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Instruction manual Estaleiro Promar Newb. No. : 12 Plant No.
: A-9067
Table of contents Warning and Cautions
818-842GB
1. Introduction Introduction Example how to use the instruction manual Questionnaire for instruction manual Table of contents
243-682 243-683 243-680
A
2. Technical specification Technical specification
3. Operating Instructions 3.1 Main System Instruction for use of warning signs Piping diagram Parts list Important Items Symbols for piping diagram Operation and maintenance of Hydraulic Deck Machinery The Hydraulic Power Transmission Lubrication instruction for open gears with Klüber lubricant Instruction lubrication pump towing drum Instruction lubrication pump anchor handling drum Instruction lubrication pump secondary winch lower unit instruction lubrication pump secondary winch upper unit
324-247 397-488 397-488-00
G D
331-093 UBR 21/92 UBR 13/90 414332 392-677-40 392-677-41 392-677-54 392-677-55
A
B
815-015 Rev. B Page1
User Instruction Towcon NT 200
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
815-015 Revision B
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page2
Issue number = A B
Reason for Change First issue Added information about wireguard alarm on page 56. Rewritten chapter 4.3 Using cable lifter.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page3
PREFACE ............................................................................................................................. 6 1
SYSTEM ........................................................................................................................ 7 1.1 System layout............................................................................................................................ 7 1.2 Workstation .............................................................................................................................. 8 1.3 Interface board......................................................................................................................... 9
2
USER CONTROLS ...................................................................................................... 10 2.1 CRT Monitor.......................................................................................................................... 10 2.2 Power Switch .......................................................................................................................... 10 2.3 Power on lamp........................................................................................................................ 10 2.4 Contrast Control .................................................................................................................... 10 2.5 Brightness Control ................................................................................................................. 10 2.6 Degaussing button.................................................................................................................. 10 2.7 Touch Screen .......................................................................................................................... 11 2.8 Screen adjustments ................................................................................................................ 11 2.8.1 Select button..................................................................................................................... 11 2.8.2 Functions with LED indicators ........................................................................................ 11 2.8.3 +/- Control........................................................................................................................ 11 2.8.4 Reset button ..................................................................................................................... 11 2.8.5 Cleaning the screen .......................................................................................................... 12
3
OPERATION................................................................................................................ 13 3.1 Using Trackball...................................................................................................................... 13 3.2 Using a Touchscreen .............................................................................................................. 14 3.3 Screen Elements ..................................................................................................................... 15 3.3.1 Folders, Tabs and Panels.................................................................................................. 15 3.3.2 System Panel .................................................................................................................... 16 3.3.3 Buttons and Lamps........................................................................................................... 17 3.3.4 Digital Displays................................................................................................................ 17 3.3.5 Bargraphs ......................................................................................................................... 18 3.3.6 Meters .............................................................................................................................. 18 3.3.7 Sliders .............................................................................................................................. 18
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page4
3.3.8 Popup Menus and Keypad ............................................................................................... 19 3.3.9 Night color / dimmer........................................................................................................ 20 3.4 The user menu .......................................................................................................................... 20 3.4.1 System info ...................................................................................................................... 20 3.4.2 Date / Time ...................................................................................................................... 21 3.4.3 Calibrate touch ................................................................................................................. 21 4
USING THE SYSTEM.................................................................................................. 22 4.1 Manual Operations .................................................................................................................. 22 4.1.1 Monitor Pictures for normal operations ........................................................................... 22 4.1.2 Preparing Operation ......................................................................................................... 23 4.1.3 Start of Hydraulic Pumps & Servo Units......................................................................... 23 4.1.4 Manual pay-out --- “Wire Length Limit”....................................................................... 26 4.1.5 Keeping the Towing Length --- “Wire Length Limit” ................................................. 27 4.1.6 Monitor motor pressure --- “Max Pressure Limit- Pmax”.............................................. 28 4.1.7 Monitor wire tension --- “ Tension Alarm “ .................................................................... 29 4.1.8 Releasing the brake – check Tension Control adjustment. ............................................. 30 4.1.9 Trend Monitoring --- What happened some minutes ago ? ............................................ 31 4.1.10 Keep an eye on Oil Temperature. ................................................................................... 32 4.1.11 Avoid motor breakdown -- Overspeed Protection ......................................................... 34 4.1.12 What went wrong? ---- Alarm monitoring..................................................................... 35 4.1.13 Get the progress on paper ---- Print-Outs....................................................................... 36 4.1.14 Measuring wire length. .................................................................................................... 37 4.1.15 Why doesn’t anything work ? --- Security Lock............................................................. 39 4.2 Automatic Operations ........................................................................................................... 40 4.2.1 Preparing Automatic Operations...................................................................................... 40 4.2.2 Automatic Pay-Out .......................................................................................................... 43 4.2.3 Automatic Dynamic Towing............................................................................................ 45 4.2.4 Automatic Hoist ............................................................................................................... 47 4.2.5 Adjusting PARAMETERS for automatic functions ........................................................ 49 4.3 Using Cable Lifters ................................................................................................................ 50 4.5 Alarm ...................................................................................................................................... 54 4.5.1 Alarm Reset button .......................................................................................................... 54 4.5.2 Alarm lamp ...................................................................................................................... 54 4.5.3 Maxvalue logging ............................................................................................................ 55 4.5.4 Emergency stop................................................................................................................ 55 4.5.5 Overspeed ........................................................................................................................ 55 4.5.6 High oil temperature ........................................................................................................ 55 4.5.7 High oilpressure ............................................................................................................... 55 4.5.8 High Tension.................................................................................................................... 55 4.5.9 Low pressure expansion system....................................................................................... 55 4.5.10 Low level expansion system ............................................................................................ 55 4.5.11 Low brake pressure .......................................................................................................... 55 4.5.12 Rotating drum .................................................................................................................. 55
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page5
4.5.13 4.5.14 4.5.15 4.5.16 5
Bitter end.......................................................................................................................... 55 Node nn lost ..................................................................................................................... 56 Bus warning ..................................................................................................................... 56 Wireguard Limit............................................................................................................... 56
OPTIONS..................................................................................................................... 56 5.1 Isolation Transformer ........................................................................................................... 56 5.2 Uninterruptable Power Supply (UPS) ................................................................................. 56 5.3 Slave monitor.......................................................................................................................... 56 5.4 Additional workstations ........................................................................................................ 56
6
INDEX .......................................................................................................................... 58
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page6
PREFACE The monitoring and control system is developed in co-operation with our customers. We have through many years had the opportunity to derive advantage from the immeasurable experience of some of the worlds most influential operators. The system is designed to give the crew precise and reliable information about the system status, as well as offering automatic functions that will enhance the useability of the winch system.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page7
1
SYSTEM
1.1
System layout The System is configured and operated from a Computer system which hereafter is referred to as a workstation .The workstation consists of a ruggedized display unit for displaying the operating condition and data for the winch system, and an Marine Grade Computer.The Display also functions as an input device enabling the operator to change system parameters and operating modes. The actual presentation and contents of the display may differ from one application to another, depending on which information is relevant to the specific application.
Max. 500 meter
• • • • • • •
Built in features for error detection. The system is easy to install. The system reduces the need for cabeling to the Brigde. The systems functionallity is expandable. Built in NMEA 0183 interface. Optional workstations may be installed. Optional VGA slave colour monitor may be installed .
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page8
1.2
Workstation The workstation is basically an marine grade monitor, computer and pointing device. The monitor is of high resolution type and may be equipped with a user interface realized by a touchscreen or a trackball if preferred. A combination of touch screen and a trackball may also be used. A Workstation may have several slave monitors connected to the same computer and they all will display the same picture. A system may also have several workstations which is operated totally independent of each other in respect to screen layout and input devices.
WORKSTATION 1
WORKSTATION 2
Max. 500 meter total bus length
A workstation consists of the following connections: •
CRT or LCD Monitor Power 230VAC VGA Video Input RS232 Touchscreen (option)
•
Trackball PS2 cable attached to trackball (2m)
•
Computer Power 24VDC CAN bus (total bus length must never exceed 500m, and must be terminated at both ends) Ethernet COM1 - 4 Serial Ports ( RS232 ) VGA output LPT1 – 2 Paralell ports (Printer Connection) PS2 Mouse port PS2 Keyboard port
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page9
1.3
Interface board All connections to the winch system is via the interface board, with exeption of NMEAcommunication, monitors and printer if fitted.The interface board consists of a highspeed processing unit and terminals for external connections.
• • •
• • • •
All digital inputs are isolated. All digital outputs are isolated. All digital outputs have separate fuses. All 44 digital I/O have built in status indication. 4 Hispeed optoisolated inputs for length counters. 4 Analog outputs , selectable between 0-10V or 0-20mA 8 Analog inputs , selectable between 0-5V,0-10V,0-20mA,4-20mA or ratiometric (potmeter).
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page10
2
USER CONTROLS
2.1
CRT Monitor
TOUCH SCREEN
CONTRAST BRIGHTNESS COVER FOR GEOMETRY CONTROLS
POWER SWITCH POWER INDICATION LAMP DEGAUSSING BUTTON
2.2
Power Switch The power switch turns the monitor and touchscreen (if fitted) on and off. The switch does not turn off the PC nor the interface board. NB! It is important that the monitor is switched on before the PC, if not the PC will not find the monitor touchscreen and the touchscreen will therfore not function properly.
2.3
Power on lamp Is lit when monitor is switched on and power cord is connected.
2.4
Contrast Control Adjusts the image brightness in relation to the background.
2.5
Brightness Control Adjusts the overall image and background screen brightness.
2.6
Degaussing button This is an special electronic feature built into the monitor which allows the operator to demagnetize the screen, this because over prolonged periods of use the screen will magnetize itself and the result is that the image on the screen could be slightly blurred , which is caused by the colors tendency to ‘bleed’ into each other . The monitor degausses itself at each power on , so this effect will be avoided if the screen is regularly switched off. For
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page11
vessels passing the equator it might also be nessesary to degauss the screen since the earths magnetic field has been reversed and in some cases results in a display with completely distorted colors. 2.7
Touch Screen The whole screen is covered in a touch sensitive film , which presents the operator with an intuitive and straightforward interface to the systems different settings and operating modes.
2.8
Screen adjustments Remove the cover on the left side of the monitor and the controls will be visible. NB! If screen geometry is adjusted the touch screen needs to be recalibrated, this because the touchscreen is relative to the front of the cathode ray tube (CRT). And will therfor stay in the same position even if the picture itself is moved . See APENDIX A
RESET BUTTON
CONTROL +
SELECT BUTTON LED INDICATORS
CONTROL -
2.8.1
Select button Select control proceeds to the next control selection. Move the led indicators across the adjustment controls from left to right.
2.8.2
Functions with LED indicators Starting from left the controls are as follows: • Horizontal position control adjusts the horizontal position of the image. • Vertical position control adjusts the vertical position of the image. • Horizontal size control adjusts the horizontal size of the image. • Vertical size control adjusts the vertical size of the image. • Side pin cushion control, adjusts the appearance of curved edges of the display image either inwards or outwards
2.8.3 +/- Control Increases or decreases the adjustment of the selected control function. 2.8.4 Reset button Resets the image settings back to factory setting.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page12
2.8.5 Cleaning the screen Monitors need to be cleaned for dust and fingerprints at regular. If the monitor is fitted with a touchscreen one can obviously not touch the screen without the risk of changing parameter and statuses unintentionally, therfore it has to be turned off first. The screen should be cleaned with special CRT cleaning towlettes or a cloth moistend with weak soapwater. Never use any strong solvents for cleaning the screen!
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page13
3
OPERATION Like so many other systems that surround us today, the monitoring and control system is based on computer technology. The operator will usually identify the control system with the Monitor and the Trackball, which he’ll use in his daily work. All communication between the operator and the control system will almost without exception be confined to these two units. This is what often is called the MMI; the Man Machine Interface. There are several possible options to choose from when selecting the MMI units, hence the configuration described in this manual may not be equal to the one of your system. The two units used for MMI are a Trackball and/or a monitor with built-in Touch-screen facility. Your system may include either options, or only a trackball and an ordinary monitor. If your system includes both options, they will both be usable at the same time.
