| on ELECTRONIC REMOTE CONTROL SYSTEM FOR BOW THRUSTERS #3 DATE OF DRAWING REVISION DATE OTHER PROPULSION UNITS THRUSTER UNITS LIFE CYCLE NO. EL. DESIGN ‘TYPE OF REMOTE CONTROL JOYSTICK SYSTEM, VERSION YARD YARD NO, OWNER ye TYPE OF VESSEL TECHN.CATHWORDS STARTER SERVO PUMP, TECHN. INFORMATION ADDITIONAL STARTER (S), TECHN. INFORMATION THIS MANUAL IS NOT FOR THIRD PARTY | CONSENT FROM Rolls-Royce Marine AS. Rolls-Royce 2145 : BOURBON OFFSHORE, : P10 HELICON X3 11559 2 28.03.2006 : 30.10.2006, 22.01.07 2 CLIS60/61 : TL1557/58 2 966498-1 JB : HELICON X3 Zhejiang Shipbuilding Co. TCNS 73/50-180, 883kW © 22KW, 440V ~ 60Hz DISTRIBUTION. NOT TO BE COPIED WITHOUT WRITTEN dep.: Propulsion - Ulstein (QNPROSNORDREIISNX_ ANLEGGMEISSACI1559_front DOCIPage 1 acinnnslllbititeninienside damning~B Rolls-Royce USER MANUAL PROPULSION REMOTE CONTROL SYSTEM Type: Helicon X3 Hull no(s): Zhejiang Shipbuilding 145/146/147/148 Rolls-Royce Marine Propulsion Ulstein Unit nos: T-11557/58, C-11559, C-11560/61 T-11562/63, C-11564, C-11565/66 T-11567/68, C-11569, C-11570/71 T-11572/73, C-11574, C-11575/76 Rev. | Date: Sign, | Changed pages: | Description: 00 | 30.08.2005 | AKK | - ‘New document 01 | 09.01.2006 __| AKK | 75-85 ‘Added section 7.2, Adjusting Parameters 02 | 21.02.2006 | AKK | 63 Local panel TCNS corrected. Product name corr. 03 | 23.06.2006 | AKK | - Document divided into subdocuments.[3] Rolls-Royce USER MANUAL HELICON X3 Page 3 of 121 ~ 4.2.1 Electronic unit (one per unit).. 4.2.2. Distributed IO cabinet (one per wn) i 4,23. Viewcon (one per vessel) 424 Pitch pump control unit (one per main thruster). 42.5 RPM transmitter (one per main thrusters)... 5 TECHNICAL DATA... 5.1 ENVIRONMENTAL CONDITIONS 5.2 ELECTRICAL SPECIFICATIONS FOR ELECTRONIC ‘unrrs 5.3 ELECTRICAL SPECIFICATIONS FoR /O MODULES... 5.4. ELECTRICAL SPECIFICATIONS FOR LEVERS 5.5 ELECTRICAL SPECIFICATIONS FoR 10.4” LCD 6 OPERATING INSTRUCTIONS 6.1 THE CONTROL LEVER 6.2 THE CONTROL PANEL 6.21 System Overview cree 6.2.2 Bow/Stern Tunnel Thruster. 6.2.3 Bow TCNS Thruster... 6.2.4 Port/Sibd Main eran 6.2.5 Alarm... 7 MAINTENANCE INSTRUCTIONS. 7.1 FUNCTIONS 7.1.1 Pitch Control ae oe 7.1.2 Pitch and RPM Combinator (Combined Control) . 7.1.3 Thruster Azimuth Control. 7.14 Transit/Manoeuvre Mode.. 7.1.5 RPM Control Electric Drive Motor. . oe 7.1.6 Load Control El. Motor sewer ‘ e100 7.1.7 Thruster (TCNS) In/Out.... 102 7.2 ADJUSTING PARAMETERS s.- 104 7.2.1 Entering the tool 104 F22 LOG iM ren 105 723 Sealing Analog inpuis 107 10 42 413 15 7.24 Scaling Analog outputs 7.25 Adjusting parameters. 7.2.6 LOg OUb oes 8.1 PARTSLISTS. 11s 8.2 EQUIPMENTNOT SUPPLIED 115 8.3 ADDITIONAL SUPPLY...... 115 9 TOOLS.. 116 10 DESIGN DRAWINGS. 117 11 INTRODUCTIO! 120 12. ETHERNET TWISTED PAIR. 120 User Manual Rev. 03 Date: 02.05.2006USER MANUAL HELICON X3 Page 5 of 121 Rolls-Royce 1 INTRODUCTION 1.1 Purpose ‘The purpose of the User Manual is to provide the necessary information for handling, operating, preserving, and maintaining the product. ‘This manual shall also provide information that allows easy and straightforward ordering of spare parts from Rolls-Royce. 1.2 Abbreviations AZP: Azipull Thruster BC: Backup Control -_~ CCW: Counter Clock Wise cw: Clock Wise GUL: Graphical User Interface MP: Main Propulsion NC: ‘Normal Control PTI: Power Take In PTO: Power Take Out RC: Remote Control TCNS: Thruster Compass Nozzle Swing-Up TT: Tunnel Thruster User Manual Rev. 03 Date: 02.05.2006 |Page 7 of 121 6 Rolls- Royce USER MANUAL HELICON X3 + Before connecting the mains, make sure that the polarity is correct and the voltage is according to ratings given in the instruction manual. 2.3 Warnings © The control VO terminals are isolated from the mains potential, but the relay outputs and other J0"s may have a dangerous voltage connection even if the power is disconnected ! «Only spare parts delivered by Rolls-Royce Marine can be used! ‘User Manual Rev. 03 Date: 02.05.2006| 6 Rol Is- Royce USER MANUAL HELICON X3 Page 9 of 121 | J 2.4.4.1 Backup control limitations The backup control system has only interface to the control levers. The backup control system does not have interface to external control systems like Dynpos, Joystick or Autopilot NB ! No azimuth restrictions or load control functions are included in the backup system. When operating using the backup system, the operator must be careful not to ‘overload the engine or the propeller system. If a load control system is included in the Rpm Drive, this will still be in operation. 2.4.4.2 Disable Dp and Joystick 1foperating using an external Dp or Joystick system, and a failure occurs on the rpm order signal from the external system, the external system is disengaged and the propeller responds to the control lever order on the manouvre station in command. Alarm will be given in the control system and in the ship’s alarm system. 2.4.5 Azimuth Control The azimuth control is also a redundant functions in the control system. The backup control system will automatically be engaged if a serious failure occurs in the normal control system. This includes loss of power supply to the normal control system, halt in the normal control cpu, failure on the normal control order potentiometer in the lever on the manouvre station currently in commend, failure on the normal control field bus and failure on the normal control feedback potentiometer. Alarm will be given in the control system and in the ship’s alarm system 2.4.5.1 Backup control limitations ‘The backup control system has only interface to the control levers. The backup control system does not have interface to external control systems like Dynpos, Joystick or Autopilot. NB! No azimuth restrictions or load control functions are included in the backup system. When operating using the backup system, the operator must be carefull not to -—~, overload the engine or the propeller system. 2.4.5.2 Disable Autopilot, Dp and Joystick If operating using an external Autopilot, Dp or Joystick system, and a failure occurs on the azimuth order signal from the external system, the external system is disengaged and the propeller responds to the control lever order on the manouvre station in command. Alarm will ‘be given in the control system and in the ship's alarm system. 2.4.5.3 Override Autopilot If operating using an external autopilot, and the azimuth lever order on the manouvre station in command is changed more then an adjustable limit, normally 20 degrees, the autopilot is disengaged and the thruster will respond to the control lever. This is indicated by blinking the “Autopilot button, and the buzzer will sound until the Autopilot button is pressed to acknowledge the mode change back to lever control [User Manual ~~ Rev. 03 Date: 02.05.2006USER MANUAL HELICON X3 Page 11 of 121 I) Rolls-Royce 3 SYSTEM DESCRIPTION 3.1 System Overview The HELICON-X remote control system is a microprocessor-based system. Following main functions are included: © Combinator control, allowing accurate and reliable control of the propeller pitch and motor speed (RPM). The combinator curve optimises the pitch/speed performance to give the best operational conditions and fuel economy. + Direction control, allowing accurate and reliable control of the thrust direction. Follow-up backup control from control levers User Manual Rev. 03, “Date: 02.05.2006Rolls-Royce USER MANUAL HELICON X3 Page 13 of 121 | 3.2 Tunnel Thruster Control Functions The control functions included in the Tunnel Thruster Control system is described in this section. ‘An principle diagram of the main functions are also included, For information of parameter tuning please refer to chapter 7 Maintenance Instruction. User Manual Rev. 03 Date: 02.05.2006| 6 Rolls-Royce USER MANUAL HELICON X3 Page 15 of 121 | ~ ‘The signal “Load_Controller_ Setpoint” is passed from the Load Controller. A pitch position set point is computed, based upon either the Pitch Order, or the Load Control Set point, depending on the loading of the engine, The set point value is compared to the actual feedback named “Pitch Feedback Clutch_I”. Test point “Pitch Setpoint_Error” represents the deviation between the position reference and the position feedback and can be considered as a pitch actuator speed signal. ‘A deviation alarm function is available through general parameter “Pitch Deviation_Alarm Selector”. The function could be configured to either give warming alarm on test point “Pitch_Deviation_Alarm” or both give alarm warning and Backup control ‘The deviation alarm is based on comparing test point “Pitch_Setpoint_Brror” with the general parameter “Pitch Deviation Alarm_Limit” . The alarm delay is adjustable with general parameter "Pitch_Deviation Alarm Delay Time”. When test point “Pitch Deviation External_Conditions” is activated the deviation alarm system is connected. ‘The deviation signal is limited with the adjustment “Pitch _Setpoin_Error_Limit” and the result is input to the PID Controller and System Interface. Adjustment “Pitch PID_Deadband Input” limits the output for small deviations that can be considered as noise. Pitch controller adjustments available are “Pitch_PID_Proportional_Gain”, “Pitch_PID_Integral Gain”, “Pitch PID_Integral Limit” and “Pitch _PID_Derivative_Gain”. ‘Test point “Pitch_Setpoint” will show the pitch order including the eventual influence of the acceleration limits. ‘Adjustments “Pitch_Output_Deadband”,” Pitch_Output_Negative_Offset” and “Pitch Output _Positive_Ofjset” are used to adapt the signal to the actuator with respect to the minimum signal levels necessary to move the actuator in astern or ahead direction. ‘The output signal from the pitch controller can be monitored at test point “Pitch_Output_Order". ‘The deviation signal “Pitch _Setpoint_Error” is used to control the Boost pump logic. Adjustment “Pitch_Boost_Pump_Engage_Limit” defines the deadband around zero deviation where the Boost pump control valves are disabled. If any system failure should occur this will immediately switch off the control signal output. 3.2.1.2 Backup control ‘The Backup Control system consists of closed loop control identical to the normal control system. The Backup Control is a separate system, and is independent of the Normal Control system. Any system failure in the Normal Control system will automatically switch to and engage the Backup Control. [ User Manual Rev. 03 Date: 02.05.2006 i}Page 17 of 121 Rol | I s- Royc e USER MANUAL HELICON X3 sin: sy.auney Sree = fusus + oueduen Date: 02.05.2006 Rev. 03 [ User Manualfa Rolls-Royce USER MANUAL HELICON X3 Page 19 of 121 3.2.2 Pitch and RPM Combinator (Combined Control) Refer to the PITCH CONTROL and RPM CONTROL drawings The function of the Combinator program is to ensure a more economical and powerful use of the engine and propeller units. Consult the engine and propeller data sheets when adjusting the Combinator program, For twin-in single-out power configurations, multiple sets of Combinator programs are available for various power take out. Programs are either automatically selected by chutch status, or manually by means of illuminated push buttons in the control panels. Lever order input to the program can be red at test point “Pitch_Lever” and the modified pitch order can be red on the test points “Pitch_Order”. The Rpm order can be red at test point ~ “Rpm_Order_Eng_1”. Important: A Combinator program needs full access to both propeller pitch and engine rpm actuators. ‘User Manual Rev. 03 Date: 02.05.2006 |G Rolls-Royce USER MANUAL HELICON X3 Page 21 of 121 consumers engaged). This is normally done with a digital signal status, engaging an rpm scaling function. Scaling parameter “Rpm_Order Scaling I] Eng_1” to “Rpm_Order Scaling_3_Eng_1” are available to the operator to define the rpm output when one of the external reduction signals “Rpm_Scaling Selector_I Eng_1” to “RPM Scaling Selector_3 Eng_I” are given.. The test point “Rpm_Order_Selected_Eng_1” shows the rpm order before the eventually scaling, while test point “Rym_Order_Setpoint_Eng_1” shows the scaled RPM order. Le, the rpm output will automatically be reduced to Shut Down rpm output when the Shut Down contact from external is activated 3.2.3.6 RPM order Output The output signal from the controller “Rpm_Order_Slew Rated Eng_I” are scaled to meet the frequency controllers signal range from idle to full rpm. The output will follow a linear > curve between idle and full rpm order. The rpm output rate of change is adjustable, and can be adapted to the frequency controllers reversing speed from idle to full rpm (increasing order) and vice versa (decreasing order). 