. No. B02

95‐102805 DS‐B09
Table of contents
1 Introduction .............................................................................................................................................. 4
2 Hardware configuration ............................................................................................................................. 4
2.1 Mounting of proximity switches (Tooth count) ......................................................................................... 5
2.2 Main engine position calculation ............................................................................................................... 5
3 Simulating Main engine ............................................................................................................................. 6
4 Moving the Compensator in manual mode ................................................................................................ 8
4.1 Enter manual mode ................................................................................................................................... 8
4.2 Move the Compensator ............................................................................................................................. 9
4.2.1 By the remote control (Option) ............................................................................................................. 9
4.2.2 From the touch screen .......................................................................................................................... 9
4.3 Leave manual mode ................................................................................................................................. 10
5 Alarms ..................................................................................................................................................... 10
5.1 System alarms .......................................................................................................................................... 11
5.1.1 Index interval....................................................................................................................................... 11
5.1.2 High vibration ...................................................................................................................................... 11
5.2 Compensator alarms ................................................................................................................................ 11
5.2.1 Oil flow ................................................................................................................................................ 11
5.2.2 Deviation error .................................................................................................................................... 11
5.2.3 Index count error ................................................................................................................................ 12
5.2.4 Speed surveillance error ..................................................................................................................... 12
5.2.5 Torque overload .................................................................................................................................. 12
5.2.6 High heat motor .................................................................................................................................. 12
5.2.7 Counter module failure ....................................................................................................................... 12
5.2.8 Lenze drive error ................................................................................................................................. 12
5.3 Alarm Log ................................................................................................................................................. 13
6 List of setup pages ................................................................................................................................... 14
6.1 System setup ............................................................................................................................................ 15
6.1.1 System setup 1/5 ................................................................................................................................. 15
6.1.2 System setup 2/5 ................................................................................................................................. 16
6.1.3 System setup 3/5 ................................................................................................................................. 17
6.1.4 System setup 4/5 ................................................................................................................................. 18
6.1.5 System setup 5/5 ................................................................................................................................. 18
6.2 Compensator setup .................................................................................................................................. 20
6.2.1 Compensator setup 1/4 ...................................................................................................................... 20
6.3 Regulator setup ........................................................................................................................................ 24
6.3.1 Regulator setup 1/2 ............................................................................................................................ 24
6.3.2 Regulator setup 2/2 ............................................................................................................................ 25
95-102805 DS-B09 2 / 35
7 IO Pages .................................................................................................................................................. 26
7.1 I/O test menu ........................................................................................................................................... 27
7.1.1 Digital input ......................................................................................................................................... 27
7.1.2 Digital output ...................................................................................................................................... 28
7.1.3 Analog I/O ........................................................................................................................................... 30
7.1.4 Teeth count monitoring ...................................................................................................................... 32
7.1.5 Encoder monitoring............................................................................................................................. 33
8 IO List ...................................................................................................................................................... 34
8.1 Digital inputs ............................................................................................................................................ 34
8.2 Digital outputs .......................................................................................................................................... 34
8.3 Analogue inputs ....................................................................................................................................... 35
8.4 Analogue outputs ..................................................................................................................................... 35
8.5 Counter modules ..................................................................................................................................... 35

95-102805 DS-B09 3 / 35
1 Introduction
This document is the technical handbook for the Vibration Compensator from Gertsen &
Olufsen AS. This manual is a supplement to the Operator Manual, document no. ”99‐102804
HU”, describing the daily use of the machine.
2 Hardware configuration
The system is based on a DIN rail mounted industrial controller with a built in PLC. This
controller unit is connected to a 6.5” touch screen. The touch screen is used to monitor system
status and to change parameters of the controller.

All inputs and outputs are handled by the Beckhoff DIN rail mounted I/O system. The I/O
system is connected to the controller and is communicating via an ultra high‐speed industrial
field‐bus called EtherCat.

The servo drives are controlled via analogue outputs for commanded velocity and position. The
speed and position is calculated based on emulated encoder feedback from the servo drives
and proximity switch signals.

Picture 2.1 Hardware configuration
95-102805 DS-B09 4 / 35
2.1 Mounting of proximity switches (Tooth count)
The proximity switches (Ref+, A & B) for Tooth count are mounted close to the turning gear
wheel in order to obtain below described direction effect.
If switch B is “high” at the same time as the rising edge of switch A occurs the direction of the
gearwheel is positive. In the other case if switch B is “low” at the time of the rising edge of
switch A the direction of the gear wheel is negative. The position and speed of the Main engine
isn’t calculated when turning in negative direction.

2.2 Main engine position calculation
The speed and position of the Main engine is calculated based on inputs from 3 pc. Proximity
switches mounted near the turning gear wheel.

The position of the Main engine (0 ‐ 359o) is calculated for each scan of the program code in
relation to the number of counted teeth.
In addition there is an interpolated calculation of each tooth.
The position and the number of counted teeth are set to zero when the Main engine index
switch (Ref+) is triggered.

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3 Simulating Main engine

After installation of the Compensator system it’s possible to simulate the Main engine speed in
order to test the function of the system with Main engine stopped.

To do so, navigate to “System setup 2/3” and change “Simulation mode” (1) to “On”.
When simulation mode is enabled the simulated Main engine speed will accelerate with the
“Simulation acceleration” (2) as long as the “+” button on the remote control (Option) is
pressed. In addition it will decelerate when the “‐“ button is pressed.