Ball
Left key
3.1
Right key
Using Trackball If you are familiar to using a PC you may most likely have used a trackball before, or you’ll pretty soon find out by yourself how it works. However, if you are new to using this type of equipment, here are some hints :
Move Cursor
”Click”
• Look at the picture on the monitor, and try to find the Cursor. Keep an eye on the cursor and at the same time rotate the ball on the Trackball. You should now see the cursor moving on your screen. Try to move the cursor to and from definite places on the picture to get used to its movements. • Now move the cursor to the top of the screen and place it on one of the tabs. Press the left key on the Trackball. The picture on your screen will now change according to
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page14
your selection. Try to change between the different pictures to get the ‘feel’ of how this works. This is what is called a “click” • Move the cursor to the lower right corner and place it on the Clock-panel. Press the left key on the trackball rapidly two times. This is what is called “double-click” Your screen should now contain a panel with the heading “Adjust Time”. Move the cursor to the “OK”-button and press the left key once more. The panel disappears. Try this a number of times to get used to “click” and “double-click” 3.2
Using a Touchscreen You have probably been using a touch-screen quite a lot of times without even thinking about what is behind the surface. What is common for all types of touchscreens is that they all display some kind of “buttons” on a monitor screen. The most familiar is maybe the type you find on some ATM’s and Infosystems at various airports. In the way of use, they are all the same: simply press your finger on the “button” on the screen. However, if you are new to using this type of equipment, here are some hints :
Move Cursor
• Look at the picture on the monitor, and try to find the Cursor. Keep an eye on the cursor and tap your finger somewhere else on the screen. Not on a “button” this time. Notice that when you withdraw your hand the cursor has now moved to where you tapped your finger. Try to move the cursor to and from definite places on the picture to get used to its movements. Be careful not to hit one of the “buttons”. • Now press your finger on the cursor and move it upwards while keeping a light pressure on the screen, then move down an around the screen. Be careful not to cross one of the “buttons”. Notice that the cursor now follows your fingertip and when you withdraw your hand it remains where you last touched the screen.
”Click”
”DoubleClick”
• Tap your finger on one of the tabsor labels at the top of the screen, the picture on your screen will now imideately change according to your selection. .Try to change between the different pictures to get the ‘feel’ of how this works. This is what is called “click” when operating the touchscreen. • Move the cursor to the lower right corner and place it on the Clock-panel by touching the screen at that point. Tap on the panel rapidly two times. You may also tap two times on the panel at once. This is what is called “double-click” when operating the touchscreen. Your screen should now contain a panel with the heading “Adjust Time”. Tap with your finger on the “OK”-button. The panel disappears. Try this a number of times to get used to “click” and “double-click”
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page15
3.3 Screen Elements This section will explain briefly about the different elements you’ll find on the monitor pictures. The monitor is not only used to display information; it is in fact more like a control console. As described in earlier the monitor is the systems most important MMI-element. Getting familiar with the MMI and the several picture elements is essential to the comprehension of how to use the system. It is advisable to study this part of the manual before proceeding to the more advanced functions. 3.3.1
Folders, Tabs and Panels Unlike many other systems this system has no pulldown menus. This means that you never need to change from one picture to another just to get access to the one you really wanted. Your monitor screen may be compared to a file cabinet with an open drawer. Just “click” on one of the tabs at the top of the picture, and the folder you have selected will display its contents on the screen. You may open any folder at any time just by one “click” on its tab. Every monitor picture is made up of numerous elements. You’ll see that the picture is divided into separate parts, called Panels. Each panel have its own special function; and some panels are even “pop-ups” that presents itself to you only when it is needed..
”Panel”
”Folder”
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
”Tab”
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815-015 Rev. B Page16
3.3.2 System Panel The System Panel occupies a narrow section across the lower part of all pictures, and is mainly intended to display the System’s condition. If some serious faults should occur in the electronic systems, there will be a message on the middle part of the panel. Normally you’ll never see any of these messages, and they are only useful for service engineers. At the left end of this panel, there are 16 small, pillar-shaped rectangles. Each of these indicates one electronic unit that may be connected to the bus-system. How many units that are in fact connected may vary on different installations. • A grey rectangle indicates that no electronic unit has occupied that special bus address. • A green rectangle indicates a unit that is connected, operating normally and is communicating on the bus. • A blue rectangle indicates that a unit is detected, has received all its messages, and is ready to communication the bus. • A yellow rectangle indicates that a unit is detected, but it is at the moment in initiallization mode, possibly waiting for data . • A red rectangle indicates that a unit has previously been detected, but has been lost. In other words it is either malfunctioning or lost its power. Next to the bus-indicators there is a small box with a text like “ 12 MPS “. The digit will vary according to the traffic on the bus. A low value will indicate that the traffic at the moment is moderate. That’ll be typical when winches are not used. The value may be very low (1-4 MPS) if no operations has been executed for a long time. When hoisting heavy loads in rough weather, with wire tension constantly changing, the bus traffic pick up and he value in the traffic indicator window will then be considerably higher. This indicator is only useful for service engineers. On the right part of the System Panel there is a box displaying a clock. The clock may be adjusted at any time to synchronise with other systems. Next to the clock, at the left; there is a box displaying a numeral of several digits. This indicates how much “free memory” that is available on the system. The value displayed will normally be changing, but variation should be insignificant. Normal variation is less than 100. This indicator is only useful for service engineers.
Node Statuses
Bus Traffic
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
System Alarms
Memory Indicator
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Clock
815-015 Rev. B Page17
3.3.3
Buttons and Lamps As described earlier in this manual the monitor screen is the main part of TOWCON’s MMI system. The pictures on the screen are more like control panels rather than just illustrations. Graphic techniques are used to make it look like the screen contains real push-buttons and indicator lamps. To activate a Button you should “click” on it as described in section 1.3.3 and 1.3.4. Buttons may have several different shapes, but they all have in common that you’ll see some kind of alternation when you activate them. Some buttons will change appearance permanently as you activate or deactivate them, while others will go back to their original look as soon as you release the left key on the trackball. ( or moves your finger away from the touchscreen ). It may seem difficult to discern between Lamps and Buttons. This doesn’t really matter, because nothing will happen if you “click” on a lamp. Lamps are only used to display changes in some kind of operation, and have no influence on the winch control.
3.3.4
Digital Displays Some pictures introduce important information in Digital Displays. This is boxes of different extent displaying a digital value of some measured and calculated indicator signal. Typical use is presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm limit related to the topical measuring result, the display’s background colour will change if calculated value is too high ( or too low ).
”Lamps”
”Digital Display”
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”Buttons”
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3.3.5 Bargraphs On other pictures, measuring results may be displayed as Bar Graphs. This is boxes of different extent, containing a coloured bar with adjacent scale lines and dimension text. Typical use is presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm limit related to the topical measuring result, the bar’s colour will change if calculated value is too high ( or too low ). 3.3.6 Meters Some measuring results will even be displayed as Panel Meters. This is images having an appearance more or less like those good, old-fashioned circular dial instruments that were used on control panels some years ago. Typical use is presentation of oil temperature, motor pressure/RPM and wire length. The dial plate may be divided in sectors with different colours, indicating for instance “low”-values, normal operation and “high”-values. 3.3.7 Sliders Both Bar Graphs, Trend Displays and Meters may have attached “Sliders”. A Slider is an image that may be moved in certain directions along a specified path, typical along the outer circle of a meter. How to “drag” sliders is explained in chapter 1.3.3 / 1.3.4. As a slider is moved, the appurtenant meter/bar’s appearance will change. As an example the size of the sectors on a meter may be adjusted in this way. As long as the slider is moving, there’ll also be a digital value displayed to show its position at the moment.
On these examples is shown how it looks like when a slider is being moved on a Meter and on a Bar Graph. Notice the black cursors and the digital values. It is also indicated by cursors in other colours where cursor must be placed to ”get a grip” on the other sliders. Hint : If you think it’s difficult to ”get a grip” of the slider you want to move, try to place the cursor on the ”bar-area” and move it towards the limit you want to change.
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3.3.8
Popup Menus and Keypad To be able to adjust wire lengths, wire diameters, or maybe just correct the system clock, a keypad is needed. The keypad is a “pop-up” that’ll be accessible by double-clicking on the right elements on certain monitor pictures. What may be adjusted by use of the numeric keypad is described in other sections of this manual. Notice that the pop-up menu for correcting the system clock is made special for this purpose, and don’t look exactly like the numeric keypad. Nevertheless, they are quite similar in the way they are used. Keypad is only accessible on monitor pictures showing system parameters such as mentioned above. These parameters are normally displayed on special pictures, and are most easily recognised as a text followed by a small, black on white digital display, and behind that some unit of measure. These picture images’s will in this manual be referred to as executing elements. When opening the keypad, place the cursor on the executing element on screen and double-click on it. The keypad will then open and be accessible until you click on the “enter”button. Illustration shows keypad opened to correct value for Wire Length. Notice that keypad becomes accessible both when double-clicking on the text-line and on the digital display box, because they are both executing elements for this winch parameter.
To get access to the keypad, double-click on one of the lines or its topical digital display. On this clip you can see the text-cursor in the display box for Wire Length. This is the only mark that for sure is indicating what digital value you are about to adjust. Click on the ”Cancel”-button if you have opened the wrong digital display, or if you after all decide not to change the value. Keypad will then close, and the digital value’ll remain unchanged. To adjust a value, click on the CLR-button until you have deleted what was wrong and then write in the correct value by using the number-buttons. As you clear faulty digits or write in the correct ones you’ll see the contents of the digital display change. When you have changed the value and can see in the digital display box that it’s correct, just click ”ENTER” and the keypad’ll close. The correct value is now stored in the system.
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Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page20
3.3.9 Night color / dimmer As it’s different requirements regarding brightness and contrast on monitor pictures at day- and night-time, TOWCON may even compensate for this. Select the ”SYSTEM” –picture and click on either ”UP”- button or ”DOWN”- button to adjust the light intensity screen in steps from 100 (very bright) to 30 (very dark). 3.4 The user menu A double-click on the canvas tab will display the user menu. This menu gives the user the possibility to view some system information, adjust the date and time, and calibrate the touchscreens.
3.4.1 System info The System Info window displays some information about the state of the system. This information is intended to service personnel, but you might be asked to read or write down this information in case of troubleshooting via phone/fax.
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3.4.2 Date / Time Use this dialog box to adjust the date and time on the system. Double clicking on the date/time field on the status line will also open this dialog. Click on the number you want to change. The keypad will pop up. Then type the new value and click the ENTER-button to apply it to the system.
3.4.3 Calibrate touch The Calibrate Touch button in the User menu will let you calibrate all connected touch screens.
Press and release point 1. It will turn yellow as long as you press it, and disappear when you release it. Now the second calibration point (number 2 in the picture above) is displayed. Repeat the procedure for this one. Finally, when you have pressed the third calibration point (number 3 in the picture above), the result of the calibration is displayed. This is shown in the picture below. If this was the last touch screen you’re asked to press the OK button in order to close the window. If not, you must perform the same operation with the next touch screen.
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815-015 Rev. B Page22
4
Using the system
4.1 Manual Operations 4.1.1 Monitor Pictures for normal operations During normal winch operations there are two monitor pictures available that’ll give the operator read-out of what is happening on the winch. The firs one “ALL DRUMS” gives you an overwiev of all the drums, with active graphical elements to indicate the position of brake and couplings. Ex. If drum 0 is coupled to motor 0 the drum will adapt the colour of the motor, which in this case is green. And if the band brake goes on it will be coloured red. In addition to this there is also separate picture for each drum, which have bigger dials and contains the control buttons for auto mode operation.
”ALL DRUMS” – picture. The couplings and brakes will move/change colour according to their feedback sensor.
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815-015 Rev. B Page23
”Single-DRUM” picture. The text, DRUM 0 ….3 is normally replaced with the actual drum name, like TOW, AH etc.
4.1.2 Preparing Operation Before starting any pumps, one should always make sure that brakes are engaged, and that there are no open valves, filters etc due to maintenance work or other, and that all personnel are alarmed against the danger of getting injured in chains, wires etc. because of winches is now being used. Further information is to be found in Users Instructions for Remote Control. Take special notice of all procedures concerning safety of crew and craft. 4.1.3 Start of Hydraulic Pumps & Servo Units On most vessels were TOWCON is the winch monitoring system, remote start of Servo Units and Hydraulic Pump Units is only executed by this system. Of course all pumps still may be started by operating switches on the starter cabinets, and the Emergency Stop system will always be in function. Start and stop of pumps is done by clicking on buttons on the monitor pictures. Some pumps may deliver oil to one or another winch dependent on use of change over valves. If pumps are running, but oil is not supplied to topical winch, this will be indicated on monitor. Oil supply to this winch may be claimed by clicking start-button belonging to the topical winch. Please study example below.