3.2.3.7 Propeller/Shaft Rpm Indication The microcomputer board computes, pre-scales and outputs signal to the analogue propeller 1pm indicators. One adjustment for each panel is available for the user : “Rpm_Indicator_Output_ECR”, “Rpm _Indicator_Output_Bridge_1” to “Rpm _Indicator_Output Bridge 5”. User Manual Rev. 03 Date: 02.05.2006a Rol Is-Royce USER MANUAL HELICON X3 Page 23 of 121 a) 3.2.4 Load Control El. Motor The load control system is designed to protect the propeller machinery from overload. Propeller pitch is automatically reduced if the specified load limit is exceeded, ‘The drawing LOAD CONTROL EL.MOTOR PE62357 describes the principle of the load control system. The drawing shows load control system with interface to two Electric Drive motors, two Generators and a power available from the power management system/MSB , but only those parts relevant for the actual propulsion machinery are used. ‘The load controller computes the propeller machinery load based on the load feedback signal from the electromotor. The feedback signal is monitored on input “Load_Drivemotor_1” and is sealed in percent of the load range. Ifa failure occurs in the load feedback transmitter, an alarm is given to the alarm plant with a corresponding error message on the operator terminal display. Separate adjustable alarm limits are available for load signal alarm. The load controller is then disabled until normal condition is obtained. Important: Observe the load conditions closely by manual readings if the load control is disabled for any reason. Acceleration limits will protect the propeller machinery during crash manoeuvring, and will slow down the pitch rate of change when the pitch approaches maximum ahead or maximum astern position. However these limits will have no effect as long as the lever order remains constant. Adjustments “Pitch Crash_Limit Ahead" and “Pitch Crash Limit_Astern” define the acceleration limits. The load controller sclects the most suitable gains depending on the amount of overload. If excessive load should occur, the pitch reduction speed is proportional to the overload signal gained with adjustment “Gain_Overloaded’. In normal load condition, the pitch is automatically increased slowly against the set point. In this case adjustment “Gain_Normal Load” is used to control the pitch rate of change when returning back to set point from underload condition. Close to the maximum load that is within the load setting deadbands the controller will use very slow speed on pitch corrections. The load setting deadbands are defined with adjustments “Deadband Below Load Limit” and “Deadband Above _Load_Limit”. The load control will only correct the pitch position in small steps. The time between each step is defined by the size of the “Load_Output_Setpoint” and adjustment “Overload _Limit”. The size of the corrective step is defined with adjustment “Load Filter Pulse”, and the frequency of the corrective pulse is defined with “Puler_Error_For_ Pulse” parameter. User Manual Rev. 03, Date: 02.05.2006 |Rol Is- Royce USER MANUAL HELICON X3 Page 25 of 121 3.2.5 Command Transfer ‘The term Command Transfer is used to describe the procedure performed when the control is transferred between manoeuvre stations without acceptance on either of the stations. This is normally the procedure between wheelhouse (bridge) stations. 3.2.5.1 Functional description aa, Set the control levers at the new station in accordance to the position of the levers at the present station in command. bb. Press the button IN COMMAND or COMMON IN COMMAND (if such a switch is, ~ mounted on the main propulsion plant) at the new station to be in command. The command is transferred immediately as the lamp IN COMMAND is lit Note: There ts normally no command transfer interlock because of discrepancy between lever position at the ‘present station in command and the lever position at the new station to be in command, COMMON IN COMMAND may be installed on the main propulsion system in order to transfer the command for all propeller systems between bridge stations, by activation only one common switch. ‘User Manual Rev. 03, Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 Page 27 of 121 3.3.1 Pitch Control ‘The function of the pitch controller is to move the propeller blades in accordance to the control lever order. The actuator unit represents the interface between the remote control and the main servo system, which performs the actual positioning of the blades. 3.3.1.1 Normal Control Refer to the PITCH ORDER DIAGRAM PE62362 and the PITCH CONTROL DIAGRAM PE62363, The output from the pitch controller is computed on the basis of the input signals from pitch lever and the actustor position feedback, Lever and feedback signals are scaled and checked against adjustable limits, with corresponding alarm for values exceeding the normal range. Levers have one set of adjustments (minimum, zero and maximum) for each manoeuvre station. Multiple sets of feedback adjustments (minimum, zero and maximum) are available for various engine power take-outs Lever order can be read at test point “Pitch_Lever”, while selected feedback is read at test point “Pitch Feedback”. The order can additionally be selected from separate systems such as dynamic positioning or joystick systems i.e. The selected order either from lever or separate system can be read at test point “Pitch_System_Order””. Ifa running up system is included and switched ON the “Pitch _System_Order” will be transmitted to the ship speed estimator /running up controller. Then the modified RUP order will be used and monitored in test point “Running Up_Output”. In Combined mode the lever signal is modified in a Combinator program, refer to chapter Pitch and Rpm Combined Control. Fixed or analogue pitch reductions are available which will limit the order, provided that the extemal conditions for limiting the propeller pitch are fulfilled. The modified order can be monitored at test point “Pitch Order”. To provide a minimum of main engine/electric drive motor protection during manoeuvring if the Load control system is out of function, the system includes adjustable pitch acceleration (or crash) limits, The acceleration limits slows the pitch speed essentially in positions that may cause excessive engine loads. However these limits will have no effect as long as the lever order is constant. Separate adjustments Crash Limits “Pitch_Crash_Limit_Ahead" and "Pitch_Crash_Limit_Astern” are available, with an override switch “Pitch Crash Limit Select” preventing the limits to operate in normal conditions, Test point “Pitch_Order_Setpoint” shows the pitch order including the eventual influence of the acceleration limits. User Manual Rev: 03, Date: 02.05.2006Rolls-Royce USER MANUAL HELICON X3 Page 29 of 121 3.3.1.2 Backup control The Backup Control system consists of closed loop control identical to the normal control system. The Backup Control is a separate system, and is independent of the Normal Control system. Any system failure in the Normal Control system will automatically switch to and engage the Backup Control. Lever order signals and feedback are monitored and verified against adjustable alarm limits. If the signals exceed the limits this will release an alarm to the alarm plant with a visual and audible system failure alarm on the manoeuvre stations. 3.3.1.3 Backup control operation Ifa failure occurs on important parts of the Normal control for the Pitch/Azimuth/RPM control function, the control will automatically be switched over to the backup control system. A system failure audible and visible alarm will be activated on each of the control panels, The thruster control will continue to follow the lever in command, and command transfer is done by using the common in command buttons. The command can be transferred between all bridge position and the bridge control levers will continue to work as in Normal Control. Any failure that occurs on important parts of the Backup control for the Pitch/Azimuth/RPM control function, will not affect the Normal control system. If a system failure occurs on the Backup Control an audible and visible alarm will be activated on each of the control panels. 3.3.1.4 Backup control limitations ‘The backup control system has only interface to the control levers. The backup control system does not have interface to external control systems like Dynpos, Joystick or Autopilot. NB ! No pitch reductions or load control functions are included in the backup system. When operating using the backup system, the operator must be careful not to overload the engine or the propeller system, 3.3.1.5 Local Control If both the normal remote control system and the back-up control should fail, itis possible to operate the propeller pitch locally from the pitch control valve. The “REMOTE/LOCAL” switch on the actuator interface box must be tumed to position “LOCAL” and the pitch control valve can be operated manually. 3.3.1.6 Pitch Indication The pitch indication system is independent of the normal pitch control system by means of separate transmitters and electronic circuits. The Pitch indicators are connected in series, and are driven from the Backup Control system. [User Manual Rev. 03 Date: 02.05.2006Page 31 of 121 | ia Rolls-Royce USER MANUAL HELICON X3 S9s7oad | Noam ERE ewer he 3 veya + qeuediueg =e) Date: 02.05.2006 Rev. 03 ‘User ManualGg Rol Is-Royce USER MANUAL HELICON X3 Page 33 of 121 ‘THRUSTER AZIMUTH CONTROL ‘The drawing AZIMUTH CONTROL PE62364 describes the function, including available adjustments and test points. The azimuth control function is to obtain the correct thruster azimuth position in accordance to the control lever order. Valve controlled hydraulic motors or frequency controlled electro motors perform the positioning of the thruster azimuth Detailed information regarding the hydraulic system or motor data is available in the thruster instruction manual. Note: Test point angle signals are ranged +/- 100 %, representing +/- 180 degrees. Some test points are named with degrees, displaying the angle in degrees (+/- 180 degrees). 