Professional Documents
Culture Documents
2 Safety
Rolls-Royce Helicon X3
P&T Control System 4 Delivery Specification
5 Technical Data
6 Operating Instructions
PRODUCT INFORMATION
Yard:
7 Maintenance Instructions
Alianca
NB/Hull No.:
AL 021 8 Trouble Shooting
Project No.:
13S000411
9 Contact List
Installation Id.:
BOW1 / BOW2
PORT_MP / STBD_MP
10 Spare Parts
Vessel type:
Offshore 11 Tools
Owner:
Asgaard Navegac„o
Date:
12 Design Drawings
03/07/2014
Revision:
A 13 Revision
Revision: A
Introduction
1
1 Purpose
The purpose of the Helicon X3 User Manual is to provide the necessary information to
plan and perform a safe and correct operation of the installed delivered system, as well
as under-standing the basic functionality of the equipment. The User Manual covers
both operational and technical aspects of the system.
The personnel involved in using the system must have relevant experience and training
with regards to the use of such systems.
2 Warranty
The product has a limited warranty. Please note that the warranty will be void if the
equipment is misused or not handled in accordance to prescribed standards, for example
dismantling the equipment to a level greater than described.
3 Contents
This manual contains the following chapters:
Chapter Contents
1. Introduction This chapter specifies the purpose and target groups for the
manual. It also contains list of used abbreviations and a
specification of the document conventions.
2. Safety This chapter specifies safety instructions to follow when
operating and maintaining system.
3. System Description This chapter briefly describes the system components, the
system design and the functionality.
4. Delivery Specification This chapter specifies the delivered equipment.
5. Technical Data This chapter contains technical specifications and
performance data.
6. Operating Instructions This chapter describes how to use the Helicon X3 system.
7. Maintenance Instructions This chapter describes how to maintain the Helicon X3
system, including both preventive and corrective actions.
8. Trouble Shooting This chapter describes how to act when a malfunction occur
in the Helicon X3 system.
9. Contact Information This chapter contains contact information for Rolls-Royce
Marine, Dept. Propulsion Ulsteinvik and Rolls-Royce World
Wide Support Organization.
10. Spare Parts This chapter specifies recommended spare parts for the
Helicon X3 system.
11. Tools This chapter describes required and recommended tools for
the maintenance of the system to use during the installation.
12. Design Drawings This chapter consists of design drawings that serve as an
information source about the installed system for the
installation.
13. Revision This chapter contains the revision history for the total binder.
14. Subsuppliers Manuals This chapter contains documentation from other suppliers
than Rolls-Royce, if such has been delivered by RRM.
4 Target Groups
The User Manual is primarily intended for the user of the system. The user must be
properly trained in using and maintaining the system.
The installation of the system components must be made by yard mechanics with
experience in fitting marine electronic equipment. Cabling into the units, wire
termination and screen/shield termination should be made by yard electricians that have
a certificate of apprenticeship or equal qualification on ship electrical installation.
Commissioning and testing must be carried out by field service personnel from Rolls-
Royce Marine, Dept. Propulsion Ulsteinvik or qualified service engineers from Rolls-
Royce Marine Global Support Network (GSN).
Revision: A
Safety
1 Introduction
This chapter provides information regarding safety precautions that must be taken to
2
prevent injury to people and damage to equipment.
Whoever is responsible for the installation, operation or maintenance of this Rolls-
Royce system, is obliged to read this chapter and fully understand its content before any
installation, operation or maintenance of the system may take place.
2 Disclaimer
Undertaking any work envisaged by this document may either directly or indirectly
create risks to the safety and health of the person undertaking the work or the product
and/or its components while the work is being performed.
It is the responsibility of the user to protect the health and safety of the persons
undertaking the work as well as risk to the product and/or its components. Therefore the
user must ensure that appropriate controls and precautions are identified and taken in
relation to the work envisaged by this document in accordance with the relevant
statutory and legal and industrial requirements.
Neither this document, nor its use, in any way absolves the user from the responsibility
to ensure that the controls and precautions referred to above are implemented.
If any Rolls-Royce product design related features which could create risks to persons,
the product and/or its components are identified, Rolls-Royce should be contacted
immediately.
It is the user's responsibility to make all relevant hazard identifications and risk
assessments of all the activities associated with the use of this document.
It is the user's responsibility to design and implement safe systems of work and to supply
safe equipment (including, without limitation, safety equipment) and training
(including, without limitation, health and safety training) to anyone using this document
to work on products to which it relates.
A user without relevant experience of working in accordance with this document, or
with products to which it relates, should seek appropriate advice to identify the health
and safety controls and precautions that need to be taken while working.
Technical assistance can be sought from Rolls-Royce and will be subject to Rolls-
Royce's terms and conditions.
3 Safety Instructions
This Rolls-Royce system is a remote control system that is controlling propulsion units
on the vessel. By operating the system, the thrusts direction and pitch/speed
performance can be controlled.
The operator must at all times be aware of:
• Consequences of operating the system to prevent injury to people, damage of
equipment, damage to the vessel operated and damage to the surroundings.
Note: 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
Note: The safety functions described underneath will only be available if the
thruster(s)/gear(s) have got the described function in the first place.
normal control cpu, failure on the normal control order potentiometer in the lever on the
manoeuvre station currently in command and failure on the normal control field bus.
