OBIS NORIS Automation GmbE Friedrich Bamowitz St. 10 [D-18119 Rostock Tet: 0981-5109440 * Fox: 0381-5190444 Mal: design@nots-automation de Remote control system for ships propulsion plants NORISTAR 2000 Technical description .___ General information ‘The NORISTAR 2000 system is desi marine propulsion plants, specifically Controllable pitch propellers Clutch contro! Reverse/reduction gear igned to provide automatic open-loop and closed-loop control of for the control of: NORISTAR 2000- C providing control of a proportional action way valve NORISTAR 2000- K Providing control of clutches /gears NORISTAR 2000- G providing control of a speed controller The system is type-tested to GL, LRS, ABS (PDA), RINA and BV and meets class requirements according to AUT24 and UMS. 4.__ Technical data Main supply: Battery supply: Operating temperature: Degree of protection: Vibrations: Inputs and outputs Central unit PS4-341-MM1 24v DC 24V DC +30)- 25% non-interruptible 0-70°C GL: Environment C IP 20/ with cubicle IP 55 0.79 2 analog inputs 4 analog output 16 binary inputs 14 binary transistor outputs Dec. expansion board EM4-101-AA2 8 analog inputs (B pes.) 4 analog outputs Dec. expansion board EM4-201-DX2 16 binary inputs pes.) Local expansion board LE4-116-XD1 (3 pes.) Signal forms Input voltage Input current Output voltage Load capacity of binary outputs 31.01.06 NORISTAR 2 16 binary transistor outputs o-5v 0-10v 41-5 41-10 0 (4)-20mA 0-10V +1 10V 1<05A 1000, Z.-Ne. 074,033. (Nb. 228-233 / ENVC) S18Frlodrich Bamewitz Str. 10 none ear pean ‘Tel: 0361-5199440 * Fax: 0381-5199444 Malt: [email protected] NORIS Automation GmbH 2 rk of the PLC components SERVICE DISPLAY MV4 Stang: 1 i 000 P54381.-MMi cut EM A101 AA2WO4 cu2 4.20 EMA101-AA2wes ECR DI 1.30 E4201 DX2 LEAT16x01 ECR D2 ECR D3 140 EM#-101-AAQW BRIDI 50 4 151 152 EM4-201-Dx2 LEATIEXDT —_LE@T08xAT BRI 02 BRIDS RIDA 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 8.218Friedrich Bamowite Str. 10 NORIS: 0.18119 Rostock Tel: 0381-5199440 * Fax: 0981-5190448 Mal: design@noris-sutomation de NORIS Automation GmbH 3.___ Physical design Physical layout of remote control components ‘The system has two power supplies, main supply and batterie supply, and both supplies are controlled by ship alarm system. Located in the central contro! cubicle in the ECR is the storage-programmable control system (PLC) consisting of the PS4-341-MM102 central unit with the ZB4-901-SF2 EEPROM and the decentralized expansion board EM4-101-AA2 mounted on the chassis. The control program is stored in the central unit, both in the battery-backed RAM and in the EEPROM. Aso fitted in the door of this cubicle is the MV4 service panel. A local control box is located in the engine room. This cubicle include the pitch control and the pitch ‘measurement system. Mounted in the ECR console are the decentralised and local expansion boards EM4-101-AA2, EM4- 201-DX2 and the LE4-116-XD1 mounted on a chassis. Mounted in the bridge console are the decentralised and local expansion boards EMé-101-AA2, EM4-201-DX2 and 2 pos. of LE4-116-XD1 mounted in a box. ‘The maximum possible inputs and outputs are indicated in Section 1. In reading-in and outputting of the analog signals it is necessary to note a few special points that influence the formatting by parameters for programming, A type LOGO (Siemens) mini-controller serves for back-up control, itis also located in the central control cubicle in the ECR. 3 Panels The equipment scope includes a total of five panels for installation in the ECR console, in the Bridge console and at the port and starboard wings, as well as an MV4 service panel in the door of the ECR control cubicle. In addition to the control levers, the operator panels include all necessary controls and indicating instruments for the operating of the vessel. ‘The MV4 service panel is located in the engine control room (ECR) and connected by means of cables with the SUCOM-A interface (RS 232 C) of the SPC. The panel provides comprehensive {acilties for the commissioning and diagnosis of the equipment. Functions p and transfer of control between control positions. After turning on the power supply, the control system takes 10 to 15 s for initialisation. This involves reading out of all parameters from the EEPROM and providing them in the RAM both for programming and also for the service panel, If the LOCALIREMOTE selector in the door of the local contro! cubicle is set at LOCAL and the engine is also in LOCAL, the system cannot be operated from any control position. Moving the selector to REMOTE causes the transfer to be prepared for. Depending on the requirements of the manufacturers of the engine and controllable pitch propeller equipment, an interchange of binary signals takes place which, when completed, results in the REMOTE CONTROL ACTIVE signal being issued Depending on the position of the ECR/BRIDGE selector, transfer of control is offered visually and audibly to the ECR or to the control position on the Bridge. On the panel of the control position selected, the HORN will be sounded and the control position lamp (ECR, BRIDGE) as well as the TAKE OVER lamp will be flashing. On the panels of the non-offered control positions, the indicating lamps of the offered control position will be flashing. The transfer is effected by the TAKE OVER button if the control lever is at neutral. The TAKE OVER lamp will go out, the control position lamp (ECR or BRIDGE) will change to steady light and the HORN will be silenced. The previously offered Control position will now be active. The active control position will also be indicated at the inactive control_positions. Upon control having been transferred to a Bridge control position, the MANOEUVRING program will be activated at the same time. 