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815-015 Rev. B Page24
Example shows part of monitoring picture for a ”Special Handling Drum” Example shows that pump 17b is in service, and that oil from this pump unit is available for the Special H. Winch. Pump 17a is also running, but oil from this pump is at the moment not available for use on the Special H. Winch. If the oil supplied from pump 17a is requested for use on the Special H. Winch, this may be achieved simply by ”clicking” on the start-button. The grey ”NO OIL” -lamp will then change to a green ”AVAILABLE”-lamp, and change over valves will be operated automatically to make oil flow from pump 17a to the Special H. Winch. Most TOWCON –Systems include a special monitor picture for control of pump units. By operation of buttons on this picture, normally all pump units can be started and stopped, and if there is Change Over Valves these may also be overrided by On/Off –buttons. Override of change over valves should not be carried out unless for function testing, because valves will automatically be activated to make oil flow to the requested winch. On examples of monitor pictures below, notice that pump 17a is monitored as ”running” on 2 panels on the ”PUMPS” –picture and on 1 panel on the ”SPECIAL H” –picture. This may in the beginning seem a little confusing, but is in fact very easy to operate. Control of pumps Start/Stop from the panel ”Manual Pump Control” will do nothing else but starting or stopping pumps. All appurtenant running indicators to a special pump will change at the same time on all panels as the pump is stopped or started. When ”clicking” on the Start-button on a panel belonging to a certain winch, also change over valves will be operated at the same time to make oil flow from the topical pump to that winch. The ”Oil Available” –indicator will vary according to position of change over valves. Requesting oil from one certain pump to a dedicated winch is always done by ”clicking” the pump’s start-button on panel belonging to that winch. If the pump is already running, only change over valves will be operated. If the pump is stopped, it will also be started
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815-015 Rev. B Page25
Example : Picture for monitoring Hydraulic System and picture for monitoring One Drum :
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815-015 Rev. B Page26
4.1.4 Manual pay-out --- “Wire Length Limit” Before starting to pay out wire or chain, operations as described in section 1.4.3 must be carried out. Shooting may be done in two different ways; either lowering by use of the speed control, or by reducing motors stalling force by the tension control until winch is rendering. Please study users instructions for the remote control to get more information about this. Often when paying out wire it is decided on beforehand what the wire-length is to be when payout is completed. Of course the operator may look after this by constantly watching the length bar graph and digital display on the monitor, but there is also a more pleasant way to do this. By giving TOWCON the right information, the operator may get a warning when a special wire length is reached, and thus do not have to pay too much attention to the monitor screen during this operation. EXAMPLE : Wire length is to be 2550 metres when pay-out is completed, and towing operation is to be carried out at that length. Operator is preparing to pay out wire by use of the tension control. ( or speed control ) Because he’ll not be constantly watching the monitor during pay-out of almost 900 metres of wire, he is now adjusting the wire length alarm limit to 2550 m. This is done by placing the cursor on the scale line between green and red on the Length Bar; and then drag the limit to the new alarm value. This narrow part of the length bar is also referred to as the “length limit bar” in this manual. Then he’ll adjust the tension control until winch starts to render, and when the length limit is reached he’ll get an audible alarm from TOWCON in time to concentrate merely on the winch before the determined towing length is exceeded. The length bar will now be red, because the alarm limit is exceeded. When towing length is reached, he’ll once again adjust the length alarm limit to get a warning if the winch pays out too much during towing operation. Hint : “Drag” See section 3.3.7 to brush up on how to operate sliders
Hint : Length Want to stop exactly at the metre ? Don’t bother the length bar graph, but rather concentrate on the Digital Length Display
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815-015 Rev. B Page27
4.1.5 Keeping the Towing Length --- “Wire Length Limit” During towing operation it is most often preferable to keep the brake disengaged and let the winch motors supply the holding power. In this way one will derive advantage from the lowpressure hydraulics’ special quality of being a strain restrictive braking device. If pressure in hydraulic motors exceeds a certain limit the winch will render, and in this way it is possible to take special care about how powerful strain is possible to get on wire. However there is always a small leakage in hydraulic motors, causing that winch will render quite slowly. Even though the rendering because of hydraulic creep is rather imperceptible, this’ll still make the wire length paid out to increase with some metres every hour. If it is very important not letting the wire length exceed a certain limit, the operator may get a warning from TOWCON. By adjusting the Wire Length Limit, an audible alarm will be heard when this special wire length is reached. In this way the winch operator don’t have to pay too much attention to the monitor screen during towing operations. EXAMPLE : Wire length is to be 2800 metres when pay-out is completed, and towing operation is to be carried out at that length. Wire length is not allowed to exceed 3000m. Operator has already paid out wire. Because he don’t want to be constantly watching the monitor during endless hours of towing operation, he’ll take benefits of using the TOWCON system to help him keeping an eye on the wire length. He’ll now adjust the wire length alarm limit to 2950 metres. This is done by placing the cursor on the scale line between green and red on the Length Limit Bar; and then drag the limit to the new alarm value. Then he’ll adjust the tension control until winch just starts to render to find the minimum necessary pressure, before he makes the final adjustment of the towing pressure; which may vary according to weather conditions, wire length and load. When the length limit is reached he’ll get an audible alarm from TOWCON in time to concentrate merely on the winch before the determined towing length is exceeded. On his monitor screen the Length Bar Graph will have changed to red colour. Hint : “Drag” See section 3.3.7 to brush up on how to operate sliders
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Want a warning also when pulling in ? It’s possible to adjust even an alarm limit for a minimum length. Do as described for adjusting the maximum length, and the lower part of the scale will change to yellow colour. When length get shorter than this limit, even the Length Bar will change colour to yellow. OOPS ! You’ll get no audible warning.
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815-015 Rev. B Page28
4.1.6 Monitor motor pressure --- “Max Pressure Limit- Pmax” During towing operation with disengaged brake one will derive advantage from the low-pressure hydraulics’ special quality of being a strain restrictive braking device. If pressure in hydraulic motors exceeds a certain limit the winch will render, and in this way it is possible to control how powerful the winch should be. However, it may be convenient to know if the pressure is frequently exceeding the adjusted level. By adjusting the alarm limit for high pressure this may be achieved. See also the users manual for remote control for more information about how to operate tension control. EXAMPLE : Wire length is to be 2800 metres when pay-out is completed, and towing operation is to be carried out at that length. Operator don’t want to be constantly watching the monitor during endless hours of towing operation, but will take benefits of using the TOWCON system to help him keeping an eye on the wire length. He has already adjusted the wire length limit, and will now adjust the tension needed to hold the load. He wants the winch to pay out smoothly if tension in wire suddenly increases, and do not want the winch to hold more than just what is necessary.
First step should be to adjust the tension control until winch just starts to render to find the minimum necessary pressure. Then, to secure that the winch is capable of holding the load without rendering, the tension adjustment should be increased a little. How much extra power to be calculated must be decided by the winch operator as a result of his experience and know-how, regarding to the present towing conditions. As a default setting may be used the measured pressure plus 15%. In our example let’s say that the winch renders at about 25 Bar, and that pressure variation is between 20 and 30 Bar. Operator estimates 32 Bar to be passable. The maximum pressure in our example system is 48 Bar. So, roughly calculated the adjustment on tension knob, which has a scale 1 – 10, should be somewhere between 6 and 7 is set to a little above 6. When this is done, an alarm limit for motor pressure may be adjusted to get a warning each time this limit is exceeded. This is done by placing the cursor on the “UP”-button for Pmax on the right side of the circular Pressure Instrument; and then click the limit to the new alarm value. One click will decrease the value by one bar. As this is done the uppermost part of the scale ,in red colour, will grove correspondingly . To increase the limit value (= decrease the red scale area) just click on the “DOWN”-button. Hint : Adjusting Pmax Find more about this in section 4.2.1.
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815-015 Rev. B Page29
4.1.7 Monitor wire tension --- “ Tension Alarm “ During towing operation with engaged brake, the winch has no other strain restriction than what is in the brake itself. Adjusting towing force must than be done by operation of the vessel. The TOWCON system offers however the possibility of setting an alarm limit at a certain load. An alarm will be given also if load exceeds this limit when brake is disengaged.
Example : Vessel is supposed to be towing with fixed wire length. Tension in wire is not allowed to exceed 280 tonnes. Winch operator has adjusted wire length to agreed value and engaged the brake. He wants TOWCON to give him a warning if wire tension approaches the allowed maximum limit of 280 tonnes. To have some safety margin he decides to set the alarm limit at 265 tonnes. This is done by placing the cursor on the scale line between green and red on the Tension Bar; and then drag the limit to the new alarm value. This narrow part of the tension bar is also referred to as the “tension limit bar” in this manual. Hint : “Drag” See section 3.3.7 to brush up on how to operate sliders
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815-015 Rev. B Page30
4.1.8 Releasing the brake – check Tension Control adjustment. During towing operation with engaged brake the winch has no other strain restriction than what is in the brake.When releasing the brake wire load is being transferred from the brake arrangement to the hydraulic motor unit, and maximum holding power is thus dependent on the adjustment of the Tension Control. To secure that winch will not render unintentionally when brake is released, it is therefor of great importance to check tension adjustments on beforehand. By benefit of TOWCON’s advantages the operator is able to adjust the tension control to almost exactly the requisite pressure to hold the load before releasing the brake.
Example : Vessel is towing with fixed wire length at 800m and brake engaged. Tension in wire is not allowed to exceed 180 tonnes, and must not be less than 120 tonnes. Wire length is to be increased to 1000m. Wire speed during this adjustment should not exceed about 15 m/min. Winch operator has to release brake to increase wire length, and has to make sure that the winch will not render to rapidly when the brake unloads. To be able to control the pay-out speed he has decided to let the winch render by use of the tension control, rather than paying out by the speed control. To secure a smooth start he adjusts the tension controller until the dynamic tension limit indicator on the Tension Bar is just above the present load. He’ll see the indicator moving as he adjusts the tension controller. As long as the tension control is being adjusted there’ll even be a digital value on the indicator. In this way he can securely release the brake, in assurance that the winch will not render uncontrolled.
He’ll than adjust tension firmly as he watches the Wire Speed Display to control the pay-out speed. On the Wire Length Display he’ll get exact information about the increasing wire length, and by increasing tension he’s able to stop the pay-out at precisely the right value. The Tension Display will show the present tension, so that this can be easily watched over at the same time. If preferable, it is also possible to get an alarm if the tension exceeds the maximum allowed limit. See section 4.1.7 for more info.
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815-015 Rev. B Page31
Notice that the Tension Controller Indicator will move up and down on the Tension Bar Scale according to more than one factor : Calculated maximum rendering force is dependent on wire-length, motor-pressure and maybe even of how many motors being connected to the topic drum at the time
Please study Users Instructions for Remote Control for info. about Tension Control
4.1.9 Trend Monitoring --- What happened some minutes ago ? During long lasting towing operations, winch operator will of course have other things to do than just gawping at the TOWCON monitor. Even in this situations when the operator has to concentrate on other duties for some minutes, the TOWCON system will come to his assistance. Trend Displays will give a rather good picture of what has happened during the last minutes. Winch data is constantly being stored in log-files, and the events just happened can be reviewed on the monitor.
Scale used on vertical axis on Tension Trend is always in Tonnes, while scale used on vertical axis on Pressure Trend is always in Bar. Scale on horisontal axis is always minutes. Notice that alarm limits ( red area of the narrow Bar Graph to the left of Trend Display ) may be adjusted both on Trend Displays and on other Bar Graphs or Meters. Adjusting limit on one of these devices will cause the limit to be corrected also on all the others. Hints : “Bar Graphs” , “Trend Displays” , “drag” , “Sliders” See section 3.3.7 to brush up on how to adjust limits on Bar Graphs, review use of Trend Displays and how to “drag” an alarm limit. Have a problem to “get a grip” on the Sliders ? Section 3.3.7 will get you a hint even about that.
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815-015 Rev. B Page32
Example : Vessel has been towing for a periode with brake engaged to keep the wire length fixed. Now the winch operator is told to concentrate on avoiding heavy jerks in wire. It is however not necessary to keep the length fixed any longer. During towing operation with disengaged brake one will derive advantage from the low pressure hydraulic’s special quality of being a strain restrictive braking device. If pressure in hydraulic motors exceeds a certain limit the winch will render, and in this way it’s possible to control how powerful the winch should be. Winch operator may then look at the trend display showing how the tension has varied the last minutes to get an idea of the holding power the winch motors will have to cope with. He’ll then be able to adjust tension according to this before releasing the brake.