Alarm will be given in the control system and in the ship's alarm system. 2
3.1.3 Azimuth Control
The azimuth control is a redundant function 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
manoeuvre station currently in command, 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.
3.1.5 Autopilot
If operating using an external autopilot system and the azimuth lever order on the
manoeuvre station in command is changed more than the 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.
4 Safety Messages
Safety messages in this manual are always accompanied by a safety alert symbol and a
signal word. The safety alert symbol is used to alert the reader about a potential risk of
personal injury or damage to the equipment.
The following types of safety messages are used within this manual:
Warning: Risk of... Indicates the presence of a hazard which could result in death or
personal injury.
Note: Alerts the reader to relevant factors and conditions which may impact the
function of the equipment.
Revision: A
System Description
1 General
This chapter provides an overview of the Helicon X3 system and a technical description
of the main components that give the required knowledge about the system.The figures,
drawings and text in this chapter are general and may not comply to the actual
installation on the vessel. For details on the delivered equipment, see chapter 4 Delivery
Specification. 3
2 System Overview
The Helicon X3 remote control system is a micro-processor-based system, controlling
the propulsion units on the vessel. The 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.
• Pitch control, allowing accurate and reliable control of the thruster pitch.
• Speed control, allowing accurate and reliable control of the motor speed (RPM).
• Direction control, allowing accurate and reliable control of the thrust direction.
• Follow-up backup control from control levers.
Bridge 1
Port Wing
Fore bridge Aft bridge
Dynpos
Autopilot
Viewcon
GPS
VDR
3 Design
3.1 Lever
Each thruster has its own lever. Their main functions are:
• Control of pitch, RPM and azimuth direction (dependant of application)
• In operation
• Command transfer
• Lever in command
• Back-up control
• Alarm
The control lever has integrated buttons and indication lamps for command transfer,
backup system on/off, alarm indication/buzzer and push button for reset of buzzer. The
display in the base shows set command (pitch and direction) from the lever.
The lever contains two redundant electronic circuits, one for the normal control system
and one for the backup system.
Figure 1 Lever
There is one command page for each thruster, in addition to one system overview page
and one alarm page. The overview page shows the most essential information for all
thrusters, but to activate functions or to view all available information for a thruster, the
particular thrusters' page must be selected.
The graphical design is based on the following principles:
• All functions pages are only one click away
• Large and simple buttons which are easy to read.
• Same design theme for all clickable objects.
• To avoid unintentional activation of functions, all function activation buttons require
press on the accept button to proceed.
1 2
3.4 Indicators
The indicators give feedback on various data and can be found on the bridge and in the
engine control room.
There are three main types of indicators:
• Azimuth indicator
• RPM indicator
• Pitch indicator
In addition a bridge order indicator may be delivered on some vessels.
PORT STBD MIN MAX PORT STBD MIN MAX MIN MAX
3.5 Viewcon
Network cabinet
The network cabinet(s) contains several switches. The network cabinet(s) connects the
panel PCs and the controller cabinets.
Network
Operator stations and electronic units are linked together in an Ethernet network. The
network is single and may contain several separate switches.
(CAN bus is the internal communication between levers, I/O modules and Marine
Controller.)
DC 1 ON
DC 2
8
FRNT
ST 1
ST 2
7
6
5
4
3
2
1
3
5
7
6
8 9
6
1
2 8
3
9
4
10
5
1. I/O modules
2. Capacitors (optional)
3. Power distribution
4. Power distribution
5. Power / network / CANBus terminals
6. Local panel connection
7. Actuator interface card(s) (optional)
8. Relays (optional)
9. Signal isolation amplifiers (optional)
10. I/O terminals
4 Functions
Tunnel Thruster Control Functions
The control functions included in the Tunnel Thruster Control system:
• Pitch control
• Command transfer
Note: No pitch reduction or load function 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.
operate the propeller pitch locally from the pitch control valve.
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).
When operating using the backup system, the operator must be careful not to overload
the engine or the propeller system.
The Rolls-Royce logotype is imprinted in remote control panels, alarm panels and cabin
panels.
Cables are marked with a cable tag at both ends.
1 3
2 4
Revision: A
Delivery Specification
1 General
For Delivery specification see the Technical specification.
Note: Upon reception of the Rolls-Royce equipment, the receiver must compare
the shipping documents with the physical items received. If any
discrepancy is found, Rolls-Royce must be informed immediately.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
01.03 Description of equipment for main thruster units (diesel-electric systems). ................. 9
Cabinets ..................................................................................................................................... 9
Cabinets ..................................................................................................................................... 12
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Remote control
Classification requirements
The equipment is dimensioned in accordance with the above classification society rules valid on
the date of this specification.
Dimension drawings, wiring diagrams, technical data and installation instruction for the propulsion
remote control system will be delivered. All according to documentation list issued for each order.
Workshop testing
The propulsion remote control system is workshop tested according to the class requirement and
RRM standard.
Shipment
Depending on transport methods and delivery time’s components may be shipped separately.
Installation into the ship and mounting of components are client's responsibility if not otherwise is
stated.