3.3.2.1 Normal Control The azimuth controller computes the thruster position and order on the basis of signals from. the thruster feedback and control levers. A two-wiper linear potentiometer provides two outputs with 90 degrees of phase shift named cosine and sine phase respectively. The lever order signals can be monitored on test point “Azimuth_Lever_ ECR”, “‘Azimuth_Lever Bridge_1” to “Azimuth Lever_Bridge_4”. The values are calculated based on analogue input signals “Azimuth Lever_Sin Wiper ECR”, “Azimuth_Lever_Sin_Wiper_Bridge_I” to “Azimuth Lever Sin Wiper Bridge_4” and “Azimuth _Lever_Cos_Wiper_ECR”,“Azimuth_Lever_Cos Wiper Bridge_I” to “Azimuth_Lever_Cos_Wiper_Bridge_4”. The inputs are scaled info the +/- 100 degrees range, but the resulting calculated order signals “Azimuth Lever ECR”, “Azimuth Lever Bridge_1” to “Azimuth_Lever_Bridge_4” are converted to +/180 degrees range. These order signals can be zero offset compensated by parameters “Azimuth Lever Zero ECR”, “Azimuth Lever_Zero_Bridge_1” to “Azimuth Lever Zero Bridge_4”. ‘The lever order signals are monitored and verified against alarm limits, If the signals exceed ™) the limits this will release an alarm to the alarm plant with a visual and audible system failure alarm on the manoeuvre stations, The current azimuth lever order can be monitored on test point “Azimuth Lever_Order”. This order is dependent of current manoeuvre site in command. The test point “Azimuth_Order_Setpoint” displays the angle order including any autopilot. ‘The thruster azimuth angle feedback signal is calculated based on the two analogue input signals “Azimuth_Feedback_Cos Wiper” and “ Azimuth Feedback Sin Wiper”. The inputs are scaled to +/-100%, but the resulting calculated feedback signal “Azimuth_Feedback" is converted to +/- 180 degrees range. The signal can be zero offset compensated by parameter “Azimuth Feedback Zero”. The feedback signals are monitored and verified against alarm limits. Ifthe signals exceed the limits this will release an alarm to the alarm plant with a visual and audible alarm on the manoeuvre stations. User Manual Rev. 03, Date: 02.05.2006 |G Rolls-Royce USER MANUAL HELICON X3 Page 35 of 121 Any failure that occurs on important parts of the Backup control for the Pitch/Azimuth/RPM control function, will not affect the Normal control system. Ifa system failure occurs on the Backup Control an audible and visible alarm will be activated on each of the control panels. 3.3.2.4 Backup control limitations The backup control system has only interface to the control levers. The backup control system. does not have interface to external control systems like Dynpos, Joystick or Autopilot. NB ! No azimuth restrictions or load control functions are included in the backup system, When operating using the backup system, the operator must be careful not to overload the engine or the propeller system. 3.3.2.5 Local Control Local control is used if both the normal control and the backup control fail to operate the thruster azimuth. The thruster azimuth can be operated locally on the actuator unit. The Control System must first be disconnected from the actuator unit. This can be done by means of the Local Control switch mounted in front of the Actuator Interface Unit, or by disconnecting the plug from the actuator unit. If frequency converter used, operate service switch inside converter cabinet. The Thruster Instruction Manual will give more details for Local Control operation. 3.3.2.6 Azimuth Indication ‘The azimuth indication system independent of the normal control system by means of separate transmitters and electronic circuits. The Azimuth indicators are connected in series, and are driven from the Backup Control system. ‘User Manual Rev. 03,Rol Is-Royce USER MANUAL HELICON X3 Page 37 of 121 3.3.3 RPM Control Electric Drive Motor ‘The RPM control system controls the speed signal to the drive motor (frequency converter). ‘The drawing RPM CONTROL EL. DRIVE MOTOR PE62365 describes the principles of the 1pm control system operating modes. The rpm control system includes selection of different operational modes as Separate mode, Combined mode and Fixed mode. Selection between modes is possible by means of push buttons, Rpm control can be managed from engine control room only or from additional control panels. ‘The following chapters describe the various modes of rpm control. Refer to the Control Panel section in the User manual. 3.3.3.1 Separate Rpm Control In separate- or variable control, the engine rpm order is taken from the rpm lever. ‘The signals are scaled to 0-100 % ranges by means of separate adjustments for each lever or knob. Analogue point “Rpm Lever ECR”, “Rpm Lever Bridge_I” to “Rpm_Lever_Bridge_5” shows the scaled RPM levers, while test point “Rom_Lever” (shows the selected rpm lever corresponding to the control panel in command. ‘The rpm lever signals are checked against pre-set limits. Any error conditions on the rpm input signals will initiate a warning to the alarm plant and an RPM LEVER error message displayed on the control panel. 3.3.3.2. Combined Rpm Control In Combined rpm mode the rpm is controlled by the “Combinator” program based on the pitch lever input, refer to chapter Pitch and Rom Combined Control. 3.3.3.3 Fixed Rpm Control ‘The selection of various fixed/generator rpm set points is done by means of push buttons in the control panel. Separate adjustments “Fixed Rpm_i_Eng_1”, “Fixed_Rpm_2_Eng 1” and “Fixed Generator Rpm _Limit_Eng_1” for each fixed mode are available. 3.3.3.4 External Rpm Control External RPM order signals from systems as DP/Joystick /Auxiliary systems can be connected to the RPM controller. The external rpm signals are checked against adjustable pre-set limits. Any error conditions on the rpm input signals will initiate a warning to the alarm plant and an error message DPWoystick/Auxiliary RPM will be displayed on the Control panel. 3.3.3.5 RPM order scaling It is possible to supply the rpm control system with external interface for scaling of the rpm order output when external events occur (Slow Down, Shut Down, Alternator on net or Heavy User Manual ~ Rev. 03 Date: 02.05.2006Page 39 of 121 Rol Is- Royce USER MANUAL HELICON X3 G9ez93d re 8: aoA0yf-S||Ou ) Ermer SER lead Date: 02.05.2006 Rev. 03 [ User ManualPage 41 of 121 fal Rolls-Royce USER MANUAL HELICON X3 [suf To] Zsezaad : 7 wana | el ‘nwa nou mses ees py EE Ho & 4 Srey —eemerrpere “eZ HH) BR Wo (a) emgaff— A von ee | t Te eaMTE Per) SETA Bouoraaen 0 < reer neces | 7} “er oe ear os1697 er sao. pean meaner smy4—eran woppae1 + jumvodiog Date: 02.05.2006 Rev. 03, User ManualRolls-Royce USER MANUAL HELICON X3 Page 43 of 121 3.3.5.1 Lowering the Thruster Lowering sequence is executed by activating the “Thruster Out” button, The sequence will ‘not be executed before necessary interlocks are completed. When initiated, the “Thruster Out” lamp will flash while the sequence is active. Note: The sequence will not go from one to another state before the checks within are completed. Thruster OUT” button pressed: * The thruster is turned to lifting position. © The thruster is lifted for approximately 5 seconds and the “Upper locking cylinder” is activated, pulling out the upper locking bolt. ‘© The proximity switch “Upper locking cylinder bolt” in unlocked position is checked and the thruster is lowered, activating the “Lowering thruster cylinder”. © The thruster is lowered until the proximity switch “Thruster in lower position” is activated, © The “Lower locking bolt cylinder” is activated, and the thruster is locked in lower position. © The proximity switch “Lower locking cylinder bolt” in locked position is checked , and when this signal is active, “Thruster locked in lower position” is given to the thruster starter. The “Thruster OUT" indication lamps stop flashing, and illuminates with steady light. The thruster system is now ready for start. ‘The sequence is predefined to take maximum 20 seconds (adjustable), if the time is exceeded the sequence will stop and both the “Thruster IN” and “Thruster OUT” indication lamps will flash. 3.3.5.2 Lifting the Thruster Lifting sequence is executed by activating the “Thruster Jn" button, The sequence will not be executed before necessary interlocks are completed. When initiated, the “Thruster In” lamp will flash while the sequence is active. Note: The sequence will not go from one to another state before the checks within are completed. Thruster IN” button pressed: © The interlocks “Thruster stopped” and “Thruster in zero position” are checked and must be fulfilled. * The thruster is lifted for approximately 5 seconds, and the “Lower locking cylinder” is activated, pulling out the lower locking bolt. © The proximity switch “Lower lock cylinder” in unlocked position is checked and the thruster is lifted, activating the “Lift thruster cylinder”. The thruster is lifted until the proximity switch “Thruster in upper position” is activated. The “Upper locking bolt cylinder” is activated, and the thruster is locked in upper position. The proximity switch “Upper locking cylinder bolt” in locked position is checked, and when the signal is active, the “Zhruster IN” lamps stop flashing and illuminates with steady light. The thruster is now secured in upper position ‘The sequence is predefined to take maximum 20 seconds, if the time is exceeded the sequence will stop and both the “Thruster IN” and “Thruster OUT" indication lamps will flash. ‘User Manual Rev. 03 Date: 02.05.2006 |Rol Is-Royce USER MANUAL HELICON X3 Page 45 of 121 3.3.6 Command Transfer The term Command Transfer is used to describe the procedure performed when the control is transferred between manocuvre stations without acceptance on either of the stations. This is normally the procedure between wheelhouse (bridge) stations. 3.3.6.1 Functional description cc, Set the control levers at the new station in accordance to the position of the levers at the present station in command. dd. Press the button IV COMMAND or COMMON IN COMMAND (if such a switch is ‘mounted on the main propulsion plant) at the new station to be in command. The a command is transferred immediately as the lamp IN COMMAND iis lit. Note: There is normally no command transfer interlock because of discrepancy between lever position at the ‘present station in command and the lever position atthe new station to be in command. COMMON IN COMMAND may be installed on the main propulsion system in order to transfer the command for all propeller systems between bridge stations, by activation only one common switch. User Manual Rev. 03 Date: 02.05.2006Rolls-Royce USER MANUAL HELICON X3 Page 47 of 121 ‘THRUSTER AZIMUTH CONTROL The drawing AZIMUTH CONTROL PE62364 describes the function, including available adjustments and test points. ‘The azimuth control function is to obtain the correct thruster azimuth position in accordance to the control lever order. Valve controlled hydraulic motors or frequency controlled electro motors perform the positioning of the thruster azimuth, Detailed information regarding the hydraulic system or motor data is available in the thruster instruction manual. Note: Test point angle signals are ranged +/- 100 %, representing +/- 180 degrees. Some test points are named with degrees, displaying the angle in degrees (+/- 180 degrees) 3.4.1.1 Normal Control ‘The azimuth controller computes the thruster position and order on the basis of signals from the thruster feedback and control levers. A two-wiper linear potentiometer provides two ouéputs with 90 degrees of phase shift named cosine and sine phase respectively. The lever order signals can be monitored on test point “Azimuth Lever ECR", “Azimuth_Lever_Bridge_1” to “Azimuth Lever Bridge_4”. The values are calculated based on analogue input signals “Azimuth Lever_Sin_ Wiper ECR’, “Azimuth_Lever_Sin_Wiper_Bridge_I” to “Azimuth Lever_Sin_Wiper_Bridge 4” and “Azimuth Lever Cos Wiper ECR”, “Azimuth Lever Cos Wiper Bridge_1" to “Azimuth Lever_Cos Wiper Bridge 4”. The inputs are scaled into the +/- 100 degrees range, but the resulting calculated order signals “Azimuth Lever ECR”, “Azimuth_Lever_Bridge_I" to “Azimuth_Lever Bridge_4” are converted to +/180 degrees range. These order signals can be zero offset compensated by parameters “Azimuth_Lever_Zero_ECR", “Azimuth Lever Zero Bridge 1” to “Azimuth Lever Zero Bridge 4”. The lever order signals are monitored and verified against alarm limits. If the signals exceed the limits this will release an alarm to the alarm plant with a visual and audible system failure alarm on the manoeuvre stations. The current azimuth lever order can be monitored on test point “Azimuth Lever_Order”. This order is dependent of current manoeuvre site in command. The test point “Azimuth_Order Setpoint” displays the angle order including any autopilot. ‘The thruster azimuth angle feedback signal is calculated based on the two analogue input signals “Azimuth Feedback Cos Wiper” and “ Azimuth Feedback Sin_Wiper”. The inputs are scaled to +/-100%, but the resulting calculated feedback signal “Azimuth_Feedback” is converted to +/- 180 degrees range. The signal can be zero offset compensated by parameter “Azimuth Feedback Zero” The feedback signals are monitored and verified against alarm limits. If the signals exceed the limits this will release an alarm to the alarm plant with a visual and audible alarm on the manoeuvre stations. [User Manual Rev. 03 Date: 02.05.2006fa Rol Is-Royce USER MANUAL HELICON X3 Page 49 of 121 Any failure that occurs on important parts of the Backup control for the Pitch/Azimuth/RPM control function, will not affect the Normal control system. Ifa system failure occurs on the Backup Control an audible and visible alarm will be activated on each of the control panels. 