4.1.10
Keep an eye on Oil Temperature. During long lasting winch operation hydraulic oil will sometimes get rather warm, and to avoid further heating action will have to be taken. Some vessels have automatic cooling systems, while on other crafts the crew will have to look after this. Anyway, the winch operator should always keep an eye on the oil temperature, because severe damages may arise in motors and pumps if oil gets too hot. TOWCON has some kind of oil temperature presentation on all the monitor pictures used during normal operation. Alarm limit is pre-set at 65 deg. Celsius, but may be adjusted to a lower value if preferable. Too quick variation in oil temperature may also harm motors and pumps; and should be avoided. On the monitor picture for control of pumps is to be found a Trend Display showing course of events in heating and cooling of the oil. If the monitored trend reveals dramatic changes in temperature; actions must be taken to stabilise this as soon as possible. A typical problem is that temperature drops too fast when water is being let into a water/oil cooler, which may cause that cold oil pour into a rather warm hydraulic motor. An even more serious problem is that hot oil my be guided into a cold motor by operation of a change over valve. If this can’t be avoided oil should be allowed to just flow through the manouver valve for a short time befor rotating the winch. Heat from oil will then spread to the motor. Example: Winch operator wants to indicate a part of the temperature scale to be the ”ideal” range. Recommended temperature is about 40 deg.Celsisus. Operator has adjusted the lower scale indication to abot 35C, and is about adjusting the upper scale indication to 55C. Notice the digital value visisble as long as limit is being adjusted. Alarm limit can not be adjusted higher than 75C.
Hint : “Drag” See section 3.3.7 to brush up on how to operate sliders
In this way the operator has made a green ”ideal sector” on the meter were the pointer should be when winches are in use.
Example : Trend Display for oil temperature to be found on the ”PUMP” monitor picture.
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815-015 Rev. B Page33
Above is an example of how the trend display for Oil Temperature may look like after some hours of operations. If the curve reveals sudden drops in temperature like indicated happened about two hours ago on this example, this should be investigated to find the reson why, and effort should be put into preventing recurrence
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815-015 Rev. B Page34
4.1.11 Avoid motor breakdown -- Overspeed Protection Although the remote control system has a built-in overspeed protection facility to prevent hydraulic motors being damaged by too high revolution speed, it’s absolutely advisable to keep in mind RPM-values when operating the winches. Especially when lowering or letting the winch pay out by rendering this should be carefully watched. TOWCON will take action if too high revolution speed is detected. If the automatic overspeed protection comes into force the winch motors will be stopped, motor pressure will be adjusted to maximum and finally the brake will be engaged. To get a warning in time to take action to recline rotation speed, the winch operator may adjust TOWCON to give an alarm at a lower RPM-value than what is in fact the guaranteed maximum limit. Adjusting the alarm limit doesn’t influence on the limit on which the overspeed protection will be activated.
Example : Vessel is to set an anchor, and will have to lower about 1800m.
Hint : “Drag” See section 3.3.7 to brush up on how to operate sliders Wondering what’s the max RPMlimit on your winch ? Just try to adjust alarm limit to max on scale, and it’ll automatically be reset to max RPM-limit.
Winch operator has adjusted tension and the winch is rendering at acceptable speed. As wire is paid out the necessary load to make the winch render will increase. To compensate this tension control will have to be continuous adjusted during the pay-out. At the same time load on wire caused by the vessels propulsion may vary, and will also influence on the necessary rendering force on winch. As a result of this, the tension control may accidentally be adjusted to low, and the rendering speed may exceed the maximum limit. If the overspeed protection system is activated it’s not a special pleasant event, because it may cause a rather severe yank in the towing line. To get a warning to take action while there’s still time, the winch operator decides to adjust the RPM alarm limit a little lower than the maximum value, which is 130 RPM in this example. Operator wants to be warned when rotation speed exceeds 120 RPM. This is done by placing the cursor on red area on RPM-scale; and then drag the limit to the new alarm value.
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815-015 Rev. B Page35
4.1.12 What went wrong? ---- Alarm monitoring No matter how proficient and experienced the winch operator is, accidents may still occur. It’s than valuable to have the opportunity to subsequently get detailed information from TOWCON about what actually happened. All alarms will be stored in a log-file, and be available later on, so that winch operator can concentrate fully on solving the problem instead of spending time on trying to read alarm-texts before they possibly disappears. When an alarm is activated, the sound will not go off unless someone “click” the Alarm Reset – button on the monitor. The Alarm-Reset –button is to be found only on the “ALARM”-picture. A text line on this monitor picture will give detailed information about what’s wrong. Alarm texts will not be deleted from list even if the reason to the alarm given is clarified. As alarms may be given from time to time, new lines will be written on top of the list while old ones will finally disappear at the bottom. All monitor pictures has an alarm-indicator that turns red when an alarm is activated and not yet acknowledged by pressing “Reset Alarm”-button. The reason why an alarm is activated is often quite obvious and easy to identify even without looking for the explaining text-line on the Alarm-picture, because it’s also clearly indicated on other pictures. As an example the colour in the Digital Display showing wire length will turn to red if the adjusted wire length limit is exceeded. Otherwise, there may also be given alarms not detectable no other place than on the ALARM –picture; such as “Emergency Stop” or “Low Level in expansion tank”. Example : Vessel is to keep a specified distance to the object it’s towing,and the winch operator has engaged the brake. Suddenly a hose on the brake cylinder blows, servo oil is flushed out on deck; and level in oil reservoir on servo unit decreases in a short time to a minimum. Because the hose blew, servo pump couldn’t maintain pressure in servo system. TOWCON detected this and activated the audible alarm. Winch operator changed to the picture “ALARMS” to see what was wrong, and pressed Alarm Reset –button. He found the message LOW BRAKE PRESSURE, but didn’t stop servo pump unit. Then he got a new alarm, LOW OIL LEVEL - MAIN SERVO. He’d had to press the Alarm Reset button once more to get rid off the audible alarm given because of the oil level. Before so is done, the explaining text’ll be red. On the monitor picture in our example we can see that there also was an alarm earlier the same day, because someone activated Emergency Stop. That situation has obviously been clarified, because the text has turned to grey. Example from ALARM-picture
Hint : Alarm Texts - Coluors Red New alarm detected “Alarm Reset” is not yet pressed. Yellow “Alarm-Reset” is pressed, Cause of alarm is still present Grey Old alarm, Cause of alarm is clarified
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Alarm-indicator to be found on all monitor pictures.
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815-015 Rev. B Page36
4.1.13 Get the progress on paper ---- Print-Outs Some times it’s essential to be able to document how things progressed during a certain operation or time period. The best way to do this is most often simply to get statistical data presented on paper. Normally this’ll be easy understandable and may be studied continuously while event is progressing. TOWCON offers print-out to be executed at adjustable intervals. In addition to this all monitor pictures includes a ”PRINT”-button. By clicking this button, each print-out line will be printed once. Keeping the button “pressed” will cause continuos printing off all print-out lines until button is “released”. Print-out interval may be set to values from 1 to 9999 seconds, in step by 1; lowest possible is 1 second. Selecting values higher than 9999 will cause printing to stop. It is not possible to adjust decimal numerals. While printing by using the “Print-button” print delay will always be 1 second between each line, which is about the quickest the printer is capable of performing. It is not advisable to use shorter print interval than number of lines to be printed. As an example, if there are 4 drums, and also 4 lines to be printed, print interval should not be shorter than 4 seconds. If printer doesn’t cope with the data it’s supposed to print each second, its memory buffer will eventually be overfilled and data will be lost.
STB TOW DRUM, TIMER, 1999/12/21, 08/34/10, 1256m, 192t, 114rpm, 42bar PRT TOW DRUM, TIMER, 1999/12/21, 08/34/10, 6m, 0t, 0rpm, 2bar STB AH DRUM, TIMER, 1999/12/21, 08/34/10, 1m, 0t, 0rpm, 0bar PRT AH DRUM, TIMER, 1999/12/21, 08/34/10, 5m, 0t, 0rpm, 0bar STB TOW DRUM, TIMER, 1999/12/21, 08/34/14, 1257m, 195t, 113rpm, 40bar PRT TOW DRUM, TIMER, 1999/12/21, 08/34/14, 6m, 0t, 0rpm, 2bar STB AH DRUM, TIMER, 1999/12/21, 08/34/14, 1m, 0t, 0rpm, 0bar PRT AH DRUM, TIMER, 1999/12/21, 08/34/14, 5m, 0t, 0rpm, 0bar STB TOW DRUM, TIMER, 1999/12/21, 08/34/18, 1257m, 194t, 114rpm, 41bar PRT TOW DRUM, TIMER, 1999/12/21, 08/34/18, 6m, 0t, 0rpm, 2bar STB AH DRUM, TIMER, 1999/12/21, 08/34/18, 1m, 0t, 0rpm, 0bar PRT AH DRUM, TIMER, 1999/12/21, 08/34/18, 5m, 0t, 0rpm, 0bar
Example above illustrates how the printout may look like on a system designed for a 4-drum winch. Printed data is as follows on one line for each drum : Drum identity, last print executor, date, time, wire length, wire tension, motor rpm, motor pressure Notice that ”last print executor” may be TIMER or USER. By using the ”Print Now”-button this text will change to USER, until the next time printing starts because of a time sequence.
”Print Now”-button. Normally to be found in lower right corner
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
”PRINTER SETUP” –panel is to be found on monitor picture PARAMETERS
EXAMPLE : Starting and Stopping a printout executed by timer. Double-click on the Timer-box to get access to the keypad. Adjust value to wanted time interval. As soon as you click on ”enter” the printer will start. To stop the printer repeat as described, but adjust the timer to a value higher than 9999. As soon as you then click on ”enter” the printer will stop.
Hint : “Pop-Up Menu”, “Keypad” See section 3.3.8 to brush up on how to operate Pop-Up Menues and Keypads
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815-015 Rev. B Page37
4.1.14 Measuring wire length. All calculations TOWCON executes are dependent on the few basic parameters concerning wire data. These parameters may be individual for wire on each drum, and they are available by selecting monitor picture PARAMETERS. It’s of coarse no problem to adjust all parameters needed to calculate wire length correct when they are known. But what is to be done when you don’t know the wire length? Entering a faulty value as wire length will most likely have influence also on tension calculations. Following example will give some hints of how to deal with such problems. Example : Vessel has to take onboard an unknown length of wire, which later on is to be paid out again when placing a buoy. All that’s known about wire is that diameter is 76mm, and that length can’t possibly be more than 2400 metres. Most likely length is something between 2000 and 2300 metres. First part of wire is already spooled up on Stb Common-Handling Drum. About 5 turns on first layer is now on drum. Winch operator decides to measure length of wire as it’s pulled in. First thing to be done is to adjust wire data, so he selects monitor picture PARAMETERS.
First-layer diameter: 1390 mm On drum: 5 turns 5turns= 1,390×3,14×5=21,8m Wire length out: 3000
Remember to click ”Reset Length” each time Length Out has been corrected.
As the Stb CH –picture shows up on the monitor screen he can see that wire length display indicates 22 metres. Pull in of wire can now be started.
21 8
2978 2
t
Wire diameter is known to be 76 mm, so that’s no problem. Assuming that wire is much shorter than this, he adjusts Wire length to 3000 metres. How much wire that’s still to be pulled in must than be the difference between what’s already on drum and the fictious total length of 3000 metres. He’ll have to calculate this and put the value into the ”Wire length out”-box. Calculation must be based on the diameter of drum on first layer and the 5 turns of wire that’s already on drum. Drum diameter on lst-layer is found on data sheets in the Users Manual for Remote Control, and is 1390 mm. Knowing this winch operator is able to calculate length of wire on drum fairly accurate to be 21,8 metres; and hence Wire length out must be 2978,2 metres. Operator enters this wire data and clicks on “RESET LENGTH” before selecting monitor picture for Stb Common Handling Drum.
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815-015 Rev. B Page38
--- example from previous page continuous ----
All wire is pulled in ……. When all wire is pulled in Length Display still indicates that there’s 978 metres left. This only shows that the winch operator was right when assuming that the wire was quite a lot shorter than 3000m. Now he has to select the PARAMETER-picture once more and readjust the wire parameters. ”Wire length” is 3000m minus the 978
978m should be left, but end of wire still lays on deck…….
Estimated wire-length: 3000m Still indicated, end on deck: 978m Actual length=3000-978=2022m
Don’t forget to click ”Reset Length” each time Length Out When wire now later on is paid out, length will be displayed correctly as contents on drum shrinks. Digital display and Length Bar will indicate length of wire paid out.
