Kongsberg AutoChief®C20

Digital Servo Unit

Quick Reference Manual

356289/A
March 2011 © Kongsberg Maritime AS
The reader
This Quick Reference Manual for the AutoChief®C20 Propulsion Control System is intended as a guide
for the ships personnel operating an engine equipped with a Digital Servo Unit. Any significant changes in
system parameters and maintenance should be handled by design and installation engineers at the shipyard,
in accordance with installation drawings applicable to the vessel.

Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.

Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.

Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com

Kongsberg Maritime AS
www.kongsberg.com
 Quick Reference Manual

Table of contents

DSU BATTERY MAINTENANCE ........................................... 5

Description ...............................................................................................................5
Alarm........................................................................................................................5
Battery type ..............................................................................................................6
How to change battery..............................................................................................6
Scheduled maintenance ................................................................................. 7
DGU SERVO DRIVE UNIT (battery) FAIL ................................................... 8
“0” ADJUSTMENT OF GOVERNOR ...................................... 9
ALARM HISTORY CHECK OMRON DRIVE .......................... 11
On OMRON (Yaskawa panel)................................................................................ 11
APPENDIX....................................................................... 12
References ..............................................................................................................13
Yaskawa Technical Note ........................................................................................14
Absolute Encoder Battery Options p1,,,3 ...................................................... 14
OMRON Uuser’s Manual ......................................................................................17
2–10 Absolute Encoder Backup Battery Specifications p2–138 ...................... 17
3–2–1 Connecting Cable p3–10 ................................................................... 18
5–2 Alarms p5–6,,,8.................................................................................... 19
5–3–1 Error Diagnosis Using Alarm Display p5–9,,,17 ................................. 22
5–6 Replacing the Absolute Encoder Battery (ABS) p5–21............................ 31

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 DSU Battery maintenance

DSU Battery maintenance

Description
Inside the Digital Servo Unit (DSU) cabinet for Kongsberg Maritime AS delivered
actuator there is a servo drive unit. The controller is equipped with a battery to provide
continuous power supply to memory circuits used to store fuel actuator calibration.

Note
We recommend to change battery for memory circuits in
the DSU cabinet every 4 years.

Alarm
Initial battery charge is 3.6 Volt. If the battery voltage drops below 3.0 Volt a critical
alarm is released in AutoChief®C20 Control Panel in control room, DGU SERVO
DRIVE UNIT FAIL.
Alarm code on the servo drive unit display is A83 or A93.

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WARNING
The alarm DGU SERVO DRIVE UNIT FAIL will block fuel rack operation
from the AutoChief®C20 Remote Control System.

Caution
While unresolved this condition will require manual operation from the Local
Control Stand, and an uninterrupted power supply in Digital Servo Unit
(DSU) cabinet. If power supply is interrupted, keep in mind that actuator
memory have capacitor batteries of very limited and unpredictable duration.

Note
Alarm codes are listed in OMRON User’s Manual 5–2, see Appendix reference 5–2
Alarms p5–6,,,8 on page 19

Battery type
Table 1 Battery specifications

Item Specifications
Battery model number ER3V
Battery voltage 3.6V
Current capacity 1,000 mA*h
Kongsberg Maritime AS part number 3800404

Note
For emergency patching only: put two fresh AA batteries in a serial connection with
the plug from the old battery, to guarantee +3V to DSU memory circuits until a fresh
replacement battery can be delivered.

How to change battery

Caution
We advise to perform this operation when the main engine is stopped, and
with power supply to the DSU cabinet on.

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 DSU Battery maintenance

Scheduled maintenance

1 We advise to perform this operation when the main

engine is stopped.

2 Open Digital Servo Unit (DSU) cabinet.

3 Inspect the power supply and servo drive unit display
where bb correspond to main engine STOP position,
confirming that the fuel rack is in stopped position.
4 Provide a replacement battery as specified in Battery
type on page 6

5 Open the battery protection cover, and disconnect

old battery. The servo drive unit display will change
to alarm code A83 or A93. and alarm DGU SERVO
DRIVE UNIT FAIL displayed on the AutoChief®C20
Control Panel.
6
Caution
While alarm is displayed it is critical to
maintain power supply in Digital Servo Unit
(DSU) cabinet to maintain stored fuel actuator
calibration values in the DSU memory circuits.
See alarm description Alarm on page 5

7 Insert and connect replacement battery as specified

in Battery type on page 6
8 Inspect alarm code on the servo drive unit display,
where bb correspond to STOP position.
9 Inspect alarm status on AutoChief®C20 Control
Panel in control room.