Safe storage
All equipment is prepared for storage in dry and dust free environments up to 6 months from
delivery.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Connections between components supplied by RRM are the client's responsibility. However, cable
type recommendations are given in the diagrams and mounting instructions.
Installation of the propulsion remote control system in the ship and mounting of components are
the client's responsibility if not otherwise stated.
Users Manuals and Installation Manuals in English language containing all technical data, are
included.
All drawings, documents and sign plates on the equipment will also be delivered in English
language.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
The Propulsion & Thruster control system is a microprocessor based system. Following main functions
are included:
- Speed control, allowing accurate and reliable control of the motor speed (RPM).
- Pitch control, allowing accurate and reliable control of the thruster pitch.
- Direction control, allowing accurate and reliable control of the thrust direction.
- Follow-up backup control from control lever.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Control Stations
ECR station
1 pc. 10.4” LCD - high-resolution colour display with touch-screen interface and built-in display
computer.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Any operation of the system can be performed through the graphical interface. The most vital operations
can in addition be performed by using dedicated pushbuttons in the control lever base (see next section).
Display pages
Thruster page information is project dependent. Below are typical examples of each propeller/ thruster
type:
Main Thruster (diesel-electric system) pages includes the following functions:
- Indication thruster steering command and actual steering feedback.
- Indication thruster speed command and actual propeller speed.
- Selection and indication of IN COMMAND.
- Indication of STEERING LOCAL CONTROL.
- Indication of SPEED LOCAL CONTROL.
- Indication of ZERO LEVER.
- Selection and indication of START/ STOP OF SYSTEM.
- Selection and indication of START/ STOP OF THRUSTER.
- Selection and indication of COMMON PORT CONTROL.
(Common control of both thrusters from port lever).
- Selection and indication of AUTOPILOT ON/OFF.
- Indication of DP/JOYSTICK CONTROL.
- Indication of POWER REDUCED.
- Dimming of lever.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Viewcon (1 pc.)
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.
Potentiometers and electronics for I/Os and control, both for normal and backup system, are included
inside the lever. The display in the base shows set command (pitch and direction) from the lever.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Cabinets
The electronic unit is designed for bulkhead mounting and should be mounted in the instrument room or
nearby the bridge. (Note! Electronic unit must not under any circumstances be removed from the
electronic cabinet and mounted into any console separately). Cable access is through a coverplate
that can be removed for fitting of cable glands. Location of the unit should be selected due emphasis on
service access.
The Remote Control System is designed to accomplish prevailing rules of DNV, ABS, LRS, BV, GL and
RINA.
The unit is designed for bulkhead mounting and should be located in the thruster room. 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 unit selects duty and stand-by pump and is designed for bulkhead mounting and should be located
close to the lub. pumps. Cable access is through cable glands. Location of the unit should be selected
with due to emphasis on service access.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
DP Interface
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
The remote control is provided with interface for a POSCON Joystick system.
Communication is via Ethernet.
(Other joystick system will be interfaced through hardwired signals)
Autopilot interface
ACON Interface
The remote control is provided with interface for an ACON Automation system.
Communication is via Ethernet.
(Other automation system will be interfaced through serial line or hardwired signals)
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Cabinets
The electronic unit is designed for bulkhead mounting and should be mounted in the instrument room or
nearby the bridge. (Note! Electronic unit must not under any circumstances be removed from the
electronic cabinet and mounted into any console separately). Cable access is through a coverplate
that can be removed for fitting of cable glands. Location of the unit should be selected due emphasis on
service access.
The Remote Control System is designed to accomplish prevailing rules of DNV, ABS, LRS, BV, GL and
RINA.
The unit is designed for bulkhead mounting and should be located in the thruster room. 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.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
The following signals are required from the drive motor starter to the control system:
- Running signal
A potential free relay closing contact when the motor is running and ready for thruster operation.
Indication light on the START push button on Main Bridge Panel.
- Overload signal (high temp. in windings). A potential free relay contact from the thermal relay for
overload indication in control panels.
- Drive motor current signal.
4-20mA signal from the drive motor starter.
The load control continuously monitors the power output from the drive motor and the propeller pitch
is automatically adjusted in response to the load changes detected.
DP Interface
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
The remote control is provided with interface for a POSCON Joystick system.
Communication is via Ethernet.
(Other joystick system will be interfaced through hardwired signals)
ACON Interface
The remote control is provided with interface for an ACON Automation system.
Communication is via Ethernet.
(Other automation system will be interfaced through serial line or hardwired signals)
One set RRM standard spare parts for two years operation, consisting of:
- Fuses for remote control.
- Bulbs for remote control.
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce.
Failure to do so is a violation of copyright laws.
Revision: A
Technical Data
1 General
This section provides the technical data of the Helicon X3 system, with focus on the
main hardware components. Detailed drawings and interface descriptions are found in
the delivery specific drawings, see chapter 12 Design Drawings.
The Helicon X3 system is designed to meet the type approval requirements stated by EU
standards and the following classification societies:
• American Bureau of Shipping (ABS)
• Bureau Veritas (BV)
• China Classification Society (CCS)
• Det Norske Veritas (DNV)
• Germanischer Lloyds (GL)
5
• Korean Register of Shipping (KR)
• Lloyd’s Register (LR)
• Nippon Kaiji Kyokai (NK)
• Registro Italiano Navale (RINA)
• Russian Maritime Register of Shipping (RS)
• Croatian Register of Shipping (Hrvatski Register Brodova) (CRS)
• Indian Register of Shipping (IRS).