3.4.1.4 Backup control limitations The backup control system has only interface to the control levers. The backup control system does not have interface to external control systems like Dynpos, Joystick or Autopilot. NB ! No azimuth restrictions or load control functions are included in the backup system. When operating using the backup system, the operator must be careful not to overload the engine or the propeller system. ~ 3.4.1.5 Local Control Local control is used if both the normal control and the backup control fail to operate the thruster azimuth. The thruster azimuth can be operated locally on the actuator unit. The Control System must first be disconnected from the actuator unit. This can be done by means of the Local Control switch mounted in front of the Actuator Interface Unit, or by disconnecting the plug from the actuator unit. If frequency converter used, operate service switch inside converter cabinet. ‘The Thruster Instruction Manual will give more details for Local Control operation. 3.4.1.6 Azimuth Indication The azimuth indication system independent of the normal control system by means of separate transmitters and electronic circuits. The Azimuth indicators are connected in series, and are driven from the Backup Control system. ‘User Manual Rev. 03 Date: 02.05.2006 |USER MANUAL HELICON X3 Page 51 of 121 Rolls-Royce 3.4.2. Transit/Manoeuvre Mode The control system operates in two separate control modes, Transit mode and Manoeuvre mode. Within each mode the thrusters are operated with restrictions, which also include the ‘vessel speed. In Transit mode, thrusters turning position are restricted to +- 35 degrees (adjustable). In Manoeuvre mode, the thrusters are controlled 360 degrees. The selected mode can be monitored one test point “Azimuth_Control_Mode". The switching from Transit to Manoeuvre and vice versa can be manually or automatically dependent of parameter setting “Auto_ Change_Transit_ Manoeuvre”. If the value is set to 0, the operator controls Transi/Manoeuvre manually. If the value is 1, the selection is automatic without need for any acknowledge from operator. If the value is 2, the selection is automatic but with audible and visual waming, and the operator have to acknowledge the selection. Recommended switch mode is automatic change with acknowledge, I.e. Parameter value 2. 3.4.2.1 Manoeuvre mode Manoeuvre mode is applied at slow speed. The vessel speed restriction for operating in manoeuvre mode is 10 knots (adjustable). The following sequences describe the selection of manoeuvre mode. 3.4.2.1.1 Manually selection of Manoeuvre mode If parameter value “Auto_ Change_Transit_Manoeuvre” is set to 0, the operator controls the ‘Transit/Manoeuvre selection manually. © The vessel speed must be reduced below 10 knots before Manoeuvre can be selected. ‘© The operator initiates the sequence by pressing the “ Manoeuvre Mode” button in the propulsion system control panel. * If the vessel speed is below the adjustable 10 knots restriction, the “Manoeuvre Mode” lamp will start to blink. If not, the sequence is interrupted, see below. ‘+ The thrusters will take the shortest way to the position given by the lever. ‘© When the thruster position is in accordance to the lever, the “Manoeuvre Mode" lamp will light steady. The sequence is completed. If manoeuvre mode is selected at a speed over 10 knots the sequence will NOT be initiated and Transit mode lamp is flashing indicating the speed is too high. Note : flashing in the “Manoeuvre Mode” lamp will only occur if the deviation between azimuth order and feedback exceeds parameter “Manoeuver_Feedback_Dev_Limit”. 3.4.2.1.2 Automatic selection of Manoeuvre mode without acknowledge ~\__Ifparameter value “Auto_Change_Transit_Manoewvre", is set to 1, the selection between Transit/Manoeuvre is automatic without need for any acknowledge from the operator. [User Manual Rev. 03 Date: 02.05.2006 |Rol Is-Royce USER MANUAL HELICON X3 Page 53 of 121 «The Transit mode is automatic engaged if the vessel speed is higher then 10 knots (adjustable). Lever order must be positioned within +- 35 degrees. «The “Zransit Mode” lamp illuminates and indicates current mode. If the lever order is NOT within +- 35 degrees, the thrusters will be forced within the range, acoustic alarm will be given and indicated by the zero position lamps. Note: flashing in Transit mode lamp occurs if the deviation between order and feedback exceeds parameter “Maneuver Feedback Dev Limit” 3.4.2.2.3 Automatic selection of Transit mode with acknowledge Ifparameter value “Auto_Change_Transit_ Manoeuvre" is set to 2, the selection between Menoeuvre/ Transit is aufomatic with audible and visual warning, and the operator have to acknowledge the selection. «The Transit mode is automatic engaged if the vessel speed is higher then 10 knots (adjustable). Lever order must be positioned within +- 35 degrees. * The “Transit Mode” lamp starts flashing, and the buzzer sounds until the operator acknowledges the mode by pressing the “Transit Mode” pushbutton. If the lever order is NOT within +- 35 degrees, the thrusters will be forced within the range, acoustic alarm will be given and indicated by the zero position lamps. Note: flashing in Transit mode lamp occurs if the deviation between order and feedback exceeds parameter “Manoeuver_Feedback_Dev Limit”. 3.4.2.3 Automatic Autopilot disengage ‘The function for automatic disengage of autopilot are trigged by manually operating the lever while the autopilot mode is selected. Exceeding an angle of +\- 20° from lever zero position will cause automatic disengage from the autopilot mode and the system will return to manual mode. This value is not adjustable. Reengage of autopilot mode must be manually selected from operator. 3.4.2.4 Transit / Manoeuvre Mode Pitch Pitch operation is influenced by the operating mode. In transit mode the propeller pitch is reduced (scaled) if the thruster azimuth angle exceeds a normal steering range. The reduction is preserved even if the thruster azimuth is returned within normal range, but only for a limited time. This is done to prevent the engines from overloading. A pitch reduction is also performed when exchanging between operation modes. The exchange can also require a reposition of the thruster azimuth angle. The propeller thrust is reduced while the thruster is tured. ‘User Manual Rev. 03, Date: 02.05.2006@ Rol Is- Royc e USER MANUAL HELICON X3 Page 55 of 121 3.4.3.5 RPM order scaling Its possible to supply the rpm control system with external interface for scaling of the rpm order output when external events occur (Slow Down, Shut Down, Alternator on net or Heavy consumers engaged). This is normally done with a digital signal status, engaging an rpm scaling function. Scaling parameter “Rpm_Order_Scaling_1_Eng_1” to “Rpm_Order Scaling 3 Eng_1” are available to the operator to define the rpm output when one of the external reduction signals “Rpm_Scaling_Selector_I_Eng_I" to “RPM_Scaling_Selector_3_Eng_1” are given.. The test point “Rpm _Order Selected_Eng_1” shows the rpm order before the eventually scaling, while test point “Rpm_Order_Setpoint_Eng_1" shows the scaled RPM order. Le. the rpm output will automatically be reduced to Shut Down rpm output when the Shut Down contact from external is activated -\ 3.4.3.6 RPM order Output ‘The output signal from the controller “Rpm_Order Slew Rated Eng_1” are scaled to meet the frequency controllers signal range from idle to full rpm. ‘The output will follow a linear curve between idle and full rpm order. ‘The rpm output rate of change is adjustable, and can be adapted to the frequency controllers reversing speed from idle to full rpm (increasing order) and vice versa (decreasing order). 3.4.3.7 Propeller/Shaft Rpm Indication The microcomputer board computes, pre-scales and outputs signal to the analogue propeller 1pm indicators. One adjustment for each pane! is available for the user : “Rpm_Indicator_Output_ECR", “Rpm_Indicator_Output_Bridge_1” to “Rpm_Indicator_Output_Bridge_: [User Manual Rev. 03 Date: 02.05.2006 ]USER MANUAL HELICON X3 Page $7 of 121 Ly Rolls-Royce 3.4.4 Load Control El. Motor The load control system is designed to protect the propeller machinery from overload. Propeller pitch is automatically reduced if the specified load limit is exceeded. The drawing LOAD CONTROL EL.MOTOR PE62357 describes the principle of the load control system. The drawing shows load control system with interface to two Electric Drive motors, two Generators and a power available from the power management system/MSB , but only those parts relevant for the actual propulsion machinery are used. ‘The load controller computes the propeller machinery load based on the load feedback signal from the electromotor. The feedback signal is monitored on input “Load_Drivemotor_1” and is _~, scaled in percent of the load range. If a failure ocours in the load feedback transmitter, an alarm is given to the alarm plant with a corresponding error message on the operator terminal display. Separate adjustable alarm limits are available for load signal alarm, The load controller is then disabled until normal condition is obtained. Important: Observe the load conditions closely by manual readings if the load control is disabled for any reason. Acceleration limits will protect the propeller machinery during crash manoeuvring, and will slow down the pitch rate of change when the pitch approaches maximum ahead or maximum astern position. However these limits will have no effect as long as the lever order remains constant. ‘Adjustments “Pitch_Crash_Limit_Ahead” and “Pitch_Crash_Limit_Astern” define the acceleration limits. The load controller selects the most suitable gains depending on the amount of overload. If excessive load should occur, the pitch reduction speed is proportional to the overload signal gained with adjustment “Gain_Overloaded”. In normal load condition, the pitch is automatically increased slowly against the set point. In this case adjustment “Gain Normal Load” is used to control the pitch rate of change when returning back to set point from underload condition. Close to the maximum load that is within the load setting deadbands the controller will use very slow speed on pitch corrections. The load setting deadbands are defined with adjustments “Deadband_Below Load _Limit” and “Deadband_Above_Load Limit”. The load control will only correct the pitch position in small steps. The time between each step is defined by the size of the “Load_Output_ Setpoint” and adjustment “Overload_Limit”. The size of the corrective step is defined with adjustment “Load_Filter_Pulse”’, and the frequency of the corrective pulse is defined with “Filter Error_For Pulse” parameter. User Manual _ Rev. 03 Date: 02.05.2006 ]8 Rol Is-Royce USER MANUAL HELICON X3 Page 59 of 121 3.4.5 Command Transfer The term Command Transfer is used to describe the procedure performed when the control is transferred between manoeuvre stations without acceptance on either of the stations. This is normally the procedure between wheelhouse (bridge) stations. 