Hint : Remember how to use the keypad ? If you want to refresh, study section 3.3.8
As the Stb CH –picture shows up on the monitor screen he can see that wire length display indicates 0 metres. This is correct because all wire now is spooled up on the drum
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Please observe: TOWCON doesn’t know anything about the outer diameter of the drums. This means that the estimated wire length may be adjusted much longer than what the drum actually can take. So you don’t have to estimate length very carefully, just decide on a length that you are sure is too long.
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815-015 Rev. B Page39
4.1.15 Why doesn’t anything work ? --- Security Lock When touchscreen or trackball has not been used for at least 5 minutes, the Security Lock will be activated. This is made like this to prevent faulty operations to be executed because someone accidentally touches surface of monitor screen ( if it’s a Touch-Screen ) or the Left Key on trackball. Security Lock will be presented on monitor picture as a red hand in the upper right corner. As long as this image is visible it’s not possible to execute any other operation from neither touch-screen nor trackball than just unlocking the system. You can still move cursor around, but trying to execute some kind of operation by clicking on one of the images on the picture will not have any effect.
Illustration to the left shows how it looks like when Security Lock is activated.
Unlock like this : Place cursor on Red Hand and click on it. Red Hand will now move to left upper corner. Now complete the unlock operation by placing cursor on the left Red Hand and click on it. The left Red Hand disappears, and system is ready for use. Hint : placing “Cursor” & “Click” See section 3.1 / 3.2 to brush up on how to move cursor around on monitor pictures and activating operations by clicking on picture images. Thinking it’s mucky to need to click on two “Red Hands” ? Click on the first one as soon as it appears. Then just one click on the left Red Hand is needed to get you online ! However, take care; you’ve already lowered the security precautions.
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815-015 Rev. B Page40
4.2
Automatic Operations
4.2.1 Preparing Automatic Operations This section will explain briefly what to be done before winch operations are executed. Before starting any pumps, one should always make sure that brakes are engaged, and that there are no open valves, filters etc due to maintenance work or other, and that all personnel are alarmed against the danger of getting injured in chains, wires etc. because of winches is now being used. Further information is to be found in Users Instructions for Remote Control. Take special notice of all procedures concerning safety of crew and craft. Be aware that there are certain restrictions attended with accessibility to automatic operations. Detailed explanations about this are to be found in document section describing the topical operation. Do also pay attention to the limits for wire lengths possibly needed to be adjusted. Select monitor picture PARAMETER to get access to these settings. These parameters should always be checked before starting any automatic function.
All automatic operations may at any time be stopped by clicking on ”MANUAL”-button.
Hint : “Auto/Manual-limit” “Pay-out brake length” “Tow/Hoist limit” See section 4.2.5 to brush up on how to adjust these parameters. Clip from monitor picture ”PARAMETERS”
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815-015 Rev. B Page41
Please observe that indicator on ”MANUAL”-button is green when this mode is selected, while indicator on ”Auto”-buttons is red. This is not because automatic operations are to be considered as dangerous, but still a reminder is given so that operator shall not forget that winch may suddenly rotate without him having even touched the speed control lever.
All automatic operations may at any time be stopped by clicking on ”MANUAL”button.
In this part of manual adjustments of the pressure limits is essential. Please find more information about use of the limits in the following examples. Illustration beneath indicates adjustment of Pmax. Click the “UP-arrow”-button on the right side of the circular Pressure Instrument to decrease Pmax One click will decrease the value by one bar. As this is done the uppermost part of the scale ,in red colour, will grove correspondingly . To increase the limit value (= decrease the red scale area) just click on the “DOWN-arrow”-button. In the opposite way clicking on the “UP-arrow” for Pmin will increase the Pmin limit. Common for Pmin and Pmax is that clicking the “UP-arrow” will make the yellow (or red) area grow bigger and clicking on the “DOWN-arrow” will make the same areas of scale smaller. Adjusting Towing Pressure is done simply by clicking the +/- buttons. Towing Pressure is indicated on scale as a black dot.
Notice that a digital value according to the limit will appear as the limit is being adjusted. After a short while without changes the digital value will disappear.
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815-015 Rev. B Page42
Also on the ”Main Winch Display” on monitor picture ”WINCHES” is indicated that one drum is now used with an automatic function in service. It is not possible to use automatic functions on more than one drum at the same time. Illustration below shows an example of a winch installation where one of the drums at the moment is used in one of the 3 automatic modes PAY-OUT, TOWING, or maybe HOIST.
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815-015 Rev. B Page43
4.2.2 Automatic Pay-Out Automatic Pay-Out is introduced to take off the winch operators hands the unpleasant job of lowering maybe several hundred metres of wire. This might of course be done in the traditional, manual way but why not let TOWCON take care of it ? Remember that to get access to this function, wire must on beforehand be paid out to a length at least equal to what’s set as Auto / Manual Limit for the current drum. Please study both the example below and the “frequently asked questions” on next page. Example : Vessel is to pay out 700m of wire. Auto/Manual limit is set to 140m.
Length = 150
Winch operator manually pays out 150m by lowering with speed control to get clear off the Manual/Auto Limit. Then he lets go off the speed control lever and turns his attention to the TOWCON monitor. First of all he takes a look at the present motor pressure and estimates how the pressure limits should be adjusted. He adjust tension controller firmly counter-clock until winch starts rendering. The pressure is then about 22 Bar, and he adjusts tension controller to maximum.
Check rendering pressure
Knowing that the winch will get increased rendering force as wire is paid out, he adjust Pay-Out pressure “P-min” a little lower than this; at about 18 Bar. When TOWCON has finished the automatic pay-out it’ll swap to the automatic function Towing. As wire length is increasing to the Brake Length Limit; TOWCON will prepare stopping the pay-out at the exact wanted towing length. During the last part of the pay-out TOWCON will gradual increase pressure to Towing Pressure. Winch operator has to estimate how much pressure the motors will need to hold the load without rendering. He estimates this to be about 24 Bar, and adjusts this on the tension meter on monitor screen. Adjust wanted Towing Length Before activating Pay-Out he’ll have to tell TOWCON the new wanted Towing Length. This is done by adjustment on the 700 m length bar graph on monitor screen.
Adjust Pay-Out pressure, Pmin
Adjust Towing Pressure
Now everything is prepared, and winch operator starts the automatic pay-out by clicking the “PAY-OUT” –button. Observe : Operator may at any time stop the automatic function, simply by clicking on “MANUAL”. Hints: See also section 4.1.4 / 4.2.5 to brush up on “Wire Length Limit”, and section 1.5.6 for adjusting “PARAMETERS” Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Pay-Out completed. System has swapped to automatic ”TOWING”
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FREQUENTLY ASKED QUESTIONS : AUTOMATIC “PAY-OUT”
Why am I not allowed to select “PAY-OUT” ? Check actual wire length on length bar graph or digital display, and also what is set as Manual/Auto Limit on the monitor picture PARAMETERS. If the actual displayed wire length is shorter than Manual/Auto Limit you’ll be denied selecting automatic “PAY-OUT”. Please re-adjust Auto/Manual Limit or manually pay out more wire. Why does the winch stop so often during automatic “PAY-OUT” ? You may have adjusted Pay-Out Pressure too low. If this is so, winch will render too rapid, and the maximum limit for motor revolution may have been exceeded. In this case TOWCON will take action by activating the Overspeed Protection. Check/adjust Pay-Out Pressure. Why isn’t TOWCON able to stop at the length, and winch continues to pay out ? You may have adjusted Towing Pressure too low, and if also maximum allowed pressure Pmax is too low, winch don’t have enough power to pull in. Check/adjust Towing Pressure and Pmax.
Refresh some concepts: Pmin = minimum allowed pressure: to be adjusted on pressure meter, displayed as the right end of yellow area on scale, digital value visible when adjusting, used when paying out during auto “PAY-OUT” Towing Pressure : to be adjusted on pressure meter, displayed as a black dot on the scale, digital value visible when adjusting, used when holding load during auto “TOWING” Towing Length : to be adjusted on Wire Length bar graph, displayed as a horizontal, dotted black line on scale, digital value visible when adjusting, used as reference-length during auto “PAY-OUT”
Hint : Want to get a warning before winch starts braking ? Use the Wire Length Alarm to give you a caution. Adjust the alarm quite a little below the wanted Towing Length minus Braking Limit. Read more about this alarm in section 4.1.4 and 4.1.5.
Hint : Don’t want any unpleasant stops because of Overspeed Protection being activated ? Use the Motor RPM-Alarm to give you a caution. Adjust the alarm a little below the maximum allowed value, and this’ll give you the chance to adjust Pmin in time to prevent overspeed. Read more about this alarm in section 4.1.1.11
Pay-out brake length : to be adjusted on monitor picture PARAMETERS, to be adjusted by use of pop-up keypad, used as braking-length in final sequence of automatic “PAY-OUT”
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815-015 Rev. B Page45
4.2.3 Automatic Dynamic Towing In section 4.1.5 is described the advantages of dynamic towing compared to towing with brake engaged. However, the winch operator doesn’t have to look after the towing length himself as he has TOWCON. By giving TOWCON the right instructions it’ll do the job for him. On a set limit the system itself will start hoisting until wire length once more is at the requested value. Like as for the automatic function “PAY-OUT” the automatic “TOWING”function is not either accessible unless wire length is at minimum equal to the Manual / Auto Limit. As already mentioned in previous section, TOWCON may have swapped to automatic “TOWING” because automatic payout has just been completed. However it is also possible to select “TOWING” if system is in “MANUAL”-mode, the only condition is that wire length must not exceed last adjusted Towing Length plus last adjusted Tow/Hoist Limit. Please study both the example below and the “frequently asked questions” on next page.
Example : Vessel is to tow a barge for several hours. Distance between vessel and barge is not allowed to exceed 400m. Winch operator manually pays out 350m by lowering with speed control.. Then he lets go off the speed control lever and turns his attention to the TOWCON monitor. First of all he takes a look at the present motor pressure and estimates how the pressure should be adjusted. He wants a smooth towing operation, but at the same time he don’t want the winch to render too rapidly. In our example winch renders continuously when pressure is about 25 bar, so he reckons 30 bar to be a suitable towing pressure. He’ll also have to estimate how high pressure the motors will need to pull in wire. To be sure the winch has enough power for hoisting, he sets the maximum allowed pressure to 35 bar.
Actual pressure = 27 Bar
After having adjusted the tension controller, he decides to let TOWCON take care of watching the wire length. On the Length Bar Graph he adjusts the Towing Length to 350m. Then he selects the monitor picture PARAMETERS, and adjusts the parameter Tow/Hoist Limit to 45m before swapping back to the monitor picture for towing drum. Now he clicks on the “TOWING”-button and TOWCON takes the job watching the wire length off his hands. When winch has rendered until wirelength has exceeded Towing Length ( 350m ) + Tow/Hoist Limit ( 45m ) = 395m, TOWCON takes action. Manoeuvre valves on hydraulic motors will be adjusted to hoist position and tension is at the same time adjusted to maximum allowed pressure Pmax. Then winch will hoist until wire length is back on towing length. At correct length winch stops and tension is once more reduced to towing pressure. This sequences will be repeated again and again as necessary until operator decides to stop the automatic towing.
Adjust ”Towing Pressure”
Adjust maximum pressure ”Pmax”
Observe : Operator may at any time stop the automatic function, simply by clicking on “MANUAL”. Hints: See also section 4.1.5 to brush up on “Wire Length Limit”, and section 4.2.5 for adjusting “PARAMETERS” Adjust ”Towing Length”
Click on ”TOWING” Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
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815-015 Rev. B Page46
FREQUENTLY ASKED QUESTIONS : AUTOMATIC “TOWING” Why am I not allowed to select “TOWING” ? Check Towing Length indicator on length bar graph, and also what is set as Towing Limit on the monitor picture PARAMETERS. If the actual displayed wire length exceeds the sum of Towing Length plus Tow/Hoist Limit you’ll be denied selecting automatic “TOWING” Please re-adjust Towing Length. Why isn’t TOWCON able to keep the length, and winch continues to pay out ? You may have adjusted Towing Pressure too low, and if also maximum allowed pressure Pmax is too low, winch don’t have enough power to pull in. Check/adjust Towing Pressure and Pmax. Why does the winch so often pull in during automatic “TOWING” ? You may have adjusted Towing Pressure too low. If this is so, winch will render too rapid, and the allowed limit is soon exceeded. You may also have adjusted the Towing Limit too short. If this is the case the allowed length limit will also be too soon exceeded, and the winch will very often have to pull in to get back on wanted length. Check/adjust Towing Pressure and Tow/Hoist Limit.