2 Environmental Data
Temperature: 0–70 °C ambient
Humidity: 97 %
Vibration: 3–100 Hz, frequency ranges
3-13.2 Hz, displacement limited to 1 +/- 1.0 mm
13.2-100 Hz, acceleration limited to 0.7G
EMC: According to the rules of the Classification Societies, and the
IEC945 standard for Electromagnetic Compatibility
Enclosure: IP22 (Control room, Accommodation and Bridge)
IP44 (Engine room)
3 Electrical Data
3.3 Levers
Analogue inputs 10 bit +/- 0.4% linear error, and +/- 1% absolute accuracy
Revision: A
Operating Instructions
1 General
This chapter gives a brief overview on how to operate the Helicon X3 system. For
practical reasons, it is not possible to go into particulars about all available functions.
Instead, the graphical user interface (GUI) is designed to be as self-explanatory as
possible. In the following sections, the most common functions are described in detail.
Caution: Before operating the equipment, please refer to chapter 2, Safety for the
general statement, safety and warnings instructions.
1 5
2
6
2 3 6
1 5
3
4
7
4
8
8
3 Standard Operations
In this section all available control functions and buttons available in the Helicon X3
user interface is described.
Note: Depending on thruster type and configuration, all functions and buttons
may not be applicable for your installation, or somehow differ from what
is presented here.
3.3 In Command
To operate the lever or activate a function it is necessary to first be In Command.
It is not possible to transfer the control to an unmanned manoeuvre station.
This is how you change responsibility between bridge stations:
1. Set the control levers at the new station in accordance to the position of the levers
at the present station in command.
2. Press the In Command button.
3. To confirm press the Accept button within 10 seconds when it starts to flash.
4. The command is transferred when the In Command button turns blue.
3.9 Autopilot
6
3.9.2 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 degrees 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. Re-engage of autopilot mode must be manually selected from
operator.
4 Alarm
The alarm page contains a list of any active alarms in the control system. Alarms for all
the thrusters connected to the system are presented in this list. The most recent alarm
will be on top of the list.
Alarm monitoring can be set up for analogue or digital signals in the remote control.
Normally alarm monitoring is activated for all essential input signals and sensors.
4.1 Silence
The alarm buzzers can be switched off in two ways:
4.1.1 Alternative 1
1. Press the Buzzer off button on one of the levers on the control system where the
alarm belongs.
4.1.2 Alternative 2
1. Press the Silence button on the alarm page on the control panel.
Note: The Silence button switches off alarm in all propeller control systems.
4.2.1 Alternative 1
1. Press the Ack button beside the alarm text.
2. The alarm text changes from flashing red to fixed red and the Ack button colour
changes to grey.
4.2.2 Alternative 2
1. Press the Ack All button in the bottom of the page.
2. All alarms that are visible on the screen are now acknowledge
3. The alarm text changes from flashing red to fixed red and the Ack button colour
changes to grey.
6
If an alarm is acknowledged and later changes status back to normal, the alarm is
removed from the list.
If an alarm is unacknowledged and changes status back to normal, the alarm changes
colour to blue. If ack is pressed on a blue alarm, the alarm is removed from the list.
4.5 Day/Night
The Day/Night button switches the screen between dark and light background. This
function is implemented to improve visibility in different light conditions.
Azimuth thruster
5.2 Ahead
Straight ahead
With any power, but both prime movers
running with equal power.
Turn starboard
It's recommended to use the starboard
thruster since the port side thruster then
helps the turn by pushing from outside
corner.
5.3 Astern
Straight astern
With any power, but both prime movers
running with equal power.
6 Crash Stop
In this section the recommended practice with regards to the crash stop manoeuvre is
described.
1 2 3
6
Note: Full power/rpm is not allowed to be used in stopping test.
7 Backup Operation
Note: Load control system handled by the frequency converter drive system
shall not be affected by changes in operation mode for the remote control
system.
The backup system can additionally be turned ON/OFF without any failure in the
system.
The maximum steering angle is limited to +/- 100% and the maximum steering speed is
limited to approx. 1 rpm, about 50% of normal steering speed.
Steering gear alarms can be observed in bridge panels (LCD) and reset from
manoeuvring station.
Note: Rpm control must be done locally from Frequency Converter Cabinet, ref.
to drive supplier procedures.
8 Emergency Operation
The Backup Control system does not have interface to external control systems like DP,
Joystick or Autopilot.
Revision: A
Maintenance Instructions
The following warnings and cautions are for your safety, for the prevention of injury
from electric shock and for a safe operation of the equipment. Also see chapter 2 Safety.
• While performing maintenance tasks, always position the equipment (and yourself) on
a stable and safe surface.
• Ensure that all accessible cables cannot be walked on, tripped over or damaged by
transportable items.
• If a device is damaged or fails to function correctly, disconnect it from the power
source. Refer to the system drawings to locate the nearest fuse/circuit breaker, see
chapter 12 Design Drawings.