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DGU SERVO DRIVE UNIT (battery) FAIL

1 The alarm DGU SERVO DRIVE UNIT FAIL will

block fuel rack operation from the AutoChief®C20
Remote Control System.

2 Open the Digital Servo Unit (DSU) cabinet.

3 Inspect the power supply and servo drive unit display.
4
Caution
While alarm is displayed it is critical to
maintain power supply in Digital Servo Unit
(DSU) cabinet to maintain stored fuel actuator
calibration values in the DSU memory circuits.
See alarm description Alarm on page 5

5 Provide a replacement battery as specified in Battery

type on page 6
6 Open the battery protection cover, and disconnect
old battery.
7 Insert and connect replacement battery.

8 Inspect alarm code on the servo drive unit display.

9 Inspect alarm status on AutoChief®C20 Control
Panel in control room.
10 Operation from the AutoChief®C20 Remote Control
System can be resumed when alarm condition is
resolved.

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 “0” adjustment of governor

“0” adjustment of governor

If alarm A81 — battery voltage dropped is displayed, the following procedure must be
performed.
1 Loosen the clamp cone on actuator.
2 Disconnect the 24V power to the extension card MCW151 (bottom right)
3 “zero set” the encoder:
Note
Both figures explain the same procedure.

Figure 1 Operational procedure 1

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Figure 2 Operational procedure 2

4 Remove 24V power from drive and reconnect both powers.

5 Fasten fuelrack at zero fuel position.

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 Alarm History check OMRON Drive

Alarm History check OMRON

Drive

On OMRON (Yaskawa panel)

1 Press MODE/SET button,
2 Fn000 will show (or else use arrows to change to 000)
3 Press DATA button for 1-2 sec
4 First of 10 stored alarm codes will show, (typical 0-A.40)
5 Use up arrow to scroll trough the alarms up to 9-X.XX
6 Write down all alarms in history:
0—
1—
2—
3—
4—
5—
6—
7—
8—
9—
7 To get back to normal operation press DATA for 1-2 sec
8 Press several times on MODE/SET until bb or run is shown again.
Note
Alarm codes are listed in OMRON User’s Manual 5–2, see Appendix reference 5–2
Alarms p5–6,,,8 on page 19

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appendix

This section contains the following topics:

References........................................................................................................................13
Yaskawa Technical Note ..................................................................................................14
OMRON Uuser’s Manual ...............................................................................................17

12 356289/A
 appendix

References
Yaskawa Technical Note
eng/02.005/mcd
Absolute Encoder Battery Options
http://www.yaskawaamerica.com/site/WebFAQMotion.nsf/
4a8e5b5f9c90918a86256d01006ec44d/86256ed000746b6a86256d67005701e7/
$FILE/eng02005%20-%20AbsEnc%20Battery.pdf

OMRON Operation Manual

MCW151 Series Motion Control Option Board
Models: R88A-MCW151-E and R88A-MCW151-DRT-E
Revision March 2003
http://www.fa.omron.com.cn/doc/source/662.pdf

OMRON User’s Manual

MODELS R88M-W_ (AC Servomotors)
MODELS R88D-WT_ (AC Servo Drivers)
AC SERVOMOTORS/SERVO DRIVERS
Revision March 2003
http://www.fa.omron.com.cn/upload/doc/data/20071106144904802.pdf

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 TECHNICAL NOTE
MOTION PRODUCT ENGINEERING GROUP

Subject: Absolute Encoder Battery Options

Product: Sigma II

Summary: The Sigma II absolute encoder requires a battery to backup the multi-turn data. There
are various ways of connecting the battery to the circuit that should be considered.

Battery Connection Options

In all, there are three options for connecting a backup battery for an absolute encoder. Only one
of these options needs to be used to back-up the absolute encoder. Yaskawa does not
recommend connection of multiple batteries to the absolute encoder circuit.

• Apply a battery (YEA part JZSP-BA01)

Battery
through connector CN8. A compartment to Compartment
hold this battery is built-in to the SGDH
Battery Connector
amplifier (see figure below). This is the (CN8)
most common option and allows for the
easiest replacement of a depleted battery.
SGDH
• Apply a battery (see specifications below) 30W to 5kW
through the CN1 connector (pins 21 & 22).
Battery Connector
• The final method is the battery backup (CN8)
cable as described in this document. The
battery backup cable is the best option in Battery
Compartment
situations where the encoder cable is
disconnected often during machine
maintenance. The backup cable will
eliminate the need to re-initialize the SGDH
encoder after encoder cable 6kW and up
disconnection.