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 8.38Friedich Bamowite St. 10 -18119 Rostock “Tel: 0361-5100440 * Fax: 0361-5190444 Mal: desigri@nors-automation de NORIS Automation GmbH If transfer of control is by means of the ECRIBRIDGE selector from an already active control position (ECR or BRIDGE), the only difference from the procedure described above is that control lever synchronism has to be established between the active and offered control positions and in that the active control position remains active until the selected control position has completed the transfer. The control position lamps will indicate the status on all three panels: The lamps of the offered control position will be flashing, the lamps of the active control position will show steady light. Instant transfer of control between the three bridge control positions is possible by pressing the respective TAKE OVER button, provided lever synchronism exists. The associated TAKE OVER lamp will then show steady light. Falling lever synchronism, this lamp will continue flashing after pressing the button until lever synchronism has been established. It will then change to steady light. The active wing control position is shown on the bridge console. Operation If the ECR is the active contro! position, settings of the speed setpoint from idling to maximum. speed (100%) is possible via a potentiometer. With the shaft generator cut in or CONST. SPEED. MODE preselected, the speed setpoint will be 100%. The pitch setpoint is selected from -100% to +100% by means of the control lever. There is no operation program not active so that the pitch setpoint follows the control lever practically in synchronism, If the Bridge is the active control position, conversion of the control lever position into a load value is time-dependent according to the selected operation program (SAILING PROGRAM / MANOEUVR. PROGRAM). Selection of the mode is by means of the program push buttons in the BRIDGE console. This status is displayed at BRIDGE console. In the COMBINATOR MODE (no CONST. SPEED MODE indicated), the load value is converted into a speed setpoint and pitch setpoint value according to the two Combinator curves for speed and pitch. Selection of the MODE is by means of the selector switch on the ECR or BRIDGE console. Switch OFF means COMBINATOR MODE, switch ON means CONST. SPEED MODE. This status is displayed at all control positions. With the shaft generator cut in or CONST. SPEED MODE preselected, the speed setpoint will be 100%. The load value will then also be converted into a pitch setpoint according to another Combinator curve. A load controller (P!-controller) is provided and programmed to protect the engine from overloading, This controller acts to reduce the manipulated variable (pitch setpoint) if the actual engine injection rate exceeds @ setpoint. In the COMBINATOR MODE, this setpoint is provided by the injection limit curve from the actual engine speed and, in the CONST. SPEED MODE, by an empirically parameterisable fixed value, seeing that it is necessary to avoid speed drops because of the shaft generator that may be running. The setpoint is limited by the CHIEF LIMIT potentiometer setting (100% down to 60%) or respectively SLOW DOWN (overriding action). AAI individual. errors of the PLC are combined in a group error signal to be fed to the ship alarm system. According to the error category, the safety system can intervene by means of a SLOW DOWN binary signal (reducing to +/-60%) or a SHUT DOWN (EMERGENCY OFF) binary signal ‘The error analysis is to be performed on the service display MV4 in the central unit. ‘An additional display is provided by means of LED indications of binary outputs on the central unit. For this purpose, open the control cubicle in the ECR and check the bottom left row of green LEDs on the unit D1. The meanings of these LEDs are as follows: Fromieft 1" LED ‘group error (ON is ok.) 5" to-8" LED error code (alternating ON/OFF is ok.) All error codes are scanned once every second. If no error exists, scanning will proceed without any interruption. If an error occurs, the 1* LED will go out and the scan will stop at the corresponding error code. Continuation of the scan can be enforced by applying a 24 V pulse to the 0.8 input (9” connection at top). The scan will then again stop at the next existing error with the associated code. 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 8.48rm sao 5.10 NORIS crea ere raseasngnts scence NORIS Automation GmbH The error codes mean: 1 — LED on, o- LED off, - ~ LED on or off o- 0000 Error analog inputs (actual load, speed, pitch, pitch back-up) o- 1000 Error analog inputs ECR (lever pitch, poti speed, chief limit) o- 0100 Error analog inputs BRIDGE (levers bridge, wing port, wing stbd) o- 1100 Error pitch (setting and actual difference) o- ooto Error date synchronisation o- toto Error parameter transmission o- otto Error central unit (memory card, power supply) o- 1110 Error decentralised expansion boards o- ooo Error local expansion boards o- toot Error SG 2000 o- otot Error analog output pitch setting o- 1101 Error analog output speed setting o- oot (not used) o- 1o1t (not used) In case of errors of the central unit and/or expansion boards, acknowledgement is necessary on the central unit after errors have been removed. To this end, open the door in the right-hand part of the central unit and operate the small switch at the top right once, Special attention should be drawn to errors in the bus connections between the PS4-341-MM102 central unit and the local expansion boards. A faulty bus connection may be restored only with the system deenergized. If the SPC should require a battery change, this should be carried out with the control system on by trained personnel. Any change of the EEPROM must also be carried out only by trained personnel but in this case it is absolutely necessary that the control system be deenergised. Back-up control In emergency situations, it is possible - and if any faults should occur in the remote contro! system, it is necessary - to change to back-up control on the panel of the active control position. NOTE: Constant speed (100%) will be instantly provided as a fixed default setting for the speed setpoint. Initially, the current pitch setpoint is accepted unchanged. A change in pitch is possible with back-up control active by means of the PITCH AHEAD / ASTERN buttons. Remote control and the control position are no longer active in the automatic mode, but the control position will continue to be identified by its lamp showing steady/flashing light. Before restoration of remote control and transfer to the control position indicated, it necessary to move the control lever at the indicated control position to correspond to the actual pitch in order to ensure bumpless transfer of the pitch. The speed setpoint is provided by the lever value selected or, respectively, constant speed. Restoration and transfer aro effected by pressing the TAKE OVER button on the operator panel. As a result, back-up control will no longer be active. Changing the control position from Bridge to ECR or vice versa is also possible with back-up control active by operating the ECR/BRIDGE selector. The control position now selected indicated by means of the lamp. Reactivation of remote control and transfer of control to the control position displayed are effected as described above. 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 8.518Feedrich Barmovntz Str. 10 -18119 Rostock “Tel: 0381-5109440 ° Fax: 0387-5190444 Nail: [email protected] 5.__MV4 panel 5.1, Function and page layout The versatile, multilanguage (black-and-white) display serves to visualise signals and operating statuses as well as to change any parameters that are important for the commissioning, maintenance ‘and operation of the equipment. In addition, it is used for fault identification. Using the internal error logic, the display shows operating statuses, error conditions and alarms in clear text. layout ‘The indications of dateitime and user rights as well as the START and MENU and FORWARD / BACKWARD ARROWS are provided on each page. Loy - Start screen Date/time, picture of vessel, plant description, name and address of NORIS company, start buttor Level 4: = Selection Buttons for dateltime, display, language, parameters, service + commissioning, alarm list, rend, login/logout, ? (help), Graph Level 2: Page 3.1.: - System settings Settings of date/time, change winter/surnmer time, boot display (warm start) Page 3.2: Display settings Contrast adjustment, brightness adjustment; Page 3.3: - Language setting ‘System languages are German, English, French, Spanish, Italian, User's; Page 3.4: - Display of parameter settings Buttons for control lever calibration, calibration of engine/propeller inputs, calibration of engine/propeller outputs, operation programs, Combinator mode, constant mode, limiter, load control, pitch control, monitoring parameters, storing parameters Page 3.5.1. - Service + commissioning Password entry for operator, service and supervisor; Page 3.5.2.: _- Display of parameter settings (corresponds to page 3.4) Page 3.6. - Alarm list Individual alarm acknowledgement, change-over of currenthhistorical alarms, acknowledgement of all alarms; Page 3.7. - Trend display Page 3.8: - Password entry (corresponds to page 3.5.1.) Page 3.9. - Project information Page 3.10.: - Graph information Level 3: P.3.4.1.12 -Service/control lever calibration Control lever for pitch_bridge, control lever for pitch_wing_port; P.3.4.1.2: - Service/control lever calibration Control lever for pitch_wing_starboard, Poti for pitch_ER; P.3.4.4.3: - Servicelcontrol lever calibration Poti speed_ER, Chief limiter_ER P.3.4.2.1: — - Service/analog inputs ‘Speed characteristic, injection rate characteristic; P.342.2: — - Service/analog inputs Characteristic chief limitation; P.3423: — - Service/analog inputs Characteristic pitch_actual, characteristic pitch_back-up; P3.4.3. - Service/analog outputs ‘Analog output of pitch_desired, analog output of speed_desired: P.3.4.4.112.: = Serviceloperation programs Sailing program (ahead/astern increase/deorease speed); 31.01.06 NORIS TAR 2000, 2 Nr. 074.033, (Nb. 228-233 / ENV) 8.68etch Bat St. 10 Shas cones NOBIS Foto Sito Fr oa stouee Si Seoangrone toner So NORIS Automation GmbH P.3.4.4.3/4.: ~ Serviceloperation programs Manoeuvring program (ahead/astern increase/decrease speed); P.3.4.5.12.: - Service/Combinator mode Loadispeed, load/pitch; P.3.4.6.1/2.: _- Service/constant mode Load/pitch, constant speed value, overload response time; P.3.4.7. = Servicellimiter Increment pitchispeed; P.3.4.8.1-4.: - Service/load control Increase without overload, decrease with overload, slow-down, load limit at n=const., load limit curve; P.3.49. = Service/pitch control Parameters of pitch controller, calibration of control edges; P.3.4.10.1.-3: - Analog input, analog outputs. Overview of analog values; P.3.4.11.1: — - Storage of parameters Buttons for storage: parameter range_0 to parameter range_6; Manipulation Changing between levels/pages: Touching the START button on the start page brings up the next lower level of the display. By entering the appropriate password, access is authorised to change the appropriate parameters. Without entering the password, access to the pages is read-only. The other levels of the display can be accessed by touching the appropriate button. The MENU button or the ARROW LEFT button provide access either to the selected level or the next higher level. Where there are several pages per level, itis possible to have other pages of the level displayed by means of the ARROW RIGHT or ARROW LEFT buttons. In the displays of the operation programs, arrows are placed between the columns of the X and Y parameters. Arrows from 0 to +/- mean increase speed ahead/astern, arrows from +/- to 0 mean decrease speed ahead/astern. Parameter changes: Changes to the parameters will directly affect the SPC program flow and must not be made except on instruction of the service personnel or by the latter themselves. 5.3. Parameter setting 1g pitch_bridge control lever: = Perform LOGIN with password. - Select Controt lever calibration, pitch_bridge control lever page. Move control lever to neutral - Read upper momentary value and enter against calibr. 0 %. = Move control lever right back. - Read upper momentary value and enter against calibr. -100 %. = Move control lever right forward. Read upper momentary value and enter against calibr. 100 %, Generally the y-values will not be changed Setting pitch analog input: = Perform LOGIN with password, - Select Calibration engine/propeller inputs page. - Decrease pitch by means of potentiometer in ER to minimum. - Read momentary value and enter against calibr. ~100%, - _ Increase pitch by means of potentiometer in ER to maximum. - Read momentary value and enter against calibr. +100%. 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 8.718Friedrich Bamowitz St. 10 18119 Rostock Toi: 0381-5198440 * Fax: 0381-5198444 Mal: designg@nors-aulomation de NORIS Automation GmbH = Calculate mean of the two values and enter against calibr. 0% (zero pitch). = Since zero thrust is a more important criterion for the correct setting, it is necessary to reduce pitch to zero and to observe the propeller wake. The value entered against cal corrected (mostly upward, say from 2000 to 2200) until no propeller wake is vi Generally, the y-values will not be changed. Setting the speed analog input: = Perform LOGIN = Select Calibration engine/propelier inputs page. = Decrease speed by means of potentiometer in ER to minimum. = Read momentary value and enter against calibr. 0%, Increase speed by means of potentiometer in ER to maximum. Read momentary value and enter against calibr. +100%. Generally, the y-values will not be changed Calibration of control edges for pitch adjustment: - Perform LOGIN with password. - Select Pitch control page. = Set AHEAD/RIGHT button to ON. - Increase parameter in steps from 0% until change in pitch takes place. = Set AHEADIRIGHT button to OFF. - Set ASTERN/LEFT button to ON. - Increase parameter in stops from 0% until a change in pitch takes place. = Set ASTERNILEFT button to OFF. ‘After the change has been made, the parameters are at once contained in the RAM of the SPC and, consequently, effective in the program. In order to have them available after shutdown again for the next startup of the control system, itis necessary to store them in the EEPROM (MC memory card). To do so, select the Store parameters page and operate the button of the storage area. Any error made during storing willbe displayed and the storing operation will then have to be repeated. Final remarks All parameters calibrated and set during commissioning are recorded and the date stated in a data sheet. Any change to the parameters should be recorded in the data sheet in order to to be able to restore the previous status in the event of any loss or wrong setting of parameters. Enclosures Data sheets for parameter setting 31.01.06 NORISTAR 2000, Z.-Nr. 074.033. (Nb. 228-233 / ENVC) 5.88