• Do not attempt to repair any sub-component yourself – consult a qualified Rolls-Royce
service technician.
7
• A serious electrical shock hazard exists within the covers of some components (i.e.
displays) and on marked locations inside the cabinets (marked with 220 VAC or
24 VDC).
Caution: It is very important that you are connected to ground before touching any
electronic components or printed circuit boards.
The life span of electronics can be affected by damage caused by electrostatic discharge.
This can happen if a charged tool or person touches a component. Therefore it is very
important that all tools and personnel are discharged by touching a grounded point
before the printed circuit board or any of the components are touched. It is equally
important to discharge the package with the new component before opening it. A person
walking on a carpet can be charged with up to fifteen thousand volt (15000 V). In worst
case, some sensitive components can be destroyed when discharged with about 100 V.
3 Routine Maintenance
The following table lists the maintenance procedures.
4 Corrective Maintenance
4.1 General
The main tasks of corrective maintenance to be covered in this manual, are replacing
parts/units inside cabinets or on operator stations and, if applicable, tuning and set-up of
a new unit.
1 1
2
Pos Component
1 Screws
7
2 Address switches
3 CAN and power connector
1 2
1 2
CAN1 Hi
CAN1 Lo
CAN1 Gnd
CAN2 Hi
CAN2 Lo
CAN2 Gnd
24V
DC
0V
3 2 1
Pos Component
1
2
USB ports
Ethernet ports
7
3 Power supply connector
4 Screws
Caution: Do not switch off display, unplug power cable or remove the USB pen
drive while software and configuration is loading into memory.
11. When the display is powered off, unplug the USB pen drive and power up the
display again by pressing the on/off switch in front. The display’s original
functionality should now have been restored.
12. Place the USB pen drive back to the storage location so it can be found next time
you need it.
4.6 Fuses
There are two general types of fuses, automatic and glass cartridge fuses.
• Automatic fuses will switch to off position when tripped. Pull the switch back to on
position to re-power the circuit.
• A glass cartridge fuse is blown if the cord inside the glass has been broken. Notice the
technical data written on the old fuse and replace it with a new with matching data.
DC OK
Adjust
32.5-28.5V
Input
AC 100-240V
L N
Please refer to chapter 12 Design Drawings and the part list for details. Never replace a
fuse with higher ampere or lower voltage characteristics than it should be.
7
4.7 Replacing the Power Supplies
If the AC/DC power supply in the main control cabinet is replaced, the output voltage
must be adjusted to +26 VDC. This is to ensure that the power supply is adjusted to
deliver a higher voltage than the DC/DC supply.
If the DC/DC power supply is replaced, adjust the output voltage to +25 VDC.
DC OK
Adjust
32.5-28.5V
Input
AC 100-240V
L N
DC 1 ON
DC 2
8
FRNT
ST 1
ST 2
7
6
5
4
3
2
1
5 6 1
Marine Controller
RS422 RS232 VIDEO
USB LAN C D DVI
A B
A CRT
COM3 COM4 COM5
B
STATUS 2
RUNNING SUPPLY
C
A B
64MB
1 2 3 4 5 6 7 8 9 10
4 3
Pos Component
1 Power supply cable
2 Compact Flash memory
3 Alarm connector
4 CAN
Pos Component
5 Ethernet
6 RS 422
7
1 1
5 5
4
5
2 3
Pos Component
1 Screws
2 Power and CAN connector
3 I/O connector
4 Address node wheels
5 Jumpers
6 Software ID-tag
The CAN I/O module is located in the Control Cabinet. To change the internal circuit
board, proceed as following:
1. Disconnect the power and CAN connector (2), which is located in the front.
2. Disconnect the I/O connector (3).
3. Loosen the three screws (1) that hold the top cover of the CAN I/O module in place
and remove the top cover.
4. Remove the circuit board from the CAN I/O module by pulling it straight out from
the housing.
5. Check the identity of the CAN I/O module (6) to get the correct new card.
6. Set the address node wheels (4) and jumpers (5) on the new CAN I/O module
circuit board identical to the one being replaced.
7. Fit and connect the CAN I/O module in reverse order.
In the UN1 Electronic Control unit there is a local ethernet switch for communication
between the controllers and the Viewcon system.
To replace the controller, proceed as following:
1. Disconnect the power by removing the corresponding fuse.
2. Remove the power supply connector (top).
3. Remove the Ethernet cables.
4. Remove the switch from the rail.
5. Fit and connect a new switch in reverse order.
4 3
5
1
6
Pos
1
Component
Signal isolation amplifier
7
2 Latches
3 Top part
4 DIP switch
5 DIP switch
6 DIP switch
When replacing a galvanic insulated, the DIP-switch must be correctly set. Compare
with the DIP-switch on the replaced amplifier and adjust as necessary. All I/O-modules
can be replaced as is and do not need further measures.
1. Disconnect the plugs.
2. Disengage the top part of the housing by carefully pressing the latches on both
sides (2).
3. Pull out the top part of the housing and the electronics section until the lock (3).
4. Set the input and output ranges, offset and bandwidth using DIP switches (4,5,6)
3. Choose Inputs.
4. Choose the desired signal from the list (e.g. Pitch_Feedback_Clutch_1_2).
5. Click the Goto button.
The scaling adjustments can be set manually or automatically. Which method to use
depends on the application. In our example we will use automatic adjustment to go to
the most accurate setting. Set the pitch tom minimum/zero/maximum by means of the
pitch lever or local control, and press Set min/zero/max button to store the value in the
memory. For other applications it might be more useful to use the manual setting. To
enter the manual adjustments press the Edit min/zero/max button. Use the + and -
buttons to increase and decrease the value in small steps until the desired value is
reached.
3. Choose the desired parameter from the list (e.g. Pitch_PID_ Proportional_Gain).
4. Type in new value by using the keyboard and the Set button.
In our example you should set the pitch controller gain to ensure fast and accurate
control with a minimum of position overshoot. Please be aware that some parameters
can change function behaviour completely. Always consult a Rolls-Royce Service
Engineer before changing parameters.
(1) = Previous value
(2) = Enter new value
(3) = Set button
(4) = Current value in use
1
3
2
7
6 Functions
This chapter describes how to adjust parameter settings for some of the functions of the
remote control system.
Please be aware of that the described adjustments are already carried out by qualified
Rolls-Royce personnel at the commissioning and the sea trial period, and normally not
need to be changed. However, if transmitters or other devices are replaced it may be
necessary to re-adjust the current device.
6.1 Levers
When a lever has been replaced the operator device has to be re-calibrated. When
calibrating a lever the current thruster should not be running. All calibration is done
using the CDP tool described in the previous chapter. Calibration must be done for both
the Normal controller and the corresponding Backup controller.
There are at the most three lever functions available for calibration, depending on the
functions available for the current thruster. This is Pitch control, Rpm control and
Azimuth control. If the thruster have both Pitch and Rpm control but is operated only
through a common Pitch/Rpm lever, calibration of the Rpm control lever will not be
necessary. The thruster is then operating through combinator curves and the only
calibration necessary is calibration of the Pitch control lever.
1. Enter the CDP tool and log into the relevant Normal Controller.
2. Select the PitchO function, signals and then Analog in.
3. Select one of the following analogue point
• Pitch_Lever_ECR
• Pitch_Lever_Bridge_X
(where X represents the bridge number, 1 to 5)
based on which lever to calibrate.
4. Set the control lever to full astern position and press the Set Min auto setting key.
The display should then respond with the updated value.
5. Set the control lever to neutral position and press the Set Zero auto-setting key.
6. Set the control lever to full ahead position and press the Set Max auto-setting key.
7. Close the window and log out of the Normal Controller.
8. Repeat the procedure for the corresponding Backup Controller.
10. Go back to the signal tab, select analog out and then read the value of the relevant
lever order signal:
• Azimuth_Lever_ECR
• Azimuth_Lever_Bridge_X
(where X represents the bridge number 1 to 5).
11. Select the parameter tab once again and select the relevant parameter:
• Azimuth_Lever_Zero_ECR
• Azimuth_Lever_Zero_Bridge_X
(where X represents the bridge number 1 to 5).
12. Enter the value found in step 10 and press the Set key.
13. It is 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 for the relevant control station. Invert the current value
(If current value is 0 change to 1. If current value is 1 change to 0) using the
keyboard, and press the Set key.
• Azimuth_Lever_Invert_ECR
• Azimuth_Lever_Invert_Bridge_X
(where X represents the bridge number 1 to 5).
7
14. Close the window and log out of the Normal controller.
15. Repeat the procedure for the corresponding Backup controller.
Revision: A
Trouble Shooting
1 General
The aim for the troubleshooting chapter is to be of assistance to the operator during fault
tracing of the Helicon X3 system. The main part of the chapter is:
• Alarms - this section contains a list with all typical alarms including alarm text, and
possible cause, effect and proposed action for each alarm.
2 Alarms
2.1 General
The diagnostics of errors are given by the issued alarms. The troubleshooting is based
on the proposed fault tracing and corrective actions given in the alarm descriptions.
The first part of the alarm describes which thruster it concerns, example PORT MP NC
(port main propeller normal control).
Equally it exists alarms for STBD MP NC, BOW1 NC, STERN1 NC etc.
All these alarms will be shown on the alarm page on the touch screens.
Alarms from the mechanical part of the thruster and the optional frequency converter
also appears on the the alarm page. For more information about these alarms see the
manual for the trusters mechanical parts or the manual for the frequency converter.
Every alarm in the alarm list (1) appears with red text. These alarms will flash red until
the Ack button (3) is pressed or the problem ceases to exist. An alarm that has been
acknowledged will remain red until problem ceases to exist and then disappear. An
unacknowledged alarm will turn blue when the problem ceases to exist, remain blue
until it has been acknowledged and then disappear.
2 3
Pos Component
1 Alarm list
2 Silence
3 Acknowledge all button
See chapter 12 Design Drawings for wiring diagrams for the Helicon X3 system and
applicable cabinets.