Refresh some concepts: Towing Pressure : to be adjusted on pressure meter, displayed as a black dot on the scale, digital value visible when adjusting, used when holding load during auto “TOWING”
Hint : Want to get a warning before winch starts to pull in ? Use the Wire Length Alarm to give you a caution. Adjust the alarm quite a little below the sum of wanted Towing Length plus Towing Limit. Read more about this alarm in section 4.1.4 and 4.1.5
Pmax = maximum allowed pressure: to be adjusted on pressure meter, displayed as the left end of red area on scale, digital value visible when adjusting, used when pulling in during auto “TOWING” ( also used in automatic “HOIST” ) Towing Length : to be adjusted on Wire Length bar graph, displayed as a horizontal, dotted black line on scale, digital value visible when adjusting, used as reference-length during auto “TOWING” Tow/Hoist Limit : to be adjusted on monitor picture PARAMETERS, to be adjusted by use of pop-up keypad, used as rendering-length during auto “TOWING”
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815-015 Rev. B Page47
4.2.4 Automatic Hoist In other sections of this manual are described the great advantages TOWCON can offer during towing and anchor-handling operations. Not mentioned in any other section is the possibility of getting help when wire is to be pulled in. In fact, TOWCON can take care of the hoisting operation on its own. Just tell the system what the new length should be, click the “HOIST”-button and consider the job as done. Notice that there’s still a certain limitation: you are not allowed to let the system hoist automatically unless there’s more than 100 metres of wire remaining to be pulled in. System will stop hoisting when the Auto/Manual Limit is reached; and it’s not possible to adjust this limit to values lower than 100 m. In fact the automatic hoist operation will always be stopped at the Auto/Manual Limit, so you may stop at any length you wish, just by adjusting this limit. Please study section 4.1 to learn more about limits- and parameter-settings. Example : Vessel has paid out a lot of wire during a towing operation, and all this wire must now be spooled back on drum. The present wire length is almost 2400 metres. Brake is not engaged, and pressure in hydraulic motors is about 28 Bar. Winch operator considers the spooling of wire to be the main thing to concentrate on rather than holding the speed controller in hoistposition, so he decides to let TOWCON take care of the pull-in. Anyway, he wants to take full control of all winch operations when there’s less than 250 metres left to be pulled in.
Pressure is about 28 Bar
Knowing that the winch will need more pressure to pull in the same load as the drum is filled with wire, he adjusts the maximum allowed pressure Pmax high enough to compensate for this. He estimates that 35 Bars should do. After having adjusted the hoisting pressure, he select the picture PARAMETERS on monitor, and adjust the setting of Auto/Manual Limit to 250 metres.
Length is almost 2400 metres as ”HOIST” is selected
Now he once more selects the Towing-Drum picture on monitor, and clicks on the ”HOIST”-button. TOWCON now adjusts pressure regulation valves to let pressure increase to maximum allowed, which operator decided to be 35 Bar, firmly adjusts manoeuvre-valves on winch motors to hoistposition and the pull-in operation has started.
Maximum pressure Pmax must be adjusted to secure enough pull-in force
When length of wire remaining to be pulled in is only 250 metres, TOWCON stops the winch, and system swaps to ”MANUAL”mode. Hint : Auto/Manual Limit Learn about adjusting this limit in section 4.2.5 When there’s 250 m remaining to pull in system swaps to ”MANAUAL”
More hints to be found on next page.
Activate by ”clicking” the ”HOIST”-button …
Observe : Operator may at any time stop the automatic function, simply by clicking on “MANUAL”.
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815-015 Rev. B Page48
FREQUENTLY ASKED QUESTIONS : AUTOMATIC “HOIST” Why am I not allowed to select “HOIST” ? Check actual wire length on length bar graph or digital display, and also what is set as Auto / Manual Limit on the monitor picture PARAMETERS. If the actual displayed wire length is shorter than Auto / Manual Limit you’ll be denied selecting automatic “HOIST”. Please re-adjust Auto / Manual Limit . Why does the winch stop pulling in during automatic “HOIST” ? You may have adjusted maximum alloyed pressure too low. If this is so, winch will eventually not have enough power to continue pulling in as drum is filled by wire. Check/adjust maximum allowed pressure, Pmax Why does TOWCON swap to “MANUAL” when there’s still much to pull in ? You may accidentally have adjusted Auto / Manual Limit to a high value. Check/adjust Auto / Manual Limit.
Refresh some concepts: Pmax = maximum allowed pressure: to be adjusted on pressure meter, displayed as the left end of red area on scale, digital value visible when adjusting, used when pulling in during auto “HOIST” ( also in automatic “TOWING” )
Hint : Have to make a short stop ? No problem ! Just click on “MANUAL”, do whatever you have to and click on “HOIST” to re-start the automatic hoist operation. You may use the speed-control for both lowering and hoisting as normal when system is in “manual”-mode without having to re-adjust anything before you start the automatic hoisting again. Hint : Auto / Manual Limit
Auto / Manual Limit : Find more about how to adjust this parameter to be adjusted on monitor picture PARAMETERS, in section 4.2.5 to be adjusted by use of pop-up keypad, Hint : Length Alarm used as the minimum wire length to be remaining to be pulled in when TOWCON swap from Want a reminder before system swaps to MANUAL ? Study section 4.1.4 / 4.1.5 about how to use Length Alarm “HOIST” to “MANUAL” and you’ll get a yellow Length Bar Minimum possible value = 100 metres. before the winch stops.
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815-015 Rev. B Page49
4.2.5 Adjusting PARAMETERS for automatic functions In prior sections in this part of reference guide are described the use of some parameters that TOWCON will need to do a proper job. This section will explain more in detail what these parameters are used for, and hints of how they should be adjusted. Auto / Manual limit: This is a wire length that TOWCON will use to decide if it’s legal to choose an automatic function or not. Value is to be entered in metres. If the limit is adjusted to high, it’ll exclude all auto-functions. The limit is meant to stop hoisting automatically the last few metres of wire, as well as preventing automatic pay-out to be started by an accident when there’s possibly wire handling work carried out on deck. But even though the limit is meant to secure that there must be a human controlling the winch when end of wire is onboard or very near to the vessel, it may even be used to lock all access to automatic functions completely. It’s not possibly to adjust this limit to values lower than 100 metres. Pay-out brake length: This parameter decides how firmly the winch will stop when wire is paid out to a certain length automatically by the “PAY-OUT” function. Value is to be entered in metres. A long braking length will give a very firm stop, but it’ll take some more time. Too short braking length may however give a rather brutal stop, especially if pay-out speed is high. TOWCON will use the braking length to increase pressure from being the pay-out pressure Pmin to being the on beforehand-adjusted Towing Pressure. Adjustment of this value must be based on experience and skills of the crew. Tow / Hoist limit: This parameter is only used during automatic “TOWING”. Parameter is to be entered in metres and is used to describe how big deviation is tolerated to the wanted towing length unless it has to be corrected. As soon as deviation to Towing Length exceeds this limit, TOWCON will try to pull in wire to get length back on wanted value. Adjusting this limit to very small values will make the winch keep the length very tight up to the wanted Towing Length, but at the same time this’ll also make the towing operation a lot more noisy as the winch will start and stop very often. Of cause this depends on both weather conditions and wire tension as well as other circumstances. Again, it must be said that adjustment of this value should be based on experience and skills of the crew. Hint : “Pop-Up”-menu & Keypad Find more about how to adjust values/ parameters by use of the keypad in section 3.3.8 Notice that on this example illustration the Auto / Man limit is adjusted to minimum possible value. If you adjust a lower value and click on “enter”, the value will change to 100m as soon as the keypad disappears.
Illustration shows keypad opened to adjust Auto / Man limit
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815-015 Rev. B Page50
4.3
Using Cable Lifters When handling rig-chain TOWCON will give almost the same advantages as described for dealing with wire operations, although not all topics mentioned are equally relevant. However the monitoring functions like length, tension, motor pressure and so on are available just like they are when dealing with wire. All alarm limits may also be adjusted like described earlier in this reference guide. Just remember to click the “CABLE LIFTER”-button, and don’t forget to choose the right pitch diameter and to reset the length. Do also remember that when using cable lifters there are certain load limitations that must not be exceeded ! Please study the Users Instructions for Remote Control and/or information board in wheelhouse for further details. Example 1 : Vessel is to pull in a 100 mm rig chain. It’s essential to know how much chain that’s being pulled in. Cable Lifter is already mounted on Stb Common-handling drum and the first few links has been pulled in. Before starting to pull in and meassure the rig chain operator’ll have to choose the rigth pitch diameter and enter this in the parameter settings for the topical winch. First of all the winch operator selects the monitor picture for Stb CH –Drum and clicks on the ”CAB”-button. Then he selects the monitor picture PARAMETERS to adjust the pitch diameter. He finds the pitch diameter in the table on the ”Rig Chain Data”-panel, and enters this into the ”Cable lifter diam”-box belonging to the Stb CH Winch. Next step is to enter 0 (zero) in the”Wire Length Out” –box. Then ”RESET LENGTH” must be clicked to tell TOWCON to start using the new values. ( ”Wire diameter” and “Wire length” will now not be used, so what’s ever displayed in this box doesn’t matter )
Select ”CAB” ( cable lifter ).
”PARAMETER” –picture even includes a panel called ”Rig chain data”, displaying a table of chain diameters and the Hint : Remember how to use the keypad ? If you want to refresh, study section 3.3.8
Remember to click ”Reset Length” each time Length Out has been corrected.
When this is done he’ll have to estimate How much chain has already been pulled in. The first few chain links has just reached the bottom of the chain locker, and he reckons the length to be about 15m from there and through the chain pipes to the cable lifter. He makes a note of this to have it available later on
Chain : Pulled in before Reset about 15 m.
more about this example on next page ….. Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page51 example from previous page continues …… Winch operator now selects the monitor picture for Stb CH Drum, and starts the pull-in operation When pull-in of chain stops, the digital display shows 345m. Operator swaps to PARAMETER picture and re-adjusts the ”Wire length out” value. To enter the correct length operator now has to add the first part of chain ( 15m ) that were pulled in before measuring started. Measuring is now completed, and length indicated on monitor screen will show how much chain is pulled in.
Chain : Pulled in before Reset : about 15 m. Meassured : 345 m Total length in locker: 345+15 = 360m
Remember to click ”Reset Length” each time Length Out
Hint : Length Alarm Want a reminder before chain length left in locker becomes indefensible short ? Study section 4.1.4 / 4.1.5 about how to use Length Alarm
has been corrected.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page52
Example 2 : Vessel is to pull in an anchor attached to a 100 mm rig chain. Cable Lifter is mounted, correct pitch diameter is selected and length is reset before starting to pull in. Some chain is pulled in when operation has to be stopped. Anchor is obviously stuck in something on sea bed. Brake is now engaged. Winch operator is aware of the limitation on this special winch to be just 370 Tonnes when operating with this chain dimension. To be on the safe side he wants an alarm if tension of any reason should approach to even levels far beneath this. In fact he don’t expect tension to exceed 250 tonnes, so he decides to adjust the tension alarm to just 230 tonnes. If this limit is exceeded he’ll get an audible alarm as well as the Tension Bar being red on his monitor picture.
Hint : “Tension Alarm” See section 4.1.7 to brush up on how to adjust tension alarm. See section 3.3.7 to refresh how you should operate sliders.
General when using Cable Lifter : All limits related to length, RPM, tension, and pressure is applicable, and may be used as explained in other sections of this reference guide. Pay special attention to what’s discussed in the section MANUAL OPERATION, but don’t forget that even Automatic Functions are available. Special caution has to be performed if automatic functions are executed. Tension alarm limit should be used consistently to give an alarm at a value safely below what is described as maximum allowed for the topical cable lifter. Do remember that when using cable lifters there are certain load limitations that must not be exceeded !
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page53
4.4
System Settings, Wire-data All calculations TOWCON executes are dependent on the few basic parameters concerning wire data. These parameters may be individual for wire on each drum, and they are available by selecting monitor picture PARAMETERS.