3.4.5.1 Functional description ee. Set the control levers at the new station in accordance to the position of the levers at the present station in command. fi. Press the button IN COMMAND or COMMON IN COMMAND (if such a switch is ~ ‘mounted on the main propulsion plant) at the new station to be in command. The ‘command is transferred immediately as the lamp IN COMMAND is lit. Note: There is normally no command transfer interlock because of discrepancy between lever position at the present station in command and the lever position at the new station to be in command, COMMON IN COMMAND may be installed on the main propulsion system in order to transfer the command for all propeller systems besween bridge stations, by activation only one common switch. User Manual Rev. 03 Date: 02.05.2006 |] Rolls-Royce USER MANUAL HELICON x3 Page 61 of 121 | 6 4 DELIVERY SPESIFICATION 4.1 Control Stations ‘The purpose of the control stations is: * Selection and indication of panel In Command * Selection and indication of operational modes, settings and functions * Selection and indication of thruster status and thruster settings, * System and operational alarm indication 4.1.1 Bridge control stations (3 pes. — fore bridge and manoeuvre chairs aft bridge) Each control station consists of: ) — 2pes. Main propulsion levers - Combined Pitch, Speed and Steering control lever. Ipc. Bow azimuth thruster - Combined Pitch, Speed and Steering control lever, 1 pe. Bow Tunnel thrusters - Combined Pitch and Speed control lever. (The lever is common for two bow thrusters) Tpe. 10.4" LCD - high-resolution colour display with touch-screen interface and built-in display computer. The graphical interfaces are specially designed for touch-screen purposes. 4.1.2 ECR station (1 pe.) The control station consists of: +pes. Main propulsion levers - Combined Pitch, Speed and Steering control lever, Ipc. 10.4” LCD - high-resolution color display with touch-screen interface and built-in display computer. 4.1.3 Overhead indicator panels (2 pes. — fore/ aft bridge) Each indicator panel consists of: > Spes. Pitch indicator. Ses. Propeller RPM indicator. 3pes. Steering indicator. 4.1.4 Wing indication panels (2 pes. — port/stbd wing) Each indicator panel consists of: Spes. Pitch indicator. Spes. Propeller RPM indicator. 3pes. Steering indicator, 4.1.5 Emergency Stop panels (2 pes. — fore/ aft bridge) Each panel consists of: Specs. Emergency Stop push buttons, hardwired to the variable speed drive (alternatively to the main switchboard) 4.1.6 Rudder lever panel on fore bridge (one common for the main thrusters) >) The control panel contains the following functions: User Manual Rev. 03 Date: 02.05.2006 |Rol Is-Royc @ USER MANUAL HELICON x3 Page 63 of 121 The Local indicator/Control panel bow azimuth thruster contains the following functions + UPPER POS. LOCK SYLINDER UNLOCKED, push button w/ light. + UPPER POS. LOCK SYLINDER LOCKED, push button w/ light. + LOWER POS. LOCK SYLINDER UNLOCKED, push bution w/ light. + LOWER POS. LOCK SYLINDER LOCKED, push button w/ light. + THRUSTER IN, push button w/ light. + THRUSTER OUT, push button w/ light. * LIFTING POSITION, signal lamp. * Lamp test. 4.2.3 Viewcon (one per vessel) The unit is designed for bulkhead mounting and should be located on the bridge. Cable access is through a cover plate that can be removed for fitting of cable glands. Location of the unit ) should be selected with due to emphasis on service access, ‘The Viewcon cabinet includes a switch for routing of Ethernet signals to the bridge control panels. 4.2.4 Pitch pump control unit (one per main thruster) The unit selects duty and stand-by pump and is designed for bulkhead mounting and should be located close to the pitch pumps. Cable access is through cable glands. Location of the unit should be selected with due to emphasis on service access. 4.2.5 RPM transmitter (one per main thrusters) The rpm transmitter is a proximity switch, which has to be mounted adjacent to the thruster rive shaft flange. This component measures the propeller speed by giving a pulse to the electronic unit each time a flange bolt passes. (Mounting is not included.) ~ ~ User Manual Rev. 03 ae Date: 02.05.2006 |fi Rolls-Royce USER MANUAL HELICON X3 Page 65 of 121 6 OPERATING INSTRUCTIONS 6.1 The Contro! Lever ‘The control lever controls Pitch/Rpm and Azimuth direction (dependant of application). The control lever has integrated buttons and indication lamps for command transfer, backup system on/off, alarm indication/buzzer and pushbutton for reset buzzer. The display in the base shows set command (pitch and direction) from the lever. The lever contains two redundant electronics circuits, one for the normal control system, and one for the backup system. “ = In operation/Running 2g Command transfer _ Lever in command T backup contro! A Ata ~ Figure 6.1 The Control Lever > User Manual Rev. 03 Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 Page 67 of 121 ‘NOTE : THE SCREEN-SHOT ABOVE IS ONLY AN EXAMPLE TO SHOW THE PRINCIPLE. THE GUI (GRAPHICAL USER INTERFACE) WILL REFLECT THE THRUSTER CONFIGURATION ON THE SPECIFIC ‘VESSEL. User Manual Rev. 03, Date: 02.05.2006Rol Is- Royce USER MANUAL HELICON X3 Page 69 of 121 6.2.2 Bow/Stern Tunnel Thruster ‘The Bow or Stem Tunnel Thruster pages contain all information and functions available for the tunnel thrusters. 6.2.2.1 In Command To operate the lever or activate a function e.g. start or stop the pump etc it is necessary to first take command. Pressing the In Command button does this — Accept button then starts to flash. If the Accept button is pressed within 10 seconds, command is transferred. This is indicated with blue colour in the In Command button, 6.2.2.2 Startistop pump If the manoeuvre station is In Command it is possible to use the Start/Stop Pump. Accept >) button then starts to flash, and if the Accept button is pressed within 10 seconds, the start or ‘stop sequence activates. Pump running is indicated with steady green colour in the Start button. Pump stopped is indicated with red colour in the Stop button, 6.2.2.3 Startstop thruster If the manocuvre station is In Command, the pump is running and the pitch is below 10% it is possible to use the Start Thruster button. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the start sequence activates. There is no interlock for the stop button, only station In Command. Thruster running is indicated with steady green colour in the Start button. Thruster stopped is indicated with red colour in the Stop button, 6.2.2.4 Reset Drive ~ If the manoeuvre station is In Command it is possible to use the Reset Drive function. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the Reset Drive signal is given to the Drive. User Manual Rev. 03 Date: 02.05.2006Rolls-Royce USER MANUAL HELICON X3 Page 71 of 121 (3 6.2.3 Bow TCNS Thruster The Bow TCNS Thruster ‘Page contains all information and functions available for the TCNS. Swing Up Thruster. 6.2.3.1 In Command To operate the lever or activate a function e.g. start or stop the pump etc it is necessary to first take command, Pressing the In Command button does this — Accept button then starts to flash. If the Accept button is pressed within 10 seconds, command is transferred. This is indicated with blue colour in the In Command button, 6.2.3.2 Start/stop pump If the manoeuvre station is In Command itis possible to use the Starv/Stop Pump. Accept >) button then starts to flash, and if the Accept button is pressed within 10 seconds, the start or stop sequence activates. Pump running is indicated with steady green colour in the Start button. Pump stopped is indicated with red colour in the Stop button. 6.2.3.3 Start/stop thruster Ifthe manoeuvre station is In Command, the thruster is locked in lower position, the pump is running and the pitch is below 10% it is possible to use the Start Thruster button, Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the start sequence activates. There is no interlock for the stop button, only station In Command. ‘Thruster running is indicated with steady green colour in the Start button. Thruster stopped is indicated with red colour in the Stop button, 6.2.3.4 Reset Drive >) Ifthe manoeuvre station is In Command itis possible to use the Reset Drive function. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the Reset Drive signal is given to the Drive. 6.2.3.5 LiftLower Ifthe manoeuvre station is In Command, the thruster is in litlower position and the truster is stopped, it is possible to use the Lift/Lower function. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the Lift/lower sequence will start. 6.2.3.6 Autopilot If fore bridge is In Command, itis possible to enable signal from an external Autopilot. Ifthe Autopilot bution is pressed, the Accept button starts to flash, and if the Accept button is pressed within 10 seconds, azimuth order from the external Autopilot controls the thruster. If the Autopilot button is pressed again, followed by Accept, lever mode is enabled again, 6.2.3.7 Bow Lever >) _Itis possible to control all Bow thrusters from one lever. If the manoouvre station is Ia Command, the swing up thruster is set in 90-degree port or 90-degree stbd position, and the [User Manual “Rev. 03 Date: 02.05.2006 |la Rol Is- Royce USER MANUAL HELICON X3 Page 73 of 121 6.2.4 Port/Stbd Main Propulsion The Port/Stbd Main Propulsion page contains all information and functions available for the Azipull Main Propulsion Thrusters. 6.2.4.1 Bridge/ECR To operate the lever or activate a function e.g. start or stop the pump etc it is necessary to first take command. The responsibility change system between Bridge and ECR requires acknowledge from the station in command before the command is transferred. According to the Class Societies ECR have priority and can take the command without acknowledge given from Bridge, but an alarm will sound until the responsibility transfer is acknowledged on Bridge by pressing the ECR button followed by the Accept button. ‘The station in command is indicated with blue colour in the ECR/Bridge buttons. 6.2.4.2 In Command Responsibility change between bridge stations is done by pressing the In Command button — Accept button then starts to flash. If the Accept button is pressed within 10 seconds, command is transferred. This is indicated with blue colour in the In Command button. 6.2.4.3 Start/stop pump If the manoeuvre station is In Command it is possible to use the Start/Stop Pump. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the start or stop sequence activates. Pump running is indicated with steady green colour in the Start button, Pump stopped is indicated with red colour in the Stop button. 6.2.4.4 Start/stop thruster If the manoeuvre station is In Command, the thruster is locked in lower position, the pump is running and the pitch is below 10% it is possible to use the Start Thruster button. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the start sequence activates. There is no interlock for the stop button, only station In Command. ‘Thruster running is indicated with steady green colour in the Start button. Thruster stopped is indicated with red colour in the Stop button. 6.2.4.5 Reset Drive If the manoeuvre station is In Command it is possible to use the Reset Drive function. Accept button then starts to flash, and if the Accept button is pressed within 10 seconds, the Reset Drive signal is given to the Drive. This signal is used to reset alarm status in the drive. It is also possible to output Reset signals to the Steering Gear Drives. See Steering Gear Manual for details. User Manual — Rev. 03 Date: 02.05.2006 |Rolls-Royce USER MANUAL HELICON X3 Page 75 of 121 In Command status/button Pitch/RPM/Azimuth Feedback (The yellow line indicates order) Command and mode status Saree Accept button (only visible when a function selection needs to be accepted) ~ Pitch/RPM Reduced Reset signal to Drive Drive Autopilot/ Start/stop Thruster/ Transit/Manoeuvre Mode Bow Lever Servo Pump Mode Figure 6.6 Port/Stbd Main Propulsion [ User Manual Rev. 8 Date: 02.05.2006 |Rol Is-Royce USER MANUAL HELICON X3 Page 77 of 121 Alarm list | Silence button pe Acknowledge All button ‘Wash Screen Day/Night Lever Light Dimmer ~ Figure 6.7 Alarm oa User Manual Rev. 03 Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 Page 79 of 121 7.1.1 Pitch Control ‘The fuunction of the pitch controller is to move the propeller blades in accordance to the control lever order. The actuator unit represents the interface between the remote control and the main servo system, which performs the actual positioning of the blades. For description of pitch controller function details, see chapter 3.2. Refer also to the PITCH ORDER DIAGRAM PE62362 and the PITCH CONTROL DIAGRAM PE62363. For Tunnel ‘Thrusters and TCNS Thrusters refer to drawing PE65247 and PE65248. 7.1.1.1 Pitch Adjustments Ref. the instruction manual chapter “Adjusting Parameters”. \ 74.4.1.1 Pitch Levers ‘The control lever has three adjustments available: Astern, Neutral and Ahead position (x- values), with respective range adjustments (y-values). aa, Select the actual control station in command. bb. Sclect analogue point “Pitch_Lever_ECR/Pitch Lever Bridge I -4" cc. Set the control lever to Full Aster, dd. Press the auto setting key. The display should respond with the updated value. ee, Set the lever to Neutral position, and press the auto-setting key. #£ Set the lever to full Ahead position and press the auto-setting key. 7.4.1.1.2 Propeller Pitch ‘The adjustments may be set manually or automatically. By manual setting the value should be decreased or increased in small steps until the desired pitch is reached. By automatic setting the propeller pitch should be set to its end positions by means of the pitch lever, or by means of back-up or local control. The auto-setting key should be used to save the position in ~ memory. Note that there are two separate propeller pitch ranges, depending on the operation mode: There is one setting for the Manoeuvre mode and one for the Transit mode. Note: Disable the Load controller while adjusting the propeller pitch. 7.1.4.1.2.1 Pitch Neutral Method 1: Auto setting: aa. Operate the actuator locally until zero (neutral) pitch position is obtained. Select the appropriate analogue point “Pitch_Feedback Clutch_1” (Pitch Feedback Manoeuvre), “Pitch_Feedback_Clutch_2” (Pitch Feedback, Transit) depending on the operation mode. bb. Press the anto setting key. Method 2: Manual setting. aa, Operate the actuator locally until zero (neutral) pitch position is obtained. UserManual Rev. 03 Date: 02.05.2006 |USER MANUAL HELICON X3 Page 81 of 121 Rolls-Royce 7.4.4.1.4.1Pitch Deviation Alarm Configuration ‘The deviation alarm function can either be configured only to give alarm waming or both to give alarm warning and emergency pushbutton control. Note this parameter is common for both pitch and azimuth control aa, Select parameter “Pitch Deviation Alarm Selector". bb. Enter the configuration: “0 = Deviation alarm function OFF, “]" = Alarm warning, jarm warning and emergency control, Use the keyboard and finish by pressing the key. 7.4.1.1.4.2Pitch Deviation Alarm Limit ‘The deviation alarm limit is the allowed deviation between set point and feedback. aa, Select parameter “Pitch_Deviation_Alarm_Limit”. bb. Enter the alarm limit value in % using the keyboard and press key. 7.1.1.1.4.3Pitch Deviation Alarm Delay Time ‘The deviation alarm delay time is the time from a deviation occurs to alarm is given. aa, Select parameter “Pitch_Deviation_Alarm_Delay Time”. bb. Enter the alarm delay time in seconds using the keyboard and press key. 7.4.1.1.5 Pitch PID Controller ‘The pitch controller gain should be adjusted to ensure fast and accurate control with a minimum of position overshoot. Separate adjustments are available for gain, integral and derivative time constants. 7.4.4.1.5.1 Pitch Controller Deadband ‘A small deadband should be introduced to make the pitch actuator less sensitive against noise. aa, Select parameter “Pifch_PID_Deadband_Input" bb. Enter a small value, using the keyboard and press the key. 7.4.4.4.5.2 Pitch Gain aa, Select parameter “Pitch_PID_Proportional_Gain”. bb. Enter the gain value using the keyboard and press the key. Higher values give faster setting, but increase the possibility of instability in the pitch controller. Reduce the gain if position "overshoot" occurs. 1.1.5.3 Pitch Integral Time aa, Select parameter “Pitch_PID_Integral_Gain”. bb. Enter the time constant in seconds using the keyboard and press the key. Higher values give slower integration. 1.5.4 Pitch Integral Limit Select parameter “Pitch_PID_Integral_Limit Enter the value using the keyboard and press the key. Higher values increase the integration range, but also increase the risk for instability. User Manual Rev. 03 Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 Page 83 of 121 ii, Hf deadband adjustment is required to eliminate the unnecessary output signal, select parameter “Pitch Output_Deadband”’ , and if necessary increase the value in small steps. 7.1.1.2 Boost Pump Control Some Main Propulsion hydraulic installations includes Boost Pump interface. The Boost Pump interface means control of three additional solenoids: Pitch_Boost_Pump_Unloaded, Pitch_Boost_Pump_Ahead and Pitch Boost_Pump_Astern. When the deviation between pitch order and pitch feedback, “Pitch Setpoint Error” is higher then an adjustable parameter “Pitch Boost_Pump Engage Limit”, solenoids “Pitch Boost_Pump_Unloaded and “Pitch Boost Pump Ahead” are activated. Default value of parameter “Pitch Boost_Pump_Engage_Limit”is 10.0%. > When “Pitch_Setpoint_Error” is lower then the inverse value of “Pitch Boost_Pump Engage Limit", the solenoids “Pitch Boost_Pump_Unloaded” and “Pitch Boost_Pump_Astern” are activated. When “Pitch_Setpoint_Error” is between “Pitch Boost Pump Engage Limit” and the inverse value of “Pitch_Boost_Pump_Engage_Limit”, no solenoids are activated. 7.1.1.3 Reduced Pitch Order To reserve engine power to heavy consumers as alternators, fire pumps, ctc., it may be necessary to reduce the available propeller output power. This is normally done by means of a fixed propeller pitch reduction. The pitch reduction can either be activated from a digital or an analogue input signal. 7.1.1.3.1 Reduced Pitch Adjustments, digital input Tree digital signals “Pitch Scaling 1_On”- “Pitch Scaling_3_On”, are available for > reductions determined by parameter “Pitch Scaling I On_Digital_Input” ~ Pitch Scaling_3_On Digital Input”. aa, Select the relevant parameter “Pitch_Scaling_I_On_Digital_Input” ~ “Pitch_Scaling_3_On_Digital_Input” bb. Enter the value using the Keyboard and press the key. Higher values increase relative to the maximum pitch available, i.e. 0.8 = 80 %. 7.1.1,3.2 Reduced Pitch Adjustment, analogue signal An analogue signal “Load_Generator_1”, can have tree independent sct of pitch reduction invout limits: “Generator Load Scaling_] Point_I, “Generator Load Scaling 1 Point_2”, “Generator_Load Scaling 2 Point_1”, “Generator Load Scaling 2 Point_2”, “Generator Load Scaling 3 Point_I” and “Generator Load Scaling 3 Point 2” The size of the pitch reductions is determined by: “Pitch Scaling_1_On_Generator_Load” — “Pitch Scaling 3 On_Generator Load”. IN/OUT time delays can be adjusted with parameter “Pitch_Reduction_I_Time_In”, “Pitch_Reduction_I_Time_Out”, “Pitch Reduction_2_Time_In”, [User Manual Rev. 03, Date: 02.05.2006ig Rol Is- Royce USER MANUAL HELICON X3 Page 85 of 121 onder will stop increasing to a higher value, only decrease of pitch order against zero is possible, 7.1.1.3.3.1Pitch Reduced Adjustment, Fuel limiter The pitch position working area for the fuel limiter contact can be adjusted with parameter “Fuel_Limiter Pitch _Limit_1” and "Fuel_Limiter_Pitch_Limit_2”. The time delay from the contact opens and back to normal operation can be adjusted with parameter “Fuel_Limiter Delay Time”. aa. _ Select parameter “Fuel_Limiter_Pitch_Limit_1”. ce. Enter the value using the keyboard, and finish by pressing the key. This is the ow pitch position for the Fuel limiter. The Fuel limiter can only be enabled if Pitch Feedback is higher then “Fuel_Limiter Pitch _Limit_”. dd. Select parameter “Fuel Limiter Pitch Limit 2”. ce. _ Enter the value using the keyboard, and finish by pressing the key. This is the ~ high pitch position for the Fuel limiter. The Fuel limiter can only be enabled if Pitch Feedback is lower then “Fuel_Limiter_Pitch_Limit_2”. ff. Select parameter “Fuel_Limiter Delay Time”. gg. Enter the value using the keyboard, and finish by pressing the key. This is the time delay from the Fuel limiter contact opens and to system is back in normal 7.1.1.3.4 Pitch reduced, Azimuth feedback order deviation This type of reduction is only applicable on azimuth thruster installations, not on tunnel thruster or conventional. propulsion installations. If the azimuth order is changed faster then the thruster azimuth servo can follow, a pitch reduction will be activated. ‘The azimuth order and feedback is compared, and if the deviation is bigger then an adjustable parameter “Azimuth Deviation Scaling Limit”, a digital signal “Pitch Scaling_On Azimuth” is activated. This signal activates a pitch reduction, and the pitch is reduced down to the adjustable parameter “Pitch_Scaling Azimuth_Feedback”. The pitch reduction is active as long as the deviation between order and feedback is bigger then “Azimuth Deviation Scaling_Limit”. When the deviation becomes less the pitch reduction is deactivated. 7.1.1.3.4.1Pitch Reduced Adjustment, Azimuth Order/FB Deviation The azimuth order and feedback deviation before activating pitch reduction can be adjusted with parameter “Azimuth Deviation Scaling Limit". ‘The size of the pitch reduction can be adjusted with parameter “Pitch Scaling Azimuth_Feedback”. aa. Select parameter “Azimuth Deviation Scaling Limit”. bb. Enter the max deviation value in degrees with the keypad and press the key. ce, Select parameter “Pitch Scaling_Azimuth Feedback”. dd. Enter the pitch reduction limit with the keypad and press the key 7.1.1.3.5 Pitch reduced, Azimuth within restricted sectors On ships equipped with twin Azimuth thrusters, a pitch and rpm reduction is activated when the thruster position is so that the water current from one of the propellers hit the hub of the other. If the azimuth feedback is within sectors around +/-90 degrees, a pitch and rpm reduction is activated. [User Manual Rev. 03 ‘Date: 02.05.2006| Rol Is-Royce USER MANUAL HELICON X3 Page 87 of 121 cc. Repeat the procedure described in bb for neutral pitch 0 % , and full ahead 100% ‘User Manual Rev. 03 Date: 02.05.2006i Rol Is-Royce USER MANUAL HELICON X3 Page 89 of 121 PITCH ORDER Xe -y1 100% Note: Zere = x0,¥0 Figure 7.1 Pitch Curve. The pitch curve shows the relationship between the pitch lever position (XO-X¢) and the related pitch order (¥0-Y4), normally five (X, Y) points are used. The pitch curve is symmetric round the 'Y-axe with opposite sign. Only positive X, Y parameter values should be used, 7.1.2.2 Rpm Combinator Adjustments ‘The control lever signal is modified with adjustments “Rpm Combined Curve_I_X Value_1” to “Rpm Combined Curve_1_X Value_5” and “Rpm_ Combined Curve_1_Y Value_1” to “Rom_Combined_Curve_I_¥ Value_5”, “X” defines the lever position and “Y” the corresponding Rpm curve output values. 7.1.2.2.1 Rpm Curve X-Values aa. Select parameter “Rpm_Combined_Curve_I_X Value_1”. bb. This parameter defines the RPM lever curve start point and is normally set to zero, or neutral lever position. Enter the value in percent using the keyboard and press the key. ce. Repeat procedure bb, for the second breakpoint “Rpm Combined Curve_I_X Value_2", third breakpoint “Rom _Combined_Curve_I_X Value_3”, forth breakpoint “Rpm_ Combined Curve_I_X Value_4” and for Combinator RPM lever endpoint “Rpm_Combined_Curve_I_X Value_5”. 7.1.2.2.2 Rpm Curve Y-Values aa. Select parameter “Rpm_Combined_Curve_l_¥ Value_1”. ‘bb. ‘This parameter defines the RPM curve output start point and is normally set to zero. ~ Enter the value in percent using the keyboard and press the key. ‘User Manual Rev. 03 Date: 02.05.2006 |Rol Is-Royce USER MANUAL HELICON X3 Page 91 of 121 7.1.3 Thruster Azimuth Control The drawing AZIMUTH CONTROL PE62364 describes the function, including available adjustments and test points The azimuth control function is to obtain the correct thruster azimuth position in accordance to the control lever order. Valve controlled hydraulic motors or frequency controlled electro ‘motors perform the positioning of the thruster azimuth, Detailed information regarding the hydraulic system or motor data is available in the thruster instruction manual. Note: Test point angle signals are ranged +/- 100 %, representing +/- 180 degrees. Some test points are at named with degrees, displaying the angle in degrees (+/- 180 degrees). 7.1.3.1 Azimuth Adjustments Ref. the instruction manual chapter “Adjusting Parameters”, 7.1.3.1.1 Azimuth Lever Each azimuth lever must be calibrated in three steps. First the Sinus analogue input signal is calibrated to +/-100%, second the Cosinus analogue signal is calibrated, and third the zero lever position is calibrated, 4a. Select the actual control station in command. Select analogue point “Azimuth Lever_Sin Wiper_ECR", “Azimuth Lever Sin Wiper Bridge_I” to “Azimuth _Lever_Sin_Wiper_Bridge_4” for the actual command site. The un-calibrated analogue value from the AD-converter, the Raw Value is monitored. bb. Tum the azimuth lever slowly until minimum Raw Value is obtained. Press the auto setting key. cc, Tum the azimuth lever slowly until maximum Raw Value is obtained. Press the auto setting key, dd. Repeat procedure a2. to cc. for “Azimuth_Lever_Cos_Wiper_ECR”, “Azimuth Lever_Cos Wiper Bridge I” to "Azimuth Lever Cos Wiper Bridge 4”. ee. Set the control lever to zero (neutral) position and select parameter “Azimuth Lever Zero ECR”, “Azimuth Lever Zero Bridge 1” to “Azimuth Lever Zero_Bridge_4” for the actual control station, ff Enter value 0 using the keyboard and press the key. Itis possible to change the succession of the sine and cosine phase by means of a software switch. Engage this switch if the displayed angle is moving in the opposite direction with respect to the physical lever scale (due to external exchange of signals). Select parameter "Azimuth Lever_Invert_ECR", "Azimuth Lever Invert Bridge "to “Azimuth Lever_Invert_Bridge_4” for the actual control station. Invert the current me [ User Manual Rev. 03 Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 Page 93 of 121 “3” = Alarm warning and Backup control, Use the keyboard and press the key. 7.1.3.1.4.2Azimuth Deviation Alarm Limit The deviation alarm limit is the allowed deviation between set point and feedback. aa, Select adjustment “Azimuth Deviation Alarm Limit”. bb. Enter the alatm limit value in degrees using the keyboard and press the key. 7.1.3.1.4.3Azimuth Deviation Alarm Delay Time 23, Select adjustment “Azimuth Deviation Alarm_Time” bb. Enter the alarm delay time in seconds using the keyboard and press the key. 7.1.3.1.5 Azimuth Controller The azimuth controller gain should be adjusted to ensure fast and accurate control with a ) minimum of position overshoot. The controller is a conventional PID-type with adjustable threshold level (deadband). Separate adjustments are available for gain, integral and derivative time constants. 7.1.3.1.5.1 Azimuth Controller Deadband A small deadband or threshold level should be introduced to make the actuator less sensitive and immune against noise. aa, Select adjustment “Azimuth Controller Deadband’’ bb. Enter a small value, using the keyboard and press the key. 7.1.3.1.5.2Azimuth Proportional Gain aa, Select adjustment “Azimuth Controller Prop Gain”. bb. Enter the gain value with the keypad and press the key. Higher values will give shorter settling time, but increases the possibility of instability in the azimuth controller. Reduce the gain if "overshoot" occurs, > 7.1.3.1.5.3Azimuth Integral Time aa. Select adjustment “Azimuth Controller Integral Time”. bb. Enter the time constant in seconds with the keypad and press the key. High values give slower integration. 7.1,3.1.5.4Azimuth Integral Limit aa, Select adjustment “Azimuth Controller _Integral Limit”, bb. Enter the value with the keypad and press the . Higher values will increase the integration range, but increases the risk for instability. 7.1.3.1.5.5Azimuth Derivative Time aa, Select adjustment “Azimuth_Controller Derivative”, bb. Enter the time constant in seconds with the keypad and press the key. Higher values will increase gain, but also increases the risk of instability in the controller, 1.6 Azimuth Actuator >) Aset of adjustments is available to adapt the signal to the selected actuator type. This regards signal noise suppression and the necessary signal offset levels, [ User Manual Rev. 03, Date: 02.05.2006Rol l s-Royce USER MANUAL HELICON X3 Page 95 of 121 ce. If double actuator system is used, repeat procedure aa. to ii. for parameters tzimuth_Output_2_DB”, “Azimuth _Output_2_Negativ Offset” and “Azimuth_Output_2 Positiv_Offvet™. 7.4.3.1.6.3Azimuth Actuator Direction If the azimuth moves clockwise and counter clockwise without stabilising, a reason can be that the polarity of the order signal to the actuator is exchanged. Check first if the order and the feedback potentiometer show correct angle on the display (Positive angle when clockwise movement). If displayed angle is-90 degrees when the lever or the thruster is moved to 90 degree clockwise, then this must be corrected first. See paragraphs Azimuth Lever Adjustment and Azimuth Feedback Adjustment. For inverting azimuth output order: ~\ aa Select adjustment “Azimuuth_Invert_Output”. bb. Enter the value “0/1” with the keypad (Non-invert/invert) and press the key, 7.1.3.2 Backup Control The backup system must be calibrated in the same way as the normal system. 7.1.3.3 Azimuth Indication ‘The azimuth indicating system is separated from the normal azimuth controller system. The indicators are connected in series and are driven from analogue output “Azimuth Feedback” in the Backup Control system. aa, Select analogue output “Azimuth_Feedback”. The analogue output value to the DA-converter is monitored. bb. Select the key. Enter the value for -180 degrees cow using the <+> or <-> keys. (6000 = 4mA, 18000=12mA, 30000=20mA). cc. Repeat the procedure described in bb for 0 degrees , and +180 degrees ew ~ . (User Manual Rev. 03 Date: 02.05.2006USER s-Royce MANUAL HELICON X3 Page 97 of 121 7.1.4.2.1 Thruster azimuth turning range in Transit Mode This adjustment will determine the thruster azimuth range when Steering in Transit mode. Normally the thruster azimuth is Testricted to +-35 degrees, but the adjustment gives the operator the option to extend or reduce this range. aa, Select adjustment “Transit Mode Max Angle”. bb. Enter the new value in degrees with the keypad and press the key. 7.1.4.3 Transit / Manoeuvre Mode Pitch Pitch operation is influenced by the operating mode. In transit mode the propeller pitch is reduced (scaled) if the thruster azimuth angle exceeds a normal steering range. The reduction is preserved even if the thruster azimuth is returned within normal range, but only for a limited time. This is done to prevent the engines from overloading, ) A pitch reduction is also performed when exchanging between operation modes, The exchange can also require a reposition of the thruster azimuth angle. The propeller thrust is reduced while the thruster is turned. 7.1.4.3.1 Entry point for Pitch Scaling in Transit Mode The adjustment defines the azimuth angle where scaling is introduced. The angle is relative to zero degrees, ie. the vessel course, and the reduction is proportional to the steering offset exceeding the normal range. aa, Select parameter “Pitch Scaling Entrypoint_Transit Mode”. bb. Enter the value in degrees with the keypad and press the key. 7.1.4.3.2. Maximum Pitch Scaling in Transit Mode The adjustment defines the maximum reduction and is related to the previous Entry point adjustment. aa, Select parameter “Pitch Scaling Transit Mode”. bb. Enter the value in percent with the keypad and press the key, a 7.1.4.3.3 Time Delay for Pitch Scaling in Transit Mode The adjustment defines the time delay before normal propeller pitch is restored after thruster azimuth angle is returned back to normal. aa, Select parameter “Pitch_Reduction_Timeout_Transit Mode”’ bb. Enter the value in seconds with the keypad and press the key. a [User Manual Rev. 03 Date: 02.05.2006G Rol Is- Royce USER MANUAL HELICON X3 Page 99 of 121 bb. Enter the required values in % (normally 80-100%) using the keyboard and finish by pressing the key. ce. — Ifrelevant, select parameter “Fixed Rpm dd. Enter the required values in % (normally 8 pressing the key. Eng_l". 