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Azimuth Lever Cause: Azimuth(direction) order pot. In ECR Lever failure
Cos ECR
Effect: No Azimuth Normal control from ECR
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Azimuth Lever Cause: Azimuth(direction) order pot. In Main Bridge Lever failure
Sin Bridge 1
Effect: No Azimuth Normal control from Bridge 1
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Azimuth Lever Cause: Azimuth(direction) order pot. In Main Bridge Lever failure
Cos Bridge 1
Effect: No Azimuth Normal control from Bridge 1
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Azimuth Lever Cause: Azimuth(direction) order pot. In Slave Bridge Lever failure
Sin Bridge 5
Effect: No Azimuth Normal control from Bridge 5
Action: Operate in Backup control or from other control station, Replace Lever/
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Azi Ext Lever Cause: Azimuth(direction) order From External Lever failure
Sin ECR
Effect: No Azimuth External lever control (Common lever etc.) from ECR
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Pitch Lever Cause: Pitch order potentiometer in Main bridge Lever failure
Bridge 1
Effect: No Pitch Normal control from Bridge 1
Action: Operate in Backup control or from other control station, Replace Lever/
Contact RR service dept.
PORT MP NC Pitch Lever Cause: Pitch order potentiometer in Slave bridge Lever failure
Bridge 5
Effect: No Pitch Normal control from Bridge 5
Action: Check the reason for alarm on the frequency converter in steering gear
compartment. Reset the alarm in the control panel.
Warning steering gear Cause: Warning something may be wrong with the steering gear
Action: Check the reason for alarm on the frequency converter in steering gear
compartment. Reset the alarm in the control panel.
High temperature steering Cause: The temperature in the steering gear is to high.
gear
Effect:
Action: Check the reason for alarm on the frequency converter in steering gear
compartment. Reset the alarm in the control panel.
Action: Check connections and fuse. System still fully operational with 24V
Backup supply
PORT MP NC 24 Volt Failure U4 Cause: 24V DC in Backup supply failure
Action: Check connections and fuse. System still fully operational with
220V AC Main supply
Action: Operate from Normal lever, identify or correct error in signal (Pot.
meter in Rudder lever)
PORT MP NC Pitch Auxiliary Cause: Pitch Order signal from Aux system failure
Order
Effect: Not possible to operate thruster from Aux
Effect: HCX3 Load control Not working, Pitch scaling activated. HCX3
Power indication not working.
Effect: HCX3 Load control Not working, Pitch scaling activated. HCX3
Power indication not working.
Action: Operate thruster with caution. Identify if fail is in Switch board or inn
HCX3 input or in cabling.
PORT MP NC Propeller RPM Cause: Propeller Rpm Feedback signal failure
Feedback
Effect: No Propeller RPM indication. If thruster with diesel engine: Load
control not working.
Effect: Alarm /warning on high and low speed according to selected mode
(Transit /Man mode) not working.
Message Description
Err. 1 Initialisation Error
Err. 2 CAN Fieldbus Error
Err. 3 Sensor IO Error
Err. 6 The lever unit has lost the communication to the Application Controller.
Revision: A
Contact Information
1 Contact Information
Note: For an updated list of contact information, please refer to our homepage:
http://www.rolls-royce.com/marine/contacts
Tel: +47 81 52 00 70
Fax: +47 70 01 4014
After market service support: +47 81 52 00 75
9
24 hrs service phone: +47 90 01 09 97
NORTHERN EUROPE
DENMARK
Aalborg (Service) Tel: +45 99 30 36 00 Fax: +45 99 30 36 01
FINLAND
Rauma (Propulsion/Deck Tel: +358 2 837 91 Fax: +358 2 837 94 804
machinery)
FRANCE
Paris Tel: +33 147 221 440 Fax: + 33 147 457 738
Rungis Tel: +33 1 468 62811 Fax: +33 1 468 79398
GERMANY
Hamburg (Sales and Service) Tel: +49 40 381 2177 Fax: +49 40 389 2177
Hamburg (Service) Tel: +49 40 780 91 90 Fax: +49 40 780 91
NORTHERN EUROPE
THE NETHERLANDS
Rotterdam, Pernis Tel: +31 10 40 90 920 Fax: +31 10 40 90 921
NORWAY
Aalesund (Ship technology) Tel: +47 815 20 070 Fax: +47 70 10 37 01
Longva (Automation) Tel: +47 815 20 070 Fax: +47 70 20 83 51
Oslo (Repr. office) Tel: +47 815 20 070 Fax: +47 23 31 04 99
Volda Tel: +47 815 20 070 Fax: +47 70 07 39 50
Ulsteinvik (Propulsion) Tel: +47 815 20 070 Fax: +47 70 01 40 14
SWEDEN
Kristinehamn (Propulsion) Tel: +46 550 84 000 Fax: +46 550 18 190
UNITED KINGDOM
Bristol (Marine Services) Tel: +44 117 979 7242 Fax: +44 117 979 6722
Dunfermline (Motion Control- Tel: +44 1383 82 31 88 Fax: +44 1383 82 40 38
Aftermarket)
Portsmouth (Marine Electrical Tel: +44 23 9231 0000 Fax: +44 23 9231 0001
Systems)
POLAND
Gdynia Tel : +48 58 782 06 55 Fax: +48 58 782 06 56
SOUTHERN EUROPE
ITALY
Genova Tel: +39 010 749 391 Fax: +39 010 749 3950
CROATIA
Rijeka Tel: +38 5515 00100 Fax: +38 5515 00101
GREECE
Piraeus Tel: +30 210 4599 688 Fax: +30 210 4599 687
SPAIN
Tarragona Tel: +34 977 296 444 Fax: +34 977 296 450
ASIA PACIFIC
AUSTRALIA
Melbourne Tel: +61 3 9873 0988 Fax: +61 3 9873 0866
Sydney (Naval) Tel: +61 2 9325 1333 Fax: +61 2 9325 1300
Perth Tel: +61 8 9336 7910 Fax: +61 8 9336 7920
INDIA
Mumbai Tel: +91 22 6640 3838 Fax: +91 22 5640 3818
SINGAPORE
Singapore Tel: +65 659 48 150 Fax: +65 659 48 199
UNITED ARAB EMIRATES
Dubai Tel: +971 4883 3881 Fax: +971 4883 3882
MALAYSIA
Kuala Lumpur (Naval) Tel: +60 3 2096 1990 Fax: +60 3 2095 7990
NORTHEAST ASIA
CHINA
Dalian Tel: +86 411 8230 5198 Fax: +86 411 230 8448
Shanghai (Sales and Services) Tel: +86 21 5818 8899 Fax: +86 21 5382 5793
Shanghai Tel: +86 21 5116 7247/7221 Fax: +86 21 5116 7288/7292
Hong Kong Tel: +852 2526 6937 Fax: +852 2868 5344
JAPAN
Tokyo Tel: +81 3 3237 6861 Fax: +81 3 3237 6846
KOREA
Busan Tel: +82 51 83 14 100 Fax: +82 51 83 14 101
RUSSIA
Vladivostok Tel: +7 4232 495 484 Fax: +7 4232 495 484
AMERICAS
BRAZIL
Rio de Janeiro Tel: +55 21 3860 8787 Fax: +55 21 3860 4410
Rio de Janeiro (Naval) Tel: +55 21 2277 0100 Fax: +55 21 2277 0186
CANADA
Halifax Tel: +1 90 24 68 28 83 Fax: +1 90 24 68 27 59
Vancouver (Propulsion) Tel: +1 60 49 42 11 00 Fax: +1 60 49 42 11 25
St. John’s Tel: +1 709 364 3053 Fax: +1 709 364 3054
CHILE
Santiago Tel: +56 2 586 4700 Fax: +56 2 586 4705
USA
Annapolis (Naval Marine Inc) Tel: +1 410 224 2130 Fax: +1 410 266 6721
Houston Tel: +1 28102300 Fax: +1 281 902 3301
Miramar Tel: +1 954 436 7100 Fax: +1 954 436 7101
New Orleans
Seattle
Tel: +1 504 464 4561
Tel: +1 206 782 9190
Fax: +1 504 464 4565
Fax: +1 206 782 0176 9
Pascagoula (Foundry-Naval Tel: +1 228 762 0728 Fax: +1 228 769 7048
Marine Inc)
Walpole (Naval Marine Inc) Tel: +1 508 668 96 10 Fax: +1 508 668 2497
Washington (Naval Marine Inc) Tel: +1 703 834 1700 Fax: +1 703 709 6086
10
Revision: A
Spare Parts
10
Note: It is very important that you are connected to ground before touching any
electronic components or printed circuit boards.
Note: During the inspection a representative for the vessel should be present.
The vessel representative must be informed if any damage is found during
the inspection.
A damage report, listing damages found and possibly including pictures of the damaged
parts, should be produced. The report must then be sent to Rolls-Royce immediately. 10
11
Revision: A
Tools
1 General
This chapter lists required and recommended tools for installation and maintenance
purposes.
Note: Tools required for maintaining subsuppliers equipment are not listed in
this chapter. Please refer to chapter 14 Subsuppliers Manuals for details.
For maintenance and/or replacement of the sensors and position reference systems, the
separate manual from each manufacturer must be used.
2 Tools
Caution: Always use appropriate tools for all maintenance tasks. Use of
inappropriate tools can lead to system malfunction.
12
Revision: A
Design Drawings
1 General
A complete set of design drawings for the delivered system can be found in the
Appendix.
12
13
Copyright © 2010 Rolls-Royce plc
The content of this document is the property of Rolls-Royce plc and may not be redistributed in whole or in part thereof without
Doc. No.: 13S000411
express written consent of Rolls-Royce plc. Revision: A
Doc. No.: 13S000411 Copyright © 2010 Rolls-Royce plc
Revision: A
Revision
1 Revision History
This chapter specifies the revision history for the complete manual. If only one version
exists, the revision history table is omitted.
For descriptions of this manual’s contents, see chapter 1 Introduction.
13
Doc. No.: 13S000411 Copyright © 2010 Rolls-Royce plc Page 3 of 4
Revision: A
Revision
14
Doc. No.: 13S000411 Copyright © 2010 Rolls-Royce plc
Revision: A
Subsuppliers Manuals
1 General
This chapter contains customer documentation for equipment that is part of the Rolls-
Royce Marine's scope of supply, but not covered by the Installation Manual or the User
Manual.
In case of documents consisting of excerpts from the subsuppliers original
documentation, this has been made by Rolls-Royce with the expressed consent of each
subsupplier. If any doubts regarding a specific excerpt, please refer to the complete
manual from the subsupplier.
14
Subsuppliers Manuals