The simulation mode can only be changed when the AC‐servo drive is switched off (Status =
STANDBY).

An identical function is available at the screen menu. In order to operate the simulated Main
engine speed from the screen, navigate to “Setup menu” and press “Simulation controls” (3).
This button is only visible in simulation mode.
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When pressing “Simulation controls” the following page will appear. From here it’s possible to
accelerate and decelerate the simulated Main engine velocity by pressing “Positive (+)” or
“Negative (‐)”.

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Picture 3.1 Warning page

When the operator chooses to turn simulation mode off, the controller shows a confirmation
screen with a warning. When the “Ok” button is pressed the controller switches into normal
operation.
4 Moving the Compensator in manual mode
4.1 Enter manual mode
 To enter manual mode the state of the Compensator control has to be “STANDBY”.
 Press the “ON” button on the remote control unit (Option).
 Press the start button for the respective Compensator.

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4.2 Move the Compensator
4.2.1 By the remote control (Option)
The Compensator can be operated in positive or negative direction by pressing the “Remote +”
or “Remote ‐” button on the remote control unit.
4.2.2 From the touch screen

It’s also possible to operate the Compensator from the touch screen buttons.
When the Compensator state is “MANUAL” the screen “Setup menu” displays a button named
“Manual” (1). By pressing this button the “Manual running 1/1” screen appears.

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From this page it’s possible to move the respective Compensator in the same way as with the
remote control.
4.3 Leave manual mode
When the “ON” button on the remote control unit (Option) is released, the operator is asked to
confirm leaving manual mode. This is done by showing the same warning page as above
(Picture 3.1 Warning page). When the operator is ready to let the Compensator enter
automatic mode, press “OK”.
5 Alarms
This chapter lists and describes the possible alarms of the controller.
Alarms can be divided into two groups.
System alarms: Common for all Compensators.
Compensator alarms: Referring to the specific Compensator.
Alarms are handled in a queue that operates with the FIFO principle. This means that alarms
are put back in the queue and they can be reset one at a time. System alarms are always put in
top of the alarm queue as they are given higher priority than Compensator alarms.

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5.1 System alarms
5.1.1 Index interval
This alarm is activated if the number of counted teeth exceeds the number of teeth given for
the gear wheel or the number of counted teeth is less than the number of teeth given for the
gear wheel subtracted a setup value. This setup value is called “Max. teeth count error”.
The “Index interval” alarm is divided into 3 separate alarms in order to improve trouble
shooting in case of failure. Following alarms can occur:
Index interval (Ref+) : Failing or missing signal from proximity switch Ref+ (tdc 1)
Index interval (A) : Failing or missing signal from proximity switch A
Index interval (B) : Failing or missing signal from proximity switch B
This alarm is not being watched when the state is either “Parameter mode”, “Standby”,
“Manual” or “Simulation”.
5.1.2 High vibration
This alarm will be activated if the input “High Vibration” is set to 0.
This alarm is always watched.
5.2 Compensator alarms
5.2.1 Oil flow
The alarm “Oil flow” is generated if oil flow is missing or below allowed alarm set point.
Check the digital input ”oilflow_comp1” and if 2 Compensators are operated from same
cabinet, ”oilflow_comp2”.
5.2.2 Deviation error
This error will be activated if the deviation between Compensator and Main engine exceeds the
setup threshold “Max. deviation error” for more than a given period of time “Max. deviation
time”.
The deviation is calculated when the Main engine is at zero degrees (tdc 1).
This alarm is only watched in the state “Running”.
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5.2.3 Index count error
This alarm will be generated when the counted number of pulses between two index pulses
from the Compensator deviates from set point.
This alarm is only checked in the state “running”.
5.2.4 Speed surveillance error
This alarm will be set, if the measured feedback velocity compared to the commanded velocity
of the Compensator deviates more than the setup value in “Compensator surveillance limit”.
This alarm is only checked in the state “Running”.
5.2.5 Torque overload
This alarm is generated when the measured torque from the drive exceeds the specified value
in “Torque peak limit “ or more than “Torque average limit “ in a period of time higher than
specified in “Torque average time”.
This alarm is only checked in the state “Running”.
5.2.6 High heat motor
This alarm will be activated if either ”highTemp_comp1” or ” highTemp_comp2” is ”off”
This alarm isn’t checked in states ”Parameter mode” or ”Standby”.
5.2.7 Counter module failure
This alarm will be activated if it’s detected that one or more of the signals from the encoder
emulation are missing on the counter module.
5.2.8 Lenze drive error (Vertical Compensator type)
If an error occurs in one of the Lenze drives the alarm text is received from the Lenze drive via
the EtherCat connection and shown on the touch display. When the operator clears the error
on the touch display the error is reset in the drive.
This alarm is always watched on configurations with Lenze drives.

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Following describes LED display in front panel of the Lenze controller:

Labeling Color Description
CAN‐RUN Green CAN bus is OK
CAN‐ERR Red CAN bus error
DRIVE READY Green Standard device is ready for operation
DRIVE ERROR Red Warning / Trouble / Fault
24 V Green 24 V supply voltage is OK
USER Yellow Message parameterized by the application
5.3 Alarm Log
The alarm log is a tool for the technician to be able to track alarm history.

The alarm log can contain a maximum of 100 listings. New alarms will be inserted at the top of
the list, and in case the list is full the oldest alarm will be cleared.

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6 List of setup pages
When pressing the “Setup” button from the main menu a setup menu will be shown.

From this setup menu it’s possible to enter 5 sub pages:
 “System” (1) ‐ Contains system setup values. See chapter 6.1
 “Compensator” (2) ‐ Contains operational values for the Compensator system. See
chapter 6.2
 “Regulator” (3) ‐ Proportional & Integral values used for speed and position control of
the Compensator. See chapter 6.3
 “I/O test” (4) ‐ For a description of I/O test see chapter 7
 “Manual” (5) ‐ This button will be visible in case “Manual” mode is activated.
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6.1 System setup
6.1.1 System setup 1/5
System setup 1/5

Tel.: +45 45763600
Compensator type: C‐200V1
Software No.: 93‐102807‐001
Software Revision: Rev. B02

<< Previous page Main menu Next page >>

On this page it is possible to enter the type of Compensator and observe the Software number
and revision.

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System setup 2/5

Number of compensators: 1
Simulation mode: Off
Simulation acceleration: 1.00 rpm/s
Angle V4: 0 deg
Average factor 10


 Number of compensators ‐ The attached number of Compensators.
 Simulation mode ‐ Enables / disables simulation of Main engine.
 Simulation acceleration ‐ Acceleration rate used for velocity change of the simulated
Main engine speed.
 Angle V4 ‐ Offsets the Main engine position from tdc cyl. 1 (Ref+).
 Average factor ‐ Determines how much the Main engine velocity is being smoothed.
If the average factor is 10, the current velocity is 50 and the new sampled speed is 52,
the new calculated current velocity will be 50 + ((52‐50)/10) = 50.2. The speed is
sampled for every 0.1 mS

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System setup 3/5

Teeth on gear wheel: 76
Max. allowed deviation: 1
Number of teeth counted: 0
Analog torque scaling: 44.5 %/V
Automatic Slowturn: On On/Off
Main engine time: 25 hrs.


(1) Main engine pulses/revolution
(2) Max. allowed deviation
(3) Number of teeth counted
(4) Analog torque scaling
(5) Automatic Slowturn
(6) Main engine time

 (1) ‐ The number of teeth from gear wheel on the Main engine.
 (2) ‐ When the controller fails to detect the value in (1) subtracted the value in (2)
during one Main engine revolution an alarm will be activated.
 (3) ‐ Shows the number of teeth counted by the controller between the latest two index
pulses (Ref+).
 (4) ‐ Scaling of the analogue output value from the servo drive (Scaling per V).
 (5) ‐ Compensator Slowturns when the Main engine is running above 10 rpm and the
Compensator isn’t started (Green start button).
 (6) ‐ Main engine running hrs. above 10 rpm.

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System setup 4/5

Current date and time: 28‐01‐2011 13:00
New date (YYYY/MM/DD): 2011/01/28
New time (HH:MM:SS): 13:00:00
Set date and time


Enter the correct date and time and press the “Set date and time” button to change the system
time. The time is used to timestamp alarms.
System setup 5/5

!!CAUTION!! The below button deletes the current setup file.

!!! Delete setup file !!!

System running normally


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The “System setup 5/5” page should only be used if the setup file has been corrupted during
update of the software to a higher revision. If needed, this page can be used to restore default
values for all control parameters.

!CAUTION!
Don’t use this button unless you’re absolute sure about the function.

Procedure:
1. First write down the values of all control parameters.
2. Press the button “!!! Delete Setup File !!!”
3. When the lower text shifts to “Setup file has been deleted. Update the system now”,
you have to turn the controller off.
4. Wait at least 10 seconds and then turn the controller back on.
5. The control parameters will now have default values.
6. Reinsert the control parameters.

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6.2 Compensator setup
6.2.1 Compensator setup 1/4
Compensator setup 1/4 Compensator 1

Low speed velocity: 20 rpm
High speed velocity: 100 rpm
Slowturn velocity: 10 rpm
Inactive range of max. speed: 5 rpm
Inactive range of min. speed: 5 rpm
Speed factor: 2


 Low speed velocity ‐ The lower limit of the area where the Compensator is allowed to
synchronize with the Main engine.
 High speed velocity ‐ The upper limit of the area where the Compensator is allowed to
synchronize with the Main engine.
 Slow turn velocity ‐ When this parameter is set to zero the Compensator is stopped
when Main engine speed is outside the area of operation. Other values will lead the
Compensator to turn with the programmed setting.
 Inactive range of max. speed ‐ This parameter is acting as a dead band where the
Compensator stops following the Main engine when “High speed velocity” plus “Inactive
range of max. speed” is reached at programmed value and starts again when Main
engine speed is below “High speed velocity” setting.
 Inactive range of min. speed ‐ This parameter is acting as a dead band where the
Compensator stops following the Main engine when “Low speed velocity” minus
“Inactive range of min speed” is reached at programmed value and starts again when
Main engine speed is above “Low speed velocity” setting.
 Speed factor ‐ This parameter provides the Compensator to operate with the Main
engine speed x Ks factor. I.e. a speed factor of 4 means that the Compensator will run
four times as fast as the Main engine (4th Order).
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Compensator pulses/revolution: 1024
Compensator speed at 10V: 880 rpm
Motor surveillance limit: 50 rpm
Angle Vc: 25 deg
Max. deviation error: 10 deg
Max. deviation time: 10 sec