Hint : Remember how to use the keypad ? If you want to refresh, study section 3.3.8
Wire Data :
Auto Limits :
Wire length : to be adjusted by use of pop-up keypad, total length of wire on topical drum Wire length out: to be adjusted by use of pop-up keypad, length of wire paid out, measured from drum. Wire diameter: to be adjusted by use of pop-up keypad, check that value is correct according actual wire. Cable lifter diameter: to be adjusted by use of pop-up keypad, check that value is correct according to actual chain.
Pay-out brake length : to be adjusted by use of pop-up keypad, used as braking-length in final sequence of automatic “PAYOUT” Read more about this limit in section 1.5.3 Tow/Hoist Limit : to be adjusted by use of pop-up keypad, used as rendering-length during auto “TOWING” Read more about this limit in section 1.5.4 Auto / Manual Limit : to be adjusted by use of pop-up keypad, used as the minimum wire length remaining
check “Rig chain data” if you don’t know the value. Read more about this limit in section 1.6
to be pulled in when TOWCON swap from “HOIST” to “MANUAL” Minimum possible value = 100 metres. Read more about this limit in section 1.5.5
Don’t forget to click ”RESET LENGTH” –button when you’ve made changes to Wire Data before you select another picture. Unless you click this button your adjustments won’t be used in TOWCONs calculations, even though they are displayed in the parameter-boxes on monitor picture PARAMETERS. Notice that if you want to use the stern of ship as the point were wire paid out is to be zero, you’ll have to ”lie” to TOWCON and use the actual wire length minus the distance from drum to stern as the Wire Length –parameter. Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page54
4.5
Alarm
By pressing the ALARM tab at top of the screen the picture changes to the alarm folder where alarms are shown, both currenent and past. The alarms have 3 different statuses differentiated by color. Red alarms are new alarms not yet acknowledged. Yellow alarms are acknowledged by user but the situation is not resolved. Gray alarms are acknowledged by the user and is no longer valid. All alarms recorded and kept on the screen until they disappear at the bottom of the alarm window. In addition to the alarms mentioned in the following chapters a Towcon system may have several customer specific alarms.
4.5.1 Alarm Reset button By pressing the ALARM RESET button at the bottom right corner of the screen the user resets the audible alarm ( if any ) and signals to the system that he is aware of the situation. if alarm is still active ( Valid ) it will turn Yellow othervise it will turn Black. In other words this button resets all current alarms. 4.5.2 Alarm lamp The alarm lamp turns Red as soon as an alarm situation has occurred. And switches to Green as soon as the operator have pressed the reset alarm button. This is basically to inform the operator that there is an new alarmsituation that needs his attention.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page55
4.5.3 Maxvalue logging The system is also equipped with an internal logging system that keep track of the maximum pressures ,speeds and temperatures of the systems winches. The last registered value is visible in the four display windows ( one for each winch ) just below the alarmwindow. 4.5.4 Emergency stop If one or more of the emergency stop switches has been pressed the system responds by setting off both visual and audible alarm. 4.5.5 Overspeed There is three different overspeed limits. Prewarning which is the adjusted hi limit on the rpm dial. Hi and HiHi limits is factory preset depending on type of motor is used. The three different alarms produce individual texts in the alarm picture so they can easely be separated. The Hi and HiHi alarms may also on some systems activate rpm slowdown or system shutdown functions. 4.5.6 High oil temperature There is three different temperature limits. Prewarning which is the adjusted hi limit on the temperature dial. Hi and HiHi limits is factory preset. The three different alarms produce individual texts in the alarm picture so they can easely be separated. The Hi and HiHi alarms may also on some systems activate rpm slowdown or system shutdown functions. 4.5.7 High oilpressure If the oilpressure has exceeded the system pressure + 10% an alarm will be trigged. When trigged it gives both visual and audible warning. 4.5.8
High Tension The high tension alarm is activated if the tension exceeds the limit set in the tension bar.
4.5.9 Low pressure expansion system Indicates that the pressure in the oil expansion tank has dropped below the set limit , and both an visual and audible alarm is set off. 4.5.10 Low level expansion system Indicates that the oil level in the expansion tank has sunken below the set limit , and both an visual and audible alarm is set off. 4.5.11 Low brake pressure This alarm is activated if the pressure in the servo unit goes below a certain value. Check the servo unit and accumulators. 4.5.12 Rotating drum This alarm is activated if the drum starts moving while the brake is activated. 4.5.13 Bitter end Is active at all times and informs the operation that he is within a 100 meters from the end of the wire, and is likely to loose it if he continues to pay out. The alarm is both visual and audible.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page56
4.5.14 Node nn lost Informs the operator that the operator station has lost communication with one of the system nodes ( distributed control units). 4.5.15 Bus warning Informs the operator that there has been registered an abnormal amout of communication errors. 4.5.16 Wireguard Limit Is active during towing mode and is trigged if the wirelength exceeds towing length setpoint + towing length limit + wireguard limit. Towing length limit and wireguard limit is set on the parameter screen, towing length setpoint is set on the wirelength bar.
5
OPTIONS The system can be delivered in several configurations and options.
5.1
Isolation Transformer It is always wise to protect the electronics from noise, and one common source of such is the ships mains supply. This noise usually appears as 'spikes' of high voltage, generated by large inductive loads such as large motors - the hydraulic pumps for example. These 'spikes' may cause electronics containing microprocessors to reset or in serious cases to halt completly. The control unit is microprocessor based and is as such susceptibel to this kind of noise.
5.2
Uninterruptable Power Supply (UPS) In more critical systems one may wish to ensure that the system is functional even during a blackout situation, and then the solution is an uninterruptable power supply (UPS). These supplies will during normal operation constantly charge its batteries, which is contained within the unit itself, and when the ships mains power fails use these to generate power for the control unit. Depending on load the UPS will be able to deliver for 15 - 30 minutes, and that should in most cases be sufficient to secure the equipment and halt the system in a controlled manner. The UPS will also protect the system from noise pulses in the line.
5.3
Slave monitor The slave monitor produces an duplicate of the main monitor picture and has the same functionality. I is intended used where there is need for a second operator station with the possibilities for changing parameters and selecting pictures. The slave unit may be placed as far as 30 meters (cord length) from the main control. In a system with slave monitor both master and slave have the same priority, so if someone presses a button at a slave the system it will react as if it came from the main unit.
5.4
Additional workstations In one system there may be as many as 8 workstations , and each is totally independent from the others, which is the difference between a workstation and a slave monitor even if they looks the same from the outside. The difference is that a workstation has its own separate control computer , a slave monitor has not it simply uses the same computer as the main monitorb. In addition a workstation may be connected at any point on the communication network (max 500m total network length).
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
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815-015 Rev. B Page57
If there is a need for displaying different pictures at different monitors at the same time, an additional workstation is needed , not an slave monitor.
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
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815-015 Rev. B Page58
6
INDEX
A Alarm alarms Auto / Manual Limit
29, 32, 35, 52, 54 35, 54 43
B Bar Brake
18, 31, 51, 52 52
C Cable Chain Click Control Cursor
50, 52 50 21, 41 10, 23, 24, 30, 31, 40, 50 13, 14
D Data
50
G Graph
31
H hoist Hoist
47 45, 46, 47, 49
K Keypad
19
L Length Limit Lock
26, 27, 30, 44, 45, 46, 49, 50, 51 26, 27, 28, 31, 43, 44, 45, 46, 47, 48 39
M Measuring MMI
37, 51 15
O Overspeed
34, 44, 55
P Pmax Pmin Pressure Printer Pumps
28, 41, 44, 46, 48 41, 44, 49 28, 31, 41, 44, 46, 49 8 23
R Reset RPM
35, 54 17, 18, 52, 55
S Security
39
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
815-015 Rev. B Page2 Slider Speed
18 30
T Temperature Tension Touchscreen Tow Towing Trackball Trend
32, 33 29, 30, 31, 52, 55 8, 14 45, 46, 49 27, 41, 44, 45, 46, 49 8, 13 18, 31, 32
W wire
16, 17, 18, 19, 26, 27, 29, 30, 32, 35, 37, 40, 43, 44, 45, 46, 47, 48, 49, 50, 53, 55
Rolls-Royce Marine AS dep. Deck Machinery - Brattvaag Årsundveien 24, N-6270 Brattvåg, Norway
Tel.: +47 70 20 85 00. Fax: +47 70 20 86 00. E-mail: [email protected] Homepage: www.rolls-royce.com
USER INSTRUCTION Project : Type of vessel : Type of equipment : Shipyard : Hull no. :
A09067 SUPPLY / ANCHOR HANDLING. REMOTE CONTROL - WINCHES PROMAR 12
PREP. BY: MFH DATE
:11.02.04
PAGE OF
1 REPLACES: 17th
USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
819-067GB REPL. BY :
Information contained herein is the property of Rolls-Royce Marine AS and may not be copied, or communicated to a third party, or used, for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Marine AS.
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TABLE OF CONTENTS : TABLE OF CONTENTS : ............................................................................................................... 2 1 Preparing operation............................................................................................................... 3 2 Start of Pumps. ..................................................................................................................... 3 3 Release Brake. ...................................................................................................................... 3 4 Long Time Towing............................................................................................................... 4 5 Limitation of Maximum Pull................................................................................................ 5 6 Motor Modes: “1 Cell, 2 Cells or 3 Cells” ........................................................................... 6 7 Rotate the Winch. ................................................................................................................. 7 8 Connecting Drums to the Motor Units. ................................................................................ 8 9 Tooth wheel Lubrication ...................................................................................................... 9 10 Operating Spooling Device ................................................................................................ 10 11 Command Change - Bridge and deck................................................................................. 11 12 Command Change - Control Panel and Winch Operators Chair........................................ 11 13 Emergency Stop.................................................................................................................. 12 14 Emergency Release............................................................................................................. 12 15 Alarm lamps on Control Panel. .......................................................................................... 13 16 Overspeed Protection.......................................................................................................... 13 17 Calibrating Joystick for speed control of winch................................................................. 14 18 Calibrating Knob for Tension Control of winch. ............................................................... 15 APPENDIX : .................................................................................................................................. 17 A User Manual - TOWCON NT 815-015.......................................................................... 17 B User Instructions for WRC1021B 812-180GB ............................................................... 17 C Operating Instruction, Tension Control 814-269 ............................................................. 17 D Winch Operators Chair 819-005GB .............................................................................. 17 E User Instruction – Radio Controller 819-018GB ............................................................ 17
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
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1
Preparing operation.
Before starting any pumps, one should always make sure that brakes are engaged, and that there are no open valves, filters etc due to maintenance work or other, and that all personnel are alarmed against the danger of getting injured in chains, wires etc. because of winches is now being used.
2
Start of Pumps.
Before starting any pump or servo unit, make sure that no work is being carried out on winch motors, pipes, valves or other part of the hydraulic systems! All hydraulic pumps and servo units may be started and stopped by switches on starter cabinets, but normal operation is remote controlled from bridge, by use of Touch Screen on monitor included in the TOWCON NT Monitoring & Control System. Please study instruction for operating as described in manual 815-015. Windlass pump may be started and stopped by pushbuttons on Windlass Control Panel.
3
Release Brake.
This vessel has got Band Brakes on the Anchor Handling (A.H.) Drum, the Towing (TOW) Drum and the Secondary Winches (SEC) that may be remote operated from the Main Control Panel. These brakes may also be manually operated at the winch, but that opportunity is normally not used under ordinary circumstances. Please study instructions for emergency use of brakes on the name plate on Emergency Brake Pump on winch. In case of leakage in servo pipes brakes on A.H./TOW Winches will be engaged by a accumulator on the Emergency Brake Unit, securing a minimum of brake force. Please spend some time to study how the emergency systems works before releasing brakes by use of remote control. Before releasing any brake, be sure about the precautions mentioned in chapter 1.1 concerning security of crew is carried out. Section of Control Panel. Illustration only ! Example of control switch and indicating lamps on a control panel. Brake will normally be marked by the name of the winch, as an example : BRAKE – TOWING DRUM. Observe : Flashing Lamp = order not fulfilled !
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Releasing or Engaging a brake is controlled by a set of selector switch with attached control lamps, one set for each drum. Release brake by turning the selector to position Brake Off. The green lamp above the selector will now start blinking, and after a few seconds it will light continuously to indicate that the brake now is completely released. When engaging the brake again, turn the selector to position Brake On. Continuous light appears in control lamp ‘Brake On’ indicating engaged brake.
NOTICE ! It is inadvisable to release brake when drum is not connected to motor unit !
CAUTION ! Do always evaluate load on winch before releasing brake !
4
Long Time Towing.