Battery Specifications
The backup battery specified for Sigma II motors with absolute encoders is Toshiba ER3V* or
equivalent. This battery is a thionyl chloride lithium battery rated at 3.6V with a life of 1000mAh.
The Yaskawa part number for the battery (with Yaskawa-added leads and connector) is
JZSP-BA01. This is the battery that is designed to be installed in the battery compartment of
SGDH amplifier.

If it is preferred to connect the absolute encoder battery through the CN1 connector, the
recommended battery is Toshiba ER6VC3*, rated at 3.6V and 2000mAh. The Yaskawa
equivalent battery is BA000518. It is not necessary to install batteries at both the host controller
and the SGDH amplifier.

*Specifications for Toshiba ER3V and ER6V batteries are available at http://www.tbcl.co.jp/tb_e/ult_a_el.htm.

Yaskawa Electric America - 2121 Norman Drive South – Waukegan IL 60085

(800) YASKAWA - Fax (847) 887-7280

3/6/2002 1 of 3 eng/02.005/MCD
TECHNICAL NOTE
MOTION PRODUCT ENGINEERING GROUP

Alternate Battery Source

An alternate source for batteries is Tadiran Battery (www.tadiranbat.com), available through
electronic distributors such as Newark. Like the Toshiba batteries used in Yaskawa JZSP-BA01,
the Tadiran batteries are "thionyl chloride lithium" batteries, available in a 1/2-AA size that is
3.6V, 1000mAh (like the SGDH abs. enc. battery JZSP-BA01) and a AA size that is 3.6V,
2000mAh (like MP940 battery BA000518). Note: Tadiran batteries do not come with the pre-
wired leads and connectors for conveniently attaching to Yaskawa equipment like the Yaskawa
JZSP-BA01 and BA000518.

Battery Life
The serial encoder used in the Sigma II motor typically draws about 20 µA of current when the
power to the SGDH amplifier is turned off. In this condition, the maximum life of the standard
encoder data backup battery (P/N JZSP-BA01) is:

1000x10-3 A-hour / 20x10-6A = 50,000 hours (5.7 years)

When power is applied to the SGDH amplifier, the current draw from the battery is typically 3 µA.
Assuming that the SGDH amplifier is on for 12 hours and off for 12 hours each day, the maximum
life of the battery in this condition is:

3x10-6A x 12 hour=0.036mAh 20x10-6A x12 hour=0.24mAh

0.036 mAh + 0.24 mAh = 0.276mAh per day

1000mAh / 0.276mAh per day = 3623.2 days (9.9 years)

Battery Alarm
If the voltage of the battery for an absolute encoder drops to approx. 2.7V, the SGDH will
generate an Absolute Encoder Battery (A.83) Alarm. This alarm occurs when the SGDH receives
a signal from the absolute encoder when the power to the
SGDH is turned on. Therefore, the SGDH will not display the
alarm when the battery voltage drops below 2.7V while power
is being supplied to the SGDH. Follow the procedure outlined
below when replacing the battery:

1. Replace the battery while the control power to the

SGDH is ON.

2. After battery replacement, turn OFF the power to the

SGDH to clear the A.83 Absolute Encoder Battery
Alarm.

3. Turn ON the power to the SGDH and confirm that it

operates properly.

Yaskawa Electric America - 2121 Norman Drive South – Waukegan IL 60085

(800) YASKAWA - Fax (847) 887-7280

3/6/2002 2 of 3 eng/02.005/MCD
TECHNICAL NOTE
MOTION PRODUCT ENGINEERING GROUP

Constructing a Battery Backup Cable

Because the Sigma II absolute encoder does not have a high-storage capacitor as in the Sigma I,
multi-turn position data will be lost within a few seconds once the encoder cable is disconnected.
Normally, the encoder cable is not disconnected, and the data will be retained by the backup
battery installed in the amplifier. In some cases, it may be necessary to disconnect the encoder
cable, and the system must be able to backup the data in the absolute encoder. In these cases,
it is recommended to use a battery backup cable.

If machine maintenance requires frequent disconnection of the encoder cable, it is recommended

that a battery backup cable be built. This cable is installed at the motor upon machine
commissioning. With this backup cable in place, the encoder cable can be safely detected
without losing absolute encoder position. To construct this cable, place an absolute encoder
battery so that it is connected to the BAT+ and BAT- connections of the encoder (consult Sigma II
User’s Manual for wiring diagrams). A blocking diode should be added to the backup cable (see
diagram below).

Yaskawa Electric America - 2121 Norman Drive South – Waukegan IL 60085

(800) YASKAWA - Fax (847) 887-7280

3/6/2002 3 of 3 eng/02.005/MCD
©2011 Kongsberg Maritime