 Compensator pulses/revolution ‐ Calculated value for one Compensator revolution
(i x pulses/motor rev.).
 Compensator speed at 10V ‐ The Compensator will run with this programmed velocity
when 10 V is applied to the analogue input of the motor drive.
 Motor surveillance limit ‐ Value in parameter indicates max. deviation in rpm. between
the commanded and the actual velocity of the Compensator.
 Angle Vc ‐ The value in this parameter is used for offset timing between tdc cyl. 1 from
Main engine and Ref+ from Compensator (Phase angle).
 Max. deviation error ‐ Variable programmed limit for allowed deviation between the
Main engine position (tdc cyl. 1) and the Compensator position (Ref+).
 Max. deviation time ‐ Variable programmed time limit allowed for the Compensator to
exceed the deviation limit in deg. as mentioned above. If the max. deviation is exceeded
for a period of time greater than this value, an alarm is generated and the Compensator
is stopped.

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Automatic acceleration: 5.00 rpm/s

Manual acceleration: 1.00 rpm/s
Manual max. speed: 2.00 rpm
Torque average limit: 0 %
Torque average time: 0.0 min.
Torque peak limit: 0 %


 Automatic acceleration ‐ This acceleration ramp is used during start of the Compensator
in automatic mode.
 Manual acceleration ‐ This acceleration ramp is used in manual operation of the
Compensator.
 Manual max. speed ‐ Max. velocity of the Compensator when operated in manual
mode.
 Torque average limit ‐ If the measured torque from Compensator exceeds the
programmed value for a period of time that exceeds “Torque average time” an alarm
will be raised. No function when set to 0.
 Torque average time ‐ See the item above. No function when set to 0.
 Torque peek limit ‐ If the measured torque from Compensator exceeds the programmed
value an alarm will be raised. No function when set to 0.

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Compensator speed at 10V: 880 rpm

Compensator speed at 0V: 0.0 rpm
Low setpoint 0.0 V: 0.0 rpm
High setpoint 0.0 V: 0.0 rpm
New speed at (0V, 10V) 0.0 0.0 rpm
Deviation: 0 deg


 Compensator speed at 10V ‐ The Compensator will run with this velocity when 10 V is
applied to the analogue input of the drive.
 Compensator speed at 0V ‐ The Compensator will run with this velocity when 0 V is
applied to the analogue input of the drive.
 Pressing the label Low set point will measure the actual voltage and actual speed and
show it.
 Pressing the label High set point will measure the actual voltage and actual speed and
show it.
 When both High and low set points are made New Speed will calculate the
corresponding speed at 0 V and at 10 V.
 Deviation is the actual deviation for the current speed used to adjust offset speed value
for Low set point and High set point.
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6.3 Regulator setup
6.3.1 Regulator setup 1/2
Regulator setup 1/2 Compensator 1

Gain factor Kp: 0.20
Integral time Tn: 4000 ms
Automatic gain factor Kp: 1
Automatic integral time Tn: 300 ms
Manual gain factor Kp: 3
Manual integral time Tn: 300 ms


 Gain factor Kp ‐ This is the proportional gain factor stage. Proportional gain gives an
output that is directly proportional to the speed and position error. This value is for the
regulator running within the controller.
 Integral time Tn ‐ This is the integrator time gain stage. Integrator gain uses the
integrator function to determine the output of a gain stage. This is a time based gain
where the magnitudes of the output is determined by the size of the error and for how
long time it has occurred. This value is for the regulator running within the controller.
 Automatic gain factor Kp ‐ This is the proportional gain factor used in the Servo drive
when running in automatic mode.
 Automatic integral time Tn ‐ This is the integrator time gain stage used in the Servo
drive when running in automatic mode.
 Manual gain factor Kp ‐ This is the proportional gain factor used in the Servo drive when
running in manual mode.
 Manual integral time Tn ‐ This is the integrator time gain stage used in the Servo drive
when running in manual mode.

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6.3.2 Regulator setup 2/2
Regulator setup 2/2 Compensator 1

Slow turn factor Kp: 3
Slow turn integral time Tn: 300 ms
Regulator: Disabled
Deviation gain factor Kp: 0.2


 Slow turn gain factor Kp ‐ This is the proportional gain factor used in the Servo drive
when the Compensator is in “Slow turn state”.
 Slowturn integral time Tn ‐ This is the integrator time gain stage used in the Servo drive
when the Compensator is in “Slow turn state”.
 Regulator ‐ It’s possible to switch between Enabled and Disabled regulator which will
enable / disable the PI regulator. It’s a helpful function when adjusting the
“Compensator speed at 10 V” – see chapter 6.2.2 Compensator setup 2/4.
 Deviation gain factor Kp ‐ The proportional gain factor is a special feature used in the
Compensator “running state”. This is used in case of a constant deviation error caused
by irregularity of the flyweights (vertical type).

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7 I/O pages
On the I/O pages it’s possible to observe and/or control the inputs and outputs.
It’s always possible to access the I/O pages for monitoring but it’s only possible to control the
outputs in parameter mode.

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7.1 I/O test menu

From the I/O test menu it is possible to enter “Digital input”, “Digital output”,
“Analog I/O”, “Teeth counting monitoring” and “Encoder monitoring”.
7.1.1 Digital input

The Digital input test page shows the current state of the inputs.
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7.1.2 Digital output

In order to enter the output page the user has to accept this warning by pressing the “Ok”
button. If the user presses the “Cancel” button, the main menu will be shown.

WARNING
When the output test page is selected, the system is operated purely manually and
no alarms are checked. It’s solely up to the technician not to damage the system by
setting an output by mistake.

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The output test page shows the current state of the outputs and the user has the option to
control them.

By pressing the respective output lamps the user is able to control the output.
When leaving the IO pages all outputs will be reset to a “default” state.

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7.1.3 Analog I/O

In order to enter the analog test page the user has to accept this warning by pressing the “Ok”
button. If the user presses the “Cancel” button, the main menu will be shown.

WARNING

When the analog test page is selected, the system is operated purely manually and

no alarms are checked. It’s solely up to the technician not to damage the system by

setting an output by mistake.

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 Velocity command compensator 1 and 2 (1) ‐ These analogue outputs can be set to any
value between ±10V. The values are automatically reset to 0 when leaving the test page.
 Torque/force feedback compensator 1 and 2 (2) ‐ Actual analogue value from outputs of
Servo drives.
 Encoder feedback compensator 1 and 2 (3) ‐ Shows the emulated encoder signals from
the resolver of the AC‐servo motors (Emulated increments x 4).

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7.1.4 Teeth count monitoring

This page can be used as a trouble shooting tool for the teeth counting system.

The values are updated on rising edge of Main engine index signal (Ref+).
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7.1.5 Encoder monitoring

Like the “Teeth count monitoring” function mentioned above, this function is available for
trouble shooting purposes.
This page gives a general idea of how well the encoder module is performing.
The 10 rows are updated in a cyclic movement going top‐down. The row marked with a frame is
currently being updated.

1. The first column “Pulses” (1) shows the counted number of pulses registered since last
index pulse.
2. “Time (ms)” (2) shows the actual time in ms between two index pulses.
3. “Encoder counter” (3) is the accumulated counted value from the counter module. This
value will be between 0 and 216 (65536).
4. “Reset” button (4) ‐ When activated the values in 5, 6, 7 and 8 are set to initial values.
5. “Min. Pulses” ‐ Value showing the minimum number of measured pulses between two
index pulses.
6. “Max. Pulses” ‐ Value showing the maximum number of measured pulses between two
index pulses.
7. “Min. Time” ‐ Value showing the minimum number of time (in ms) between two index
pulses.
8. “Max. Time” ‐ Value showing the maximum number of time (in ms) between two index
pulses.
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8 IO List
This chapter describes the inputs and outputs of the Compensator controller.
8.1 Digital inputs
Name Description Module No. Remark

Digital inputs 24 VDC (Beckhoff modules)
highVibration Exceeding allowed vibration level 0 = high vibration
parameterMode Changes between parameter mode and operating mode 1 = operating
indexMainEngine Proximity switch ‐ Index zero pulse from Main engine
teethCount A Proximity switch ‐ Teeth counting channel A
teethCount B Proximity switch ‐ Teeth counting channel B
Oilflow_comp1 Indication of oil flow 0 = no oil pressure
highTemp_comp1 Indicates too high temperature for motor 1 0 = high temperature
start_comp1 Enables compensator 1. 1 = enable
Sensor1_ comp1 Sensor input 1 activated 1 = not activated
manualEnable_comp1 Switches between manual and automatic mode 0 = automatic
manualPositive_comp1 Manual positive velocity change compensator 1 0 = no change
manualNegativ_comp1 Manual negative velocity change compensator 1 0 = no change
Index_comp1 Proximity switch – Index zero pulse from comp. 1
Oilflow_comp2 Indication of oil flow 0 = no oil pressure
highTemp_comp2 Indicates too high temperature for motor 2 0 = high temperature
start_comp2 Enables compensator 2 1 = enable
manualEnable_comp2 Switches between manual and automatic mode 0 = automatic
manualPositive_comp2 Manual positive velocity change compensator 2 0 = no change
manualNegativ_comp2 Manual negative velocity change compensator 2 0 = no change
Index_comp2 Proximity switch – Index zero pulse from comp. 2
Digital inputs 24 VDC (Drives)
driveEnable_comp1 Enables drive torque Drive 1 X31:6 0 = no torque
driveEnable_comp2 Enables drive torque Drive 2 X31:6 0 = no torque
8.2 Digital outputs

Digital outputs 24 VDC (Beckhoff modules)
alarm_2 Indicates an alarm 0 = alarm
alarmLampAlternating Alternating when alarm 0 = no alarm
alarmConstAlternating Alternating when alarm 0 = no alarm
driveEnable_comp1 Enables drive torque 0 = no torque
driveEnable_comp2 Enables drive torque 0 = no torque
heater enable Enables motor heater 0 = no heat
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8.3 Analogue inputs

Analogue inputs +/‐ 10 VDC (Beckhoff modules)
torqueMeas_comp1 Measured torque of motor 1
torqueMeas_comp2 Measured torque of motor 2
Analog inputs +/‐ 10 VDC (Drives)
speedCommand_comp1 Commanded velocity for compensator 1 Drive 1 X32:4/5 0 = stop
speedCommand_comp2 Commanded velocity for compensator 2 Drive 2 X32:4/5 0 = stop
8.4 Analogue outputs

Analogue outputs +/‐ 10 VDC (Beckhoff modules)
speedCommand_comp1 Commanded velocity for compensator 1 0 = stop
deviationAngle_comp1 Actual deviation for compensator 1
speedCommand_comp2 Commanded velocity for compensator 2 0 = stop
deviationAngle_comp2 Actual deviation for compensator 2
Analogue outputs 0‐5 VDC (Drives)
torqueMeas_comp1 Measured torque of motor 1 Drive 1 X32:1/3
Not used Drive 1 X32:2/3
torqueMeas_comp2 Measured torque of motor 2 Drive 2 X32:1/3
Not used Drive 2 X32:2/3
8.5 Counter modules

Counter module (EL5101)
feedback_comp1 Velocity feedback from compensator 1 EL5101
feedback_comp2 Velocity feedback from compensator 2 EL5101
Pin 1,5 l. Phase A
Pin 2,6 l. Phase B
Pin 3,7 l. Index pulse
Pin 4 l.
Pin 1,5 r. Output +5 volt and 0 volt to encoder
Pin 2.6 r. Input: +24 volt supply
Pin 3,7 r. Input 0 volt
Pin 8 r. Shield
Encoder emulation (Drives)
encoderEmul_comp1 Emulates the velocity feedback of motor 1 Drive 1 X8
encoderEmul_comp2 Emulates the velocity feedback of motor 2 Drive 2 X8

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Maintenance of Compensator

1. Design of bearings
2. Large main bearings
3. Small bearings
4. Servo motor bearings
5. Oil and lubricating system
6. Belt drive
7. Cabinet
8. Tension torques and setting information

1. Design of bearings

The compensator has 4 pc. Maintenance free double‐shielded identical spherical roller bearings
(lubricated for life with thermal resistant grease) mounted on two concentric shafts. The outer
bearings are locked and the inner bearings are slid able on shafts.
To enable thermal expansion of the 2 shafts bearings are mounted with 1 mm axial clearance.

The compensators gearbox is fitted with 4 cylindrical roller bearings. 2 pc. NU and 2 pc. NUP
bearings mounted in pairs on two parallel shafts. The outer rings are slid able in housing and
the inner rings are light fitted on shafts. The shafts are kept in axial position by the 2 pc. NUP
bearings (max. Clearance of 0.3 mm).

The calculated lifespan is above 20.000 hours for 90% of the bearings at max. Load.
Inside the cabinet an hour counter shows total time in operation. When new bearings are
mounted please note actual running hours.

General maintenance recommendation from bearing makers to be followed. In case of
heat, noise or increased power consumption bearings to be replaced according to Fig. No. 5 &
Fig. No. 6 and following instruction. The torque and/or power consumption of the AC‐
Servomotor can be measured on terminals X2.13 & 15 and/or compared with torque value in %
from computer display (Status page 2/2).

2. Large main bearings (Fig. No. 5)

Replacements are undertaken:

With compensator stopped.
With both set of flyweights adjusted to V = 180°.
With compensator dismantled from base frame and placed in horizontal position.
With belt covers dismounted.
With sprocket and belt dismounted.
With end cover & main bearings dismounted.
Exploded view on Fig. No. 5 (information of weights se paragraph “8. Tension torques and
setting information”).

To facilitate mounting and dismounting of bearings from house and side covers surfaces to be
applied with a thin layer of Altemp Q NB50.

1
The axial clearance is correct when the shaft mounted through bearing in end cover is pulled
tight to bearing ring by special tool drawing no. 70064 through taper lock for main sprocket.

After dismounting/mounting the bearings and end cover at one side invert the house and
repeat the procedure on the second main shaft.

3. Small bearings (Fig. No. 6)

Replacements are undertaken:

With compensator stopped.
With oil drained from gear box.
With top, bearing and belt covers dismounted.
With sprocket, belt and shaft sealing dismounted.
With seeger rings and shims dismounted.

To facilitate mounting and dismounting of bearings, house and shaft to be applied with a thin
layer of Altemp Q NB50. Remove surplus to avoid grease blocking lube oil bores.

Axial clearance of shafts is limited to natural space in NUP bearings of app. 0.3 mm.

In order to secure the outer ring of bearings from rotating they are to be locked by shims
between outer ring and bearing cover.

The 2 gear wheels are marked respectively at top of one tooth and in grove. It’s essential to fit
these marks together again in order to avoid wear.

App. 12 litres of Shell Omala HD‐150 gear oil or similar to be filled (correct level to be checked
through oil level glass).

In order to secure correct force direction both set of flyweights to be positioned as shown in fig.
No. 1 and locked by 2 pc. M12x90 mm screws before mounting of sprockets and toothed belts
at upper shafts. Adjustment of tension of toothed belts se Fig. No. 7.

Top and belt covers to be remounted.

Instruction for dismounting intermediate shafts:

With upper space of min. 500 mm the shafts can be tilted and lifted out. With upper space less
than 500 mm compensator to be dismounted and moved from its base frame.

4. Servo motor bearings

The 2Sg200L4 motor type is a conventional AC‐servomotor with maintenance free double‐
shielded ball bearings lubricated for life (thermal resistant grease).

In spite of higher calculated lifespan G&O recommends to replace bearings each 20.000
hours to avoid expensive repair of servomotor and motor drive. Inside the cabinet the hour
counter shows total time in operation.
When new bearings are mounted please note the number of hours from hour counter.

2
5. Lubricating system

The lubricating system is divided in 2 parts.

The 4 pc. Main bearings are maintenance free double‐shielded spherical roller bearings
lubricated for life (thermal resistant grease).

The 4 pc. Cylindrical roller bearings in gear box are splash lubricated with gear oil
(Shell Omala HD‐150 or similar).

When compensator is running gear wheels and bearings are lubricated by splashed lube
oil distributed to all internal parts from grooves in top of housing.

Oil to be renewed once a year. Specified oil amount corresponds to a visual level in centre of oil
inspection glass at standstill. Regarding amount of oil see paragraph “8. Tension torques and
setting information”.

If oil is leaking please check joints, oil sealing rings on shafts, fittings and air breather.

6. Belt drives (Fig. No. 7)

The toothed belt drives are maintenance free however tension to be checked after app. 500
hours and subsequent for each 4.000 hours.
In case of noise or anomalies belt drive to be checked immediately.

To achieve long lifespan the belt drive is designed with service factor 2.5 i.e. the max.
stress on belt is 2.5 times smaller than load limits of belt.

Correct alignment and tension of belt is vital for proper function. Vertical flange of servomotor
are adjustable for tension and alignment of belt drive.

As shown on Fig. No. 7 the force applied on middle of free length between sprockets should
give a sag of 1/100 x free length in mm to obtain correct tension.

Sprockets to be aligned in axial direction and parallel to shafts.

The tension torques for rotafix couplings for sprockets are mentioned in paragraph “8. Tension
torques and setting information”. The relative position of sprockets has influence on timing,
however in case sprockets are sliding on shafts the Compensator will be stopped with “Index
count error” displayed.

7. Cabinet

The electric components inside the cabinet is cooled by fan through a filter mounted in
the door. Depending on contamination air filter to be replaced as a minimum once each year.

The estimated lifespan of CPU backup battery (CCS 262 computer) is 5 years. The
battery is placed in front of computer (Part No. C200‐047).

3
8. Tension torques and setting information

Tension torques:

Holding down bolts ‐ 12 pc. M30x140 : 900 Nm (83 Nm + 35°)
M20 : 325 Nm.
M16 : 172 Nm.
M12 : 69 Nm.
M10 : 41 Nm.
M8 : 20 Nm.

Weights:

C‐200V1 : 3.984 kg
Main shaft and flyweights : 540 kg
End cover and bearing : 400 kg
Intermediate shaft with gearwheel : 37 kg
Cabinet : 200 kg
2Sg200L4 Servomotor : 268 kg

Belt drive:

Tooth belt (Motor) : Polychain, 8M2000‐36
Tooth belt (Flyweights) : Polychain, 8M2240‐36
Tension of taper lock screws (Flyweights) : 115 Nm
Tension of rotafix screws : 30 Nm

Oil (Gear oil VG 150):

Amount in gear box : 12 litres
Shell : Omala HD 150
Exxon‐Mobil Oil : SHC 629
Texaco / Uno‐X : Meropa 150
Statoil : Loadway EP 150
Total : Carter EP 150
BP : Enersyn HTX 150
Castrol : Alphasyn EP 150
Elf : Epona Z 150

Bearings 2Sg200L4 motor:

SKF : 6312‐2Z‐C3‐HT51‐P5
FAG : 6312‐2Z‐P53‐L12

4
Spare parts
For delivery of spare parts please phone or fax order to:

Savsvinget 4
DK-2970 Hørsholm
Denmark
Phone + 45 45763600
Fax + 45 45164199
E-mail info@gertsen-olufsen.dk
Tooth count Fig. No. 8
Small shafts, gearwheels and motor Fig. No. 9
Large shafts and flyweights Fig. No. 10
Toothed belts, proximity switch and cover Fig. No. 11
Synchronizer unit, front Fig. No. 12
Synchronizer unit, inside Fig. No. 13
Electrical parts 20-103037-001

Partlist
Item No. 20-103037-001

Synchronizer unit CCS262 / Lenze 30 kW (Space Heater)
Qty. Unit Stock No. Reference designation Description

1 Piece 43-502520-001 12A3 6.5” User-touch interface
1 Piece 43-502521-001 12A8 Computer, BEC262-DVI/USB
1 Piece 39-502519-001 12A8 Power supply, BEC262, E-bus
1 Piece 53-502420-001 12A8 Interface, 2AI EtherCat
1 Piece 53-502442-001 12A8 Interface, 2AO ±10V EtherCat
2 Piece 53-502642-001 12A8 Interface, 8DI EtherCat
1 Piece 53-502643-001 12A8 Interface, 8DO EtherCat
1 Piece 53-502645-001 12A8 Interface, EtherCat extension
1 Piece 53-502422-001 12A8 Interface, 1 Counter EtherCat
1 Piece 39-502434-001 3D10 Power supply, 24VDC-5Amp.
3 Piece 29-500165-001 9D8, 9D11, 17D5 Diode, SI 1N4007
1 Piece 44-502746-001 5E3 Lenze, Encoder emulation module
1 Piece 44-502749-002 5E3 Lenze, Motor drive 30kW
2 Piece 53-502781-001 5E3, 5E6 Interface, EtherCat for Lenze drive
1 Piece 44-502744-001 5E6 Lenze, Regeneration module
1 Piece 44-502745-001 5E10 Net-filter
2 Piece 54-502549-001 3F7.2, 13S4 Automatic fuse, MG C60H 1P 2A-C
1 Piece 54-502972-001 3F7.1 Automatic fuse, MG D 2A 2P 6KA
1 Piece 53-500962-003 6H9 Lamp
1 Piece 38-502784-001 9K7 Contactor, LC1D65BD (65A)
1 Piece 38-502785-001 9K7 Aux. contact, LC1D-4SL
3 Piece 38-502692-002 11K6, 17K3, 17K13 Relay, IDEC 24VDC-2 Pole
3 Piece 38-502693-002 11K6, 17K3, 17K13 Socket for IDEC relay-2 Pole
1 Piece 38-502693-003 17K6 Socket for IDEC relay-4 Pole
1 Piece 38-502692-003 17K6 Relay, IDEC 24VDC-4 Pole
1
Qty. Unit Stock No. Reference designation Description
4 Piece 38-502693-001 19K9, 19K10, 20K5, 20K6 Socket for IDEC relay-1 Pole
4 Piece 38-502692-001 19K9, 19K10, 20K5, 20K6 Relay, IDEC 24VDC-1 Pole
1 Piece 50-502436-001 6M7 Fan, 255 m³/h
1 Piece 36-500486-003 9P10 Hour counter
1 Piece 54-500964-003 3Q2 Switch, 3-Poles/80A
1 Piece 38-500881-003 3Q5 Thermal relay, GV3P65-40-63A
1 Piece 38-500765-018 4Q6 Thermal relay, GV2-ME03-0.25-0.4A
1 Piece 38-502670-001 4Q6 Aux. switch, GV2-1NO+1NC
2 Piece 38-502670-002 3Q5, 4Q6 Aux. switch, GV2-2NO
1 Piece 54-502207-003 9S5.2 Push button, ZB4 - Red
1 Piece 54-502212-002 9S5.2 Contact body, ZB4 - 1NC
1 Piece 54-500766-002 9S5.2 Sign, “Stop”
1 Piece 54-502215-001 9S7, 17P10 Push button, ZB4 - Green lamp
1 Piece 54-502217-001 9S7 Lamp body, ZB4 – Green 1NO
1 Piece 54-500766-001 9S7 Sign, “Start”
1 Piece 33-500701-003 3T7 Transformer, 208-550/230V 630VA
1 Piece 53-502429-001 11T4 Timer relay
11 Piece 40-501599-001 X1 Terminal, Beige 2.5mm², DIN35
21 Piece 40-501600-001 X1, X2 Terminal, Green/yellow 2.5mm², DIN35
69 Piece 40-501882-001 X1, X2 Terminal, Beige/double 2.5mm², DIN35
8 Piece 40-501602-004 X1 Terminal, Beige 35mm², DIN35
3 Piece 40-501604-001 X1, X2 End cover, 2.5-10mm², DIN35
16 Piece 40-501883-001 X1, X2 End cover, Double 2.5mm², DIN35
2 Piece 40-501604-002 X1 End cover, 16-35mm², DIN35
6 Piece 40-501605-001 X1, X2 End stop, 2.5-10mm², DIN35

Yangfan Group Hull 2181 Order No. 231795

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G&O Vibration Compensator

M/V Hull 2181

Gertsen & Olufsen A/S

Operators manual / Product specification

Project no. : 231795

Synchronizer Unit : BEC 20-103037-001

Ref+ (tdc cyl.1) : Balluff, BES M12MG1-PSC60B-S04G

Gear Ratio i : 9.6

Compensator Force : 84,31 kN (mcr)

1. Compensator type : C-200V1

1. Low speed velocity rpm : 50

1. Gain factor Kp - : 0.25

Lenze single drive : E94ASHE0594

Operation Modes, Scaling

Field Controller / Field Weakening Controller

Hoyer motor type (30 kW) : HMC2 200L-4

Resolver/Incremental Encoder Set-up

Regenerative power supply module

Lenze regenerative supply unit : E94ARNE0244

Mains filter type : E94AZMR0474LDB

Start (simulator and remote control)

Checklist: Visual check of oil level at inspection glass (Compensator stopped)

Synchronizing (simulator, remote control and curve recorder)

Checklist : Relation between speed of simulator and compensator (Ks)

Stop (simulator, remote control and curve recorder)

Manual operation (remote control)

Checklist : Manual turning in both directions

Teeth count operation

Checklist : Check of signals (A+, B+ & Ref+) on DI test page

Checklist: Index interval

Compensator type : C-200V1

Approved Date Signature

Gertsen & Olufsen A/S

Mr. Jakob Heidicke 12-02-2012 Jakob Heidicke

Project No. : 231795

Compensator type : C-200V1

Compensator speed (rpm) : 248

Compensator max. Imbalance (kgm) : 200,000

Angle V° Angle V2° U kgm Force in kN %

0,0 0,0 200,000 134,9 100

36,4 18,2 190,000 128,1 95

51,7 25,8 180,000 121,4 90

63,6 31,8 170,000 114,7 85

73,7 36,9 160,000 107,9 80

82,8 41,4 150,000 101,2 75

91,1 45,6 140,000 94,4 70

98,9 49,5 130,000 87,7 65

106,3 53,1 120,000 80,9 60

113,3 56,6 110,000 74,2 55

120,0 60,0 100,000 67,4 50

126,5 63,3 90,000 60,7 45

132,8 66,4 80,000 54,0 40

139,0 69,5 70,000 47,2 35

145,1 72,5 60,000 40,5 30

151,0 75,5 50,000 33,7 25

156,9 78,5 40,000 27,0 20

162,7 81,4 30,000 20,2 15

168,5 84,3 20,000 13,5 10

174,3 87,1 10,000 6,7 5

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