100%) using the keyboard and finish by 7.1.5.1.4 Rpm order scaling ‘The rpm order can be scaled through parameter “Rpm_Order_Scaling_1_Eng_1” and the belonging contact “Rpm_Scaling_Selector_1_Eng_1”. ‘Three RPM scaling parameters and the belonging contacts are available. aa. Select parameter “Rpm_Order_Scaling_I_Eng_1”. bb. Enter the required value in % (normally 80-100%) using the keyboard and finish by pressing the key. cc. If“Rpm_Order Sealing 2_Eng_1” orRpm_Order Scaling 3 Eng_1” arc used, ~ repeat the procedure described in bb, with selected parameter values, 7.1.5.1.5 Rpm Output Rate of Change To adapt the Rpm output rate of change to the electric drive, select parameter “Rpm_Output Slew Rate_Down_Eng_1" and “Rpm_Output Slew Rate Up_Eng_1”. aa. Select adjustment “Rpm_Output_Slew_Rate_Down_Eng_. bb. Enter the required rate of change value using the keyboard and finish by pressing the key. A rate of change value equal to 1 means that the signal increases 10% per second. The time from 0-100% RPM output order is then 10 seconds. cc. Repeat the procedure described in bb also for parameter “Rpm_Output Slew Rate Up Eng_1”” 7.1.5.1.6 Rpm Output order ‘The RPM output to the drive has two adjustments available: minimum and maximum order. aa, Select analogue output point “Rom Order Slew Rated Eng_1”. ‘The analogue output value to the DA-converter is monitored. —~ bb. Select the key. Enter the value for idle RPM using the <1> or <> keys, (6000 = 4mA, 30000=20mA). cc. Repeat the procedure described in bb for max RPM User Manual Rev. 03 Date: 02.05.2006 |Rolls-Royce USER MANUAL HELICON X3 Page 101 of 121 7.1.6.1.4.1 Overload Gain Gain used in overload conditions. aa, Select parameter “Gain_Overloaded”. bb. Enter the most suitable value using the keyboard and press the key. 7.1.6.1.4.2 Normal Load Gain Gain used to increase pitch after an overload condition where pitch has been reduced. aa, Select parameter "Gain_Normal Load. bb. Enter the most suitable value using the keyboard and press the key while observing the pitch increase rate. A higher value increases the speed. 7.1.6.1.4.3 Overload Limit ‘This parameter limits the overload signal to avoid to big correction signal. Normally set to approximate 10%, \ aa. Select parameter “Overload Limit”. bb. Enter the value by using the keyboard and press the key. A higher value will increase the range of the correction signal. A lower value will limit the range of the correction signal 7.1.6.1.4.4Filter Error For Pulse "Gain" used to increase or decrease the time between pitch correction pulses within the deadband area. cc. Select parameter “Filter_Error_For_Pulset”. dd. Enter the value by using the keyboard and press the key. A higher value will increase the time between pulses and will slow down the pitch rate of change. A too low value will cause the load controller to work unnecessary. 7.1.6.1.4.5 Filter Pulse Gain used to increase or decrease the length of the comection pulses within the deadband area. aa. Select parameter “Load_Filter_ Pulse”, bb. Enter the value using the keyboard and press the key. A higher value will increase Y the pulse length and the pitch actuator will move in larger steps. This may cause the load controller to work unnecessary, A lower value will slow down the pitch rate of change within the deadband area, 7.1.6.2 Electric Drive Motor Interface The load controller computes the drive motor load based on the drive motor current feedback. The feedback signal is monitored on input “Zoad_Drivemotor_1” and must be scaled in percent of the load range. 7.1.6.2.1 Drive Motor Load Adjustments aa. Run the drive motor at minimum load with minimum rpm and zero pitch. Select analogue input point “Load_Drivemotor_I”, The un-calibrated analogue value from the AD-converter, the Raw Value is monitored. bb. Press the auto setting key. ce. Run the drive motor at maximum load. Press the auto setting key. a User Manual Rev. 03 Date: 02.05.2006 }IR Rol Is- Royce USER MANUAL HELICON X3 Page 103 of 121 aa, bb. Select parameter “Analogue Valve_Slewrate_1”., If necessaty increase or decrease the value to change normal thruster in/out actuator speed. Finish by pressing the key. Select parameter “Analogue_Valve_Slewrate_2” to change the slow down actuator speed. Enter the speed value in %, and press the key. 7.1.7.1.5 Thruster In/Out (Lift/Lower) timers The maximum time for lifting/lowering the thruster, and delta time for lifting the thruster when releasing the locking bolts can be adjusted. aa. Select parameter “Time_Out_Complete_ Seq”. bb. Enter the value in seconds with the keypad and press the key. ce, If the IN or OUT (liftflower) time needs to be adjusted, select parameter “Time_Out_Lift_Seq”. 4d, Enter the value in seconds with the keypad and press the key. —\ — &_ Ifthe delta lifting time when releasing the locking bolts need to be adjusted, select parameter “Time Out_Lock_Seq”’ ff, Enter the value in seconds with the keypad and press the key. = — [User Manual Rev. 03 Date: 02.05.2006 ]8 Rolls-Royce USER MANUAL HELICON X3 Page 105 of 121 ~ CDP engineering tools tab Figure 7.6 Select CDP eng. tool 7.2.2 Log in Select the relevant propeller remote control system by using the drag down menu in the “CDP host field. The existing propeller control systems on the ship are listed in this menu, _Bowlne” is short for Bow thruster 1 normal control, “Bow/bc” is short for Bow thruster 1 backup control, “Portine”’ is short for Port Main propulsion normal control ete. [ User Mamuat Rev. 03 Date: 02.05.2006 |6 Rolls-Royce USER MANUAL HELICON X3 Page 107 of 121 | After 15 minutes of inactivity, a new login sequence with username/password is necessary. If the user logs out, and a new login to the same control system is done within 15 minutes, it is por necessary to input the password, It is then possible to use the “Connect as default user” button When connecting to another control system by changing to another “CDP host”, a new semame/password sequence is necessary, but ifit is less then 15 minutes since the password has been entered to this control system, the “Connect as default user” bution can be used 7.2.3. Scaling Analog inputs Select the relevant software function in the menu to the left. As an example, scaling of the Pitch Feedback potentiometer is described. >) Select first the “Pitch” software component by pointing on the menu item to the left. Select the “Signals” tab, and then the “Input” tab. Scroll down the page until input signal pitch Feedback Cluich_1” is found. Select the relevant input signal by pointing at it in the list, see below. Software Input Signal List of component — tab tab signals Figure 7.9 Select input signal [User Manual = Rev. 03 Date: 02.05.2006 ]a Rol Is-Royce USER MANUAL HELICON X3 Page 109 of 121 7.2.3.1 Pitch Neutral Method 1: Auto setting: aa. Operate the actuator locally until zero (neutral) pitch position is obtained. bb. Press the auto setting key. Method 2: Manual setting. aa. Operate the actuator locally until zero (neutral) pitch position is obtained, bb. Select the key ce. Change the adjustment using the <#> or <> key and press , By default the lowest significant digit is selected for adjusting. If bigger steps is required, itis also possible to select one of the other digits for adjusting. This is done by pressing one of the other digits, and using the <+> or <-> key followed by the key 7.2.3.2 Pitch Astern Maximum Method 1: Auto setting: aa, Run the engine at full speed (if possible). bb. Move the pitch lever astern until the desired engine load is obtained and press the auto-setting key at the current propeller pitch position Method 2: Manual setting. aa. Run the engine at full speed (if possible). bb. Select the key. ce. Change the adjustment using the <+> or <-> keys and press 7.2.3.3 Pitch Ahead Maximum Method 1: Auto setting: aa. Perform the procedure as described in the previous point except that the pitch lever is moved ahead and the auto setting key is used. > bb. Press the button to close the scaling window. Method 2: Manual setting, aa. Select the key bb. Change the adjustment using the <#> or <> keys and press . ce. Press the button to close the scaling window, | User Manual Rev. 03 Date: 02.05.2006Rol Is-Royce USER MANUAL HELICON X3 ] Page 111 of 121 | z| Goto button ee Ie a fhe eees Figure 7.12 Open the scaling window Scaling of analog outputs are done by decreasing or increasing the raw value in small steps until the output voltage or current is correct. ‘The Pitch Feedback output signal to Dp has three adjustments available: minimum, zero and ~ maximum, aa. Move the pitch lever astern and wait until the pitch is full astern, bb. Use a multimeter and measure the output current ce. Ifthe current is not exactly 4.0mA, select the key and Step the raw value up or down using the <+> or <-> keys succeded by the key, until the output current is exactly 4.0mA. By default the lowest significant digit is Selected for adjusting. If bigger steps is required, itis also possible to select one of the other digits for adjusting. This is done by pressing one of the other digits, and using the <+> or <-> key followed by the key. dd. Move the pitch lever to zero pitch, and measure the output current. ec. Ifthe current is not exactly 12.0mA, select the key and step ‘He Faw value up or down using the <+> or <-> keys succeded by the key, until the output current is correct. Move the pitch lever to full aheand and repeat the procedure described in ce until 20.0mA is measured. 88. Press the button to close the scaling window. Date: 02.05.2006 ] [User Manual Rev. 03Poge 113 of 121 | -~ — Previsious Value Enter new value here oe Cae Current value in use ress Set key Figure 7.14 Parameter tuning The pitch controller gain should be adjusted to ensure fast and accurate control with a minimum of position overshoot. aa. Select parameter “Pitch_PID_Proportional_Gain bb. Point at the “Value” field, enter the gain vahie using the keyboard and press the key: Higher values give faster setting, but increase the possibility of instability in the Pitch controller. Reduce the gain if position "overshoot" occurs, 7.2.6 Log out After the adjustments are finished, close the tool by selecting the button in the upper right comer of the screen. {pnother propeller control system should be accesed, press the button and select the relevant propeller control system. To go back to normal panel operation, press the key in the upper right corner of the screen, see below. [User Manual Rev. 03, Date: 02.05.2006 ]Rolls- Royce USER MANUAL HELICON x3 Page 115 of 121 a 8 SPARE PARTS 8.1 Parts lists One set RRM standard spare parts for two years operation, consisting of: © Fuses for remote control. * Bulbs for remote control. 8.2 Equipment not Supplied The following items are not included in the Rolls Royce Marine supply unless otherwise agreed: © 24. DC power supply “) © External cabling * Cable glands 8.3 Additional Supply © No additional supply { User Manual Rev. 03 Date: 02.05.2006 ]ia Rolls-Royce USER MANUAL HELICON X3 Page 117 of 121 = 10 DESIGN DRAWINGS See separate drawing list ~ = [User Manual Rev. 03 Date: 02.05.2006Roll s-Royce USER MANUAL HELICON X3 Page 119 of 121 TABLE OF CONTENTS 1 INTRODUCTION 120 2 ETHERNET TWISTED PAIR 120 3 CAN BUS 121 4 RS-422/485 TRANSMISSION 121 ~ ~ ~ ‘User Manual Rev. 03 Date: 02.05.2006 ]Rolls-Royce USER MANUAL HELICON X3 Page 121 of 121 13 can bus This type of bus do not require any special type of cable, so most common twisted pair cables available can be used. Cable Data: Type: ‘Twisted pair, shielded, low capacity, 0.75 mm? min. Cable outer diam: - Impedance: 120 Q (min. 108.0, max. 132.) 14 rs-422/485 TRANSMISSION Sa uiting of RS: 422/485 signals, itis recommend using a shielded twisted pair cable, As for the SIOX bus, RS-422/485 signals do not require any special type of cable; so most twinned pair cables and larger diameter is used. Cable Data: > Type: Twisted pair, shielded, low capacity, 0.5 mm? min. Cable outer diam; - Resistance: Max 100 Ohm totally on bus Capacity: 42pF/m maximum, Range: Max 1200m. For instance, use cables of TCX-type, RCOP-type, IFOI-type, PFOP-type or similar. ~ | User Manual Rev. 03 Date: 02.05.2006 ]