This vessel may from time to time use one of the main winches only for holding the load/tow tensioned without rotating, and with brakes engaged. In this occasions it would be convenient to stop the servo pump to prevent the servo oil getting overheated, save fuel and reduce noise. However, the brakes are depending on continuously servo oil pressure, and because of a small leakage in valves etc the servo pump would even in this occasions had to been started from time to time to maintain high enough pressure. To make this start/stop sequence of servo automatic, the servo unit is equipped with facilities to take care of this job of its own, if so is wanted. The automatic start/stop function is called ‘Long Time Towing’, and is remote controlled from the Main Control Panel on bridge. Look for the selector and control lamps marked ‘Long Time Towing’. If the automatic function is wanted, turn the selector to position ‘ON’, and the lamp to the right will be illuminated to indicate that the function is activated. Start and Stop of servo unit will be possible as normal when ‘Long Time Towing’ is activated, and the control lamp on the Control Panel will even show when the automatic system is running the pump.
Section of Control Panel. Illustration only ! Example of control switch and indicating lamps on a control panel.
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CAUTION ! When Long time Towing is active the servo unit will start automatically when pressure is below limit for start, regardless of buttons pressed on screen or on control panel. Keep this in mind when maintaining the servo system.
5
Limitation of Maximum Pull.
It is possible to control the power on the A.H.-Drum, TOW-Drum and the Secondary Winches by limiting the oil pressure in their hydraulic motors. Pressure is controlled by Tension Control knob. To limit the pressure, turn the knob counter-clock. To allow higher pressure, turn the knob clockwise. Maximum pressure is 45 Bar. Please notice that you may not see the pressure increase on panel meters or bar graphs etc even if you adjust the knob. This is so because the pressure will never exceed what is necessary to cope with the present torque on hydraulic motors. Please notice that it is necessary to have the Servo Pump in service to operate as described in this chapter.
Section of Control Panel. Illustration only ! Please notice that you may not see the pressure increase on panel meters or bar graphs etc even if you adjust the knob. This is so because the pressure will never exceed what is necessary to cope with the present torque on hydraulic motors. The little red lamp below the knob will light when controller is activated.
Change of command : If there is a second knob for adjusting tension, perhaps on the Winch Operators Chair, the red lamp below the tension knob will not be lit when the “slave controller” is in command. If the red lamp is blinking, a “command change” is denied because the knob that’s not in command isn’t adjusted equal to the activated one. Adjust the knob that’s “parked” to same position as the activated one, and the change of command will be fulfilled.
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
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6
Motor Modes: “1 Cell, 2 Cells or 3 Cells”
Operator may select operation by use of all motor cells to get maximum pull, or by “closing” one of them to get the advantage of increased rotation speed. Selection is possible by operating switch on control panel on bridge. System will automatically select “3 Cells” when “power on”. System will select use of motor cells according to operators request and what is allowed pressure, and will not accept commands that may result in uncontrolled pay out because of winch not being capable of holding load when one cell is closed. This is secured by the system evaluating measured pressure and comparing this to what the winch will be capable of holding if one motor cell is closed. If selected mode is not available, the indication lamp for this mode will be blinking. System will not close the motor cell unless pressure is safe, and tension controller is adjusted to max , but as soon as these tests are OK, the system will change to selected mode. System will not swap to another “cell-mode” unless this is indicated by user operating the selector switch. System will not take in use closed motor-cell automatically to prevent pay-out because of pressure exceeding max pressure adjusted on safety valves. In case of uncontrolled pay out when operating on 1 cell, operator should select 2 Motor Mode. This may be done at any time, regardless oil pressure and adjustment of tension control knob.
Sections of Control Panel : Illustration only ! Equipment on various vessels may look slightly different.
To select 1 Motor Cells : Adjust actual tension knob to max. Make sure that brake is not engaged. Turn selector to the right to select 1 Cells. If winch can hold the load without paying out, on motor cell will be closed. This will make speed accelerate.
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e
7
Rotate the Winch.
It’s possible to remote control rotation of the A.H.-/TOW-Drums, the Sec. Winches and the Tugger Winches from bridge. Rotation may also be controlled by manual operation of the manoeuvre valves on the winch motors, but normal operation is controlled by levers on the Control Panels on bridge. To pay out, push lever firmly ahead. To haul in, pull lever firmly against you. Avoid too quick movements on control levers to minimize stress on generators, pipes, pumps and other hydraulic equipment, and to make winch operations as little “noisy” as possible. Releasing the lever will make the winch stop, as the lever automatically returns to stop position.’ Please notice that it is necessary to have the Servo Pump in service to operate as described above.
Section of Control Panel. Illustration only ! Notice that there are also two switches at front of the joystick grip and one on each side on the rear. These switches may be used for operating a Spooling Device. Please see own part of instruction.
Before rotating any winch, be sure about the precautions mentioned in chapter 1 concerning security of crew is carried out.
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8
Connecting Drums to the Motor Units.
Select drums by operating selector switches on the Main Control Panel. A.H. Drum Coupling and Towing Drum Coupling Selection is done by a rocker switch on the Main Control Panel. Operate by switching the selector to wanted position. When the coupling position selector is turned, one of the adjacent control lamps will start blinking. When the coupling is in right position, the control lamp will light continuously. Section of Control Panel. Illustration only ! Coupling indication lamps. When the coupling is in right position, the control lamp will light continuously.
Please observe It is not possible for any of the drums to disengage the drum coupling if the brake is released. If for any reason one of the couplings should move from its decided position, the topical control lamp will start blinking to alarm the operator. It is not possible to operate both the AH-Drum and the Towing Drum at the same time.
When a coupling position selector is turned, one of the adjacent control lamps will start blinking. When the coupling is in right position, the control lamp will light continuously. If for any reason one of the couplings should move from its decided position, the topical control lamp will start blinking to alarm the operator.
CAUTION ! Disengage drum coupling when towing with brake on ! Take precautions not to exceed specified max-load on cable lifters !
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
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9
Tooth wheel Lubrication
This vessel is supplied with a lubrication system for the tooth wheels on the A.H.-Drum, TOWDrum and the Secondary Winches. Even though this system is automatic it is necessary to check the amount of grease on the wheels before every winch operation. This must be done by manual inspection because the system has no sensors that can verify that grease is in fact applied to the wheels and is not squeezed out through a damaged pipe, or that something else has made the system failing. There are inspection lids on all gear covers. If inspection unveils lack of grease, extra lubrication must be supplied by manual override of the automatic function. Push the “Force Lubrication” –button on the control panel. Grease will now be supplied continuously until drum has rotated one turn. The “Force Lub.”-button will now be blinking to remind operator that this function is activated. The “Force Lubrication” period can not be interrupted from the remote control, but the function will be aborted if drum is stopped. The control lamp on panel will be shut off immediately if the period is ended or the function of any reason is aborted. The lamp “Lubr. Now” will be lit when grease is applied to one of the wheels. Please observe this control lamp during winch operation to be sure that system is in order. If one of the drums is rotating for longer periods without this lamp being lit there is reason to suspect that there is a malfunction in the lubrication system, and tooth wheels must immediately be inspected. The lamp “Low Grease Level” will be lit if grease level in reservoir gets low. Action must immediately be taken to refill the tank or unveil any fault in the system. On the Lubrication Cabinet on winch is to be found the same control lamps that are described above, and there is also a “Force Lubrication”-switch. Be aware that pushing this button will not give continuously greasing for more than one turn of the rotating wheel.
Control lamps and ”Force Lubrication” –switch on control panel on bridge. Section of Control Panel : Illustration only ! Equipment on various vessels may look slightly different.
CAUTION ! The automatic lubrication system can fail. For this reason always check the gear transmission visually to verify that the teeth are covered with grease. The winch must never run without grease on gearwheels. If this is done, you will get breakdown of the gearwheels.
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:11.02.04
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Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
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10
Operating Spooling Device
The spooling devices are to be operated by use of small push buttons on the speed control joysticks. This makes it possible to operate both Hoist/Lower and spooling at the same time by using only one hand. Observe that when operating speed control or Spooling Devices by use of joystick on armrest of Winch Operators Chair, they must be activated by pushing the “Activate”button on stb armrest panel. Do also remember to start Spooling Servo Unit. Make spooling device move to stb by pressing the left push button at the front of the joystick head, or use the right button to make it move in port direction.
Section of Control Panel. Illustration only ! Spool STB : Press left button on front of grip. Spool PORT : Press right button on front of grip.
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11
Command Change - Bridge and deck.
Some remote control functions, such as hoist/lowering and spooling, may also be carried out by use of portable controllers operated on deck, where view to what’s going on normally is much better than from the wheelhouse. It is always officers on bridge that has the opportunity to allow crew on deck to operate the winches by use of the portable controllers and personal on bridge may at any time take over. Assigning command is done by use of selector switch on control panel on bridge, but the portable unit will not be “in service” before the crew on deck has activated it according to a special procedure. Until this is done, bridge is still in command. Please study special User Instruction for Portable Controller to get full details.
Sections of Control Panel : Illustration only ! Equipment on various vessels may look slightly different.
12
Command Change - Control Panel and Winch Operators Chair.
Functions that may be remote controlled from Winch Operators Chair is Speed Control on one or more winches, tension control on one or more winches, and even wire spooling if this function is applicable. Please study drawings of your chair and the special Users Instruction for Winch Operators Chair before taking the remote control in use. Changing command between joysticks, tension controllers, and switches for wire spooling on the chair and on the control panel will be as selected by push buttons on chair arm rests. Be ware that if operators chair has claimed command for one or more functions, this can only be undone by selectors on the chair. Winch Operators Chair should never be activated unless person in charge of winches is seated in it and is fully concentrated of all work concerning winch equipment ! Please study the special Users Instructions.
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:11.02.04
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
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13
Emergency Stop.
If something unexpected or dangerous should occur, demanding the winches to be stopped immediately, there is an Emergency Stop Switch on the Control Panel on bridge. There is also one of these switches placed on a small junction box on a convenient place on deck. Please make sure that the crew is informed about where they are placed before any winch operations are started. Section of Control Panel. Illustration only ! Pushing down one of these switches will stop the Servo Unit and all Main Pumps, make the manoeuvre valves on winches go to Stop Position, and engage all remote controlled brakes. NOTE ! Pushing down one of the Emergency Stop Switch on the Radio Controls will only stop the pumps, including spooling pumps, that may be used by the winches that are controlled from that radio control. Servo pumps will not be stopped by the Emergency Stop Switches on Radio Controls.
14
Emergency Release.
If something unexpected or dangerous should occur, demanding the winches to release the load immediately, there is an Emergency Release Switch on the Control Panel on bridge. There is also one switch placed on deck. Please make sure that the crew is informed about where they are placed before any winch operations are started. One should however be ware of the rather serious consequences using these switches may cause to ship, crew and equipment; and because of this the switches are also protected against being pushed down by accidents. Pushing down one of these switches will cause brakes being only smoothly engaged, with a rather weak force, just enough to prevent uncontrolled rotation on drum resulting wire injury. Section of Control Panel. Illustration only ! NOTICE ! Observe that pulling up again the activated switch will make the brake be engaged (if it was engaged when the Emergency Release was activated). If so is done while there is load in wire this may cause serious damages to winch equipment, towing wire, ship, and even expose crew members to great danger.
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:11.02.04
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
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15
Alarm lamps on Control Panel.
PLC Master Failed If this lamp is lit there is a fault in the remote control system, and all of the cabinets included in the system has lost contact with the master PLC that is to be found under the Control Panel inside the control desk. Stop all winch operations immediately and engage all brakes manually to secure equipment and crew. Check power supply for PLC, and that the relay marked K8 on Bridge Panel Interface is activated. You’ll need the Circuit Diagrams to examine this properly. Please look in the Instruction Book to find these, normally in the last section of chapter 6. If power supply seems to be OK, try turning key on CPU-unit from position “RUN” to position “STOP” and wait a few seconds before switching back to “RUN”; this should restart the CPU. If no fault is found, please contact RRM Deck Machinery, Service Dep. PLC Slave Failed If this lamp is lit there is a fault in the remote control system, and one of the cabinets included in the system has lost contact with the master PLC that is to be found under the Control Panel inside the control desk. Stop all winch operations and engage all brakes manually to secure equipment and crew. Contact RRM Deck Machinery, Service Dep.
Sections of Control Panel : Illustration only ! General : All alarm lamps are red, and they will be blinking in case of an alarm situation. Light intensity on alarm lamps can not be reduced by the Panel Illumination Dimmer.
16
Overspeed Protection. If the Remote Control detects rotation speed on either the Stb Motors or the Port Motors of above 130 RