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Maintenance Instructions

Page 5 of 22

Doc. No.: 13S000411
Revision: A

4.2

Replacing a Lever

To replace a lever, proceed as following:
1.

Loosen the screws (1).

2.  Carefully pull the lever straight up from the top of where it is mounted.
3.  Unplug the CAN and power connector (3) from the bottom of the operator device.
4.  Set the addresses on the node address switches (2) on the new operator device

identical to the device, being replaced.

5. Mount the new operator device in reverse order.
6.

Calibrate all operator devices on the operator station where the operator device has

been replaced, see chapter

7.6 Functions

Pos

Component

Screws

Address switches

CAN and power connector

Summary of Contents for Helicon X3

Page 1: ...s supplied without the express written consent of Rolls Royce Marine plc This information is given in good faith based upon the latest information available to Rolls Royce plc no warranty or represent...

Page 2: ......

Page 3: ...e property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 1 Doc No 13S000411 Revision A Introduction 1 Purpose 3 2 Warra...

Page 5: ...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 Dat...

Page 6: ...ne Dept Propulsion Ulsteinvik or qualified service engineers from Rolls Royce Marine Global Support Network GSN 5 Terms and Abbreviations Abbreviation or term Description AC DC Alternating Current Dir...

Page 9: ...or in part thereof without express written consent of Rolls Royce plc 2 Doc No 13S000411 Revision A Safety 1 Introduction 3 2 Disclaimer 3 3 Safety Instructions 4 3 1 Safety Functions 4 3 1 1 Pitch Co...

Page 11: ...ordance 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 precaut...

Page 12: ...rating 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 Not...

Page 13: ...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 4 Dynpos and Joystick If operating using an external Dynpos o...

Page 14: ...k 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 per...

Page 15: ...ol 10 4 1 1 Normal Control 11 4 1 2 Backup Control 11 4 1 3 Backup Control Operation 11 4 1 4 Backup Control Limitations 11 4 1 5 Local Control 11 4 1 6 Pitch Indication 12 4 1 7 Pitch Order Scaling 1...

Page 17: ...ded 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 conditi...

Page 18: ...ons 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 le...

Page 19: ...is for dimming the illumination of the LCD display The screen is divided in two areas a menu area in the left part of the screen and a bigger command area to the right The menu buttons to the left sel...

Page 20: ...s 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 p...

Page 21: ...is used for dimming the background light on the indicators situated on the same control station The dimmer may be delivered in a separate panel if the emergency stop buttons are not part of the delive...

Page 22: ...inet 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...

Page 23: ...Royce Marine Controller Backup 3 I O modules 4 Power distribution 5 Network switches and terminals 6 Signal isolation amplifiers optional 7 Power Distribution 8 Main power supply AC fuses 9 Backup pow...

Page 24: ...l Functions The control functions included in the Tunnel Thruster Control system Pitch control Command transfer Main Propulsion Azimuth Control Functions The control functions included in the Main Pro...

Page 25: ...lure alarm will be actuated at the manoeuvre stations 4 1 3 Backup Control Operation If a failure occurs on important parts of the Normal Control for the Pitch Azimuth or RPM Control function the cont...

Page 26: ...er then the thruster azimuth servo can follow 4 2 Thruster Azimuth Control The azimuth control function is to obtain the correct thruster azimuth position in accordance to the control lever order Valv...

Page 27: ...the Backup Control an audible and visible alarm will be activated on each of the control panels 4 2 4 Backup Control Limitations The backup control system has only interface to the control levers The...

Page 28: ...4 3 3 RPM Order Output The output signal from the controller is scaled to meet the actuator signal range from idle to full rpm and then fed to external governor IP converter or frequency converter Th...

Page 29: ...tion The Rolls Royce Company Identification sticker shows where the product has been produced and is found on discrete places on all delivered items e g on the inside of the cabinet doors Figure 4 Com...

Page 31: ...content of this document is the property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 4 Doc No 13S000411 Revision A D...

Page 33: ...lls Royce plc 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 i...

Page 35: ...0136_UT535E_Brasil _V2 Page 1 of 14 Technical Specification Propulsion Thruster Control System Project no 20 12 00136 Version Vessel type design UT535E Customer Project no RRM STO P12 7210 Shipowner S...

Page 36: ...ENERAL 3 01 00 SCOPE OF SUPPLY TECHNICAL DESCRIPTION 5 01 01 System Overview 5 01 02 Description of equipment common for all propulsion units 6 Control Stations 6 Control panel functions 7 Control lev...

Page 37: ...his specification Equipment not supplied Scope of supply is defined in the technical specification Not included in scope of supply are External cabling Cable glands 24 V DC power supply Technical info...

Page 38: ...ponsibility However cable type recommendations are given in the diagrams and mounting instructions Installation inspection starting up and seatrial Installation of the propulsion remote control system...

Page 39: ...upply technical description 01 01 System Overview The Propulsion Thruster control system is a microprocessor based system Following main functions are included Speed control allowing accurate and reli...

Page 40: ...high resolution colour display with touch screen interface and built in display computer Indicator panel in overhead console 2 pcs Pitch indicator 2 pcs Propeller RPM indicator 2 pcs Steering indicato...

Page 41: ...l pages these will replace the overview area The short cut area will remain available from all pages Thruster page information is project dependent Below are typical examples of each propeller thruste...

Page 42: ...ridge 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...

Page 43: ...communication with control panels I O cards DI DO AI AO serial line interfaces Circuitry monitoring w alarm output Indication circuitry Cable termination Power Supply requirement Main supply 230 VAC...

Page 44: ...to the frequency converter Closed stop pulse Emergency Stop Frequency Converter Potential free contact to the frequency converter Closed stop pulse Loop monitored in Frequency Converter resistors in e...

Page 45: ...y for JOYSTICK Remote control acknowledge of JOYSTICK mode Propeller RPM feedback signal Steering feedback signal Power reduced signal Autopilot interface The remote control is provided with interface...

Page 46: ...The electronic unit contains the following Power supply Application CPUs Main and backup including flash memory CAN fieldbus Ethernet communication with control panels I O cards DI DO AI AO serial lin...

Page 47: ...als 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...

Page 48: ...potential free to engage the JOYSTICK mode From selector switch Request for control Pitch control signal Signals available to the JOYSTICK system Remote control is ready for JOYSTICK Remote control a...

Page 49: ...yce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 5 Doc No 13S000411 Revision A Technical Data 1 General 3 2 Environmental Data 4 3 El...

Page 51: ...n 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...

Page 52: ...mited 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...

Page 53: ...e 11 3 8 Separate Common Lever 12 3 9 Autopilot 12 3 9 1 Enabling Disabling Autopilot 12 3 9 2 Automatic Autopilot Disengage 13 4 Alarm 13 4 1 Silence 14 4 1 1 Alternative 1 14 4 1 2 Alternative 2 14...

Page 55: ...equipment please refer to chapter 2 Safety for the general statement safety and warnings instructions 2 Controlling the thrusters There are three ways of controlling the thrusters with Helicon X3 Con...

Page 56: ...e plc Figure 1 Example on an Overview of propulsion unit functions Pos Marking Symbol Thruster Function 1 STBD MP Main propulsion Pitch RPM rudder feedback 2 STERN Tunnel Thruster FP RPM power feedbac...

Page 57: ...4 BOWAZ 1 Azimuth Pitch RPM direction Power feedback 5 PORT MP Main propulsion Pitch RPM rudder feedback 6 STERN 2 Tunnel Thruster FP RPM power feedback 7 BOWAZ 2 Azimuth Pitch RPM direction power fe...

Page 58: ...erating Instructions Page 6 of 22 Doc No 13S000411 Revision A Copyright 2010 Rolls Royce plc Figure 2 Screenshot of a typical Azimuth thruster page Figure 3 Screenshot of a typical Tunnel thruster pag...

Page 59: ...uctions 6 Page 7 of 22 Doc No 13S000411 Revision A Copyright 2010 Rolls Royce plc Figure 4 Screenshot of a typical Shaft line as main propulsion page Figure 5 Screenshot of a typical Azipull as main p...

Page 60: ...r pages contain all information and functions available for the tunnel thruster 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...

Page 61: ...regulate rpm to continuously hold a specific load on the main switchboard This mode is mainly meant for transit This mode will automatically be disabled if DP or Joystick is enabled Power mode will a...

Page 62: ...re it is possible to start the thruster the following must be fulfilled The manoeuvre station must be In Command The pump must be running The pitch must be below 10 1 Press the thruster Start button 2...

Page 63: ...3 The thruster is stopped when the Stop button turns steady red 3 7 Reset Drive Reset drive can be performed either form a manoeuvre station In Command or from the ECR panel PC 1 Press the Reset Drive...

Page 64: ...uvre station must be In Command 1 Press the Separate Lever button 2 To confirm press the Accept button within 10 seconds when it starts to flash 3 The main propulsion thrusters will now have separate...

Page 65: ...ngage 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...

Page 66: ...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 S...

Page 67: ...button colour changes to grey 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...

Page 68: ...ty in different light conditions 5 Steering the Ship with Azimuth Thrusters 5 1 Position Keeping The symbol of steering diagrams Azimuth thruster Combilever thrust RPM and direction Basic starting and...

Page 69: ...r straight ahead Turn port side using one thruster It s recommended to use the port side thruster since the starboard thruster then helps the turn by pushing from outside corner Turn port side using b...

Page 70: ...degrees The correct rotational direction for each thruster is shown in the figure below 2 When thruster is turned 90 degrees outward increase the power rpm order to maximum and continue to turn the th...

Page 71: ...ful not to overload the engine or propeller system Note Load control system handled by the frequency converter drive system shall not be affected by changes in operation mode for the remote control sy...

Page 72: ...to change steering direction angle Observe the gyro repeater or direction indicator at UNIT 10 or mechanical indicator and establish communication with bridge The maximum steering angle is limited to...

Page 73: ...Backup Control actual feedback should be read from the separate indicators normally mounted in overhead console NOT from the touch screen panels The Backup Control system does not have interface to e...

Page 75: ...ever Friction Adjustment 6 4 4 Azimuth Lever Friction Adjustment 6 4 5 Replacing the Display 7 4 6 Fuses 9 4 7 Replacing the Power Supplies 9 4 8 Replacing a Viewcon Switch 10 4 9 Replacing the Marine...

Page 77: ...se circuit breaker see chapter 12 Design Drawings Do not attempt to repair any sub component yourself consult a qualified Rolls Royce service technician A serious electrical shock hazard exists within...

Page 78: ...ean the inside the cabinet using a soft anti static cloth and a non abrasive cleaning agent Do not use vacuum cleaners nearby electronic components due to the risk of electrostatic discharge ESD Use c...

Page 79: ...unted 3 Unplug the CAN and power connector 3 from the bottom of the operator device 4 Set the addresses on the node address switches 2 on the new operator device identical to the device being replaced...

Page 80: ...ed as following 1 Remove the cover on the side of the lever 2 Adjust the pitch rpm lever friction with the screw 2 3 Adjust the zero detent force with the screw 1 4 Put the cover back again 4 4 Azimut...

Page 81: ...necessary software and configuration files to set up the new display 2 Unplug the following Ethernet cable s 2 24 VDC power supply connector 3 3 Loosen the four screws 4 on the bracket and remove the...

Page 82: ...tool application 10 The software and configuration will now be loaded into the display s memory When finished a confirmation message will appear Press OK and then Shut down Caution Do not switch off...

Page 83: ...h a new with matching data 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 4 7 Repla...

Page 84: ...nd optical fibre cables if applicable 4 Remove the switch from the rail 5 Fit and connect a new switch in reverse order 4 9 Replacing the Marine Controller Pos Component 1 Power supply cable 2 Compact...

Page 85: ...d the controller in place and remove the controller 6 Insert the Compact Flash memory in the new controller unit 7 Fit and connect the new controller in reverse order 4 10 Replacing a CAN I O Module T...

Page 86: ...d 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 4 11 Replacing a Local Ethernet Switch In the UN1 Electron...

Page 87: ...o 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...

Page 88: ...b 3 Choose the controller you want to enter in DP host 4 Enter username ecr 5 Enter password hcx 6 Click login button Figure 3 Hidden icon Note After 15 minutes of inactivity a new login is necessary...

Page 89: ...s 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 Se...

Page 90: ...desired signal from the list e g Pitch_Feedback 5 Press the Goto button The scaling adjustments can be set manually or automatically Which method to use depends on the application In our example we h...

Page 92: ...ler 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 Eng...

Page 93: ...rent 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 co...

Page 94: ...calibrated then the analog cosine input signal is calibrated and at last the zero lever position is set 1 Enter the CDP tool and log in to the relevant Normal Controller 2 Select the AzimuthOrder func...

Page 95: ...zimuth_Lever_Invert_Bridge_X where X represents the bridge number 1 to 5 14 Close the window and log out of the Normal controller 15 Repeat the procedure for the corresponding Backup controller 6 1 3...

Page 97: ...Rolls Royce plc 8 Doc No 13S000411 Revision A Trouble Shooting 1 General 3 2 Alarms 4 2 1 General 4 2 2 Lever Alarms 5 2 3 Steering Gear 7 2 4 Feedback Signal Alarms 8 2 5 Deviation Surveillance Alar...

Page 99: ...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 a...

Page 100: ...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 freq...

Page 101: ...ation Replace Lever Contact RR service dept PORT MP NC Azimuth Lever Sin Bridge 5 Cause Azimuth direction order pot In Slave Bridge Lever failure Effect No Azimuth Normal control from Bridge 5 Action...

Page 102: ...erate in Backup control or from other control station Replace Lever Contact RR service dept PORT MP NC Pitch Lever Bridge 5 Cause Pitch order potentiometer in Slave bridge Lever failure Effect No Pitc...

Page 103: ...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 Effect Depending on error co...

Page 104: ...NC Pitch Feedback Clutch 1 2 Cause Pitch feedback potentiometer failure Effect No Normal control automatic change to Backup control Action Operate in Backup control Check connections replace potentio...

Page 105: ...from control system Action Stop using thruster check thruster mechanical manual PORT MP NC Azimuth Deviation Alarm Cause Hydraulic Mechanical failure in azimuth servo mechanism Effect Azimuth not mov...

Page 106: ...se Effect and Action PORT MP NC 220 Volt Failure U3 Cause 220V AC Main supply failure Effect Control system operate as normal Action Check connections and fuse System still fully operational with 24V...

Page 107: ...use Azimuth Order signal from Joystick system failure Effect Not possible to operate thruster from Joystick Action Identify if error is in Joystick output or on HCX3 input or in cabling PORT MP NC Azi...

Page 108: ...cabling PORT MP NC Load Generator 2 Cause Load signal from Generator 2 Current power feedback failure Effect If generator protection included in lad control Load control stop working If only used for...

Page 109: ...yce plc PORT MP NC Vessel Speed Log Cause Vessel speed signal from speed log failure Effect Alarm warning on high and low speed according to selected mode Transit Man mode not working Action Operate t...

Page 110: ...le PORT MP NC RRAIO16 24 Error Cause RRAIO16 module with node address 24 M24 failure Effect Signals to from module not available Action Operate in Backup control check connections replace IO module PO...

Page 111: ...tion 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 Status Led Information Description Short On...

Page 113: ...f Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 9 Doc No 13S000411 Revision A Contact List 1 Contact Information 3 1 1 Rol...

Page 115: ...ine AS dept Propulsion Ulstein P O Box 1522 N 6025 lesund Norway Visiting address Rolls Royce Marine AS dept Propulsion Ulstein Sj gata 98 N 6065 Ulsteinvik Norway Tel 47 81 52 00 70 Fax 47 70 01 4014...

Page 116: ...ket Tel 44 1383 82 31 88 Fax 44 1383 82 40 38 Portsmouth Marine Electrical Systems Tel 44 23 9231 0000 Fax 44 23 9231 0001 POLAND Gdynia Tel 48 58 782 06 55 Fax 48 58 782 06 56 SOUTHERN EUROPE ITALY G...

Page 117: ...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 Jo...

Page 119: ...in whole or in part thereof without express written consent of Rolls Royce plc 10 Doc No 13S000411 Revision A Spare Parts 1 Ordering Spare Parts 3 1 1 Ordering Spare Parts Separately 3 1 2 Ordering S...

Page 121: ...ipped it is essential that each part is correctly specified in the order For part identification please refer to the parts ID in the design drawing documentation in chapter 12 Design Drawings of this...

Page 122: ...essential parts that in case of a failure may put the system out of operation until the faulty part is replaced The Helicon X3 spare parts kit is recommended to be carried onboard vessels that are off...

Page 123: ...o ground before touching any electronic components or printed circuit boards 3 2 Delivery Check Upon arrival of spare parts at the destination all items must be inspected The following steps are to be...

Page 125: ...cument is the property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 11 Doc No 13S000411 Revision A Tools 1 General 3 2...

Page 127: ...be used Note For maintenance on electronic equipment the use of electrostatic discharge protection such as a wrist band connected to a grounding point is mandatory A grounded surface is also recommend...

Page 129: ...The content of this document is the property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 12 Doc No 13S000411 Revision...

Page 131: ...Design Drawings 12 Page 3 of 4 Doc No 13S000411 Revision A Copyright 2010 Rolls Royce plc 1 General A complete set of design drawings for the delivered system can be found in the Appendix...

Page 133: ...he content of this document is the property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 13 Doc No 13S000411 Revision...

Page 135: ...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 ch...

Page 137: ...e content of this document is the property of Rolls Royce plc and may not be redistributed in whole or in part thereof without express written consent of Rolls Royce plc 14 Doc No 13S000411 Revision A...

Page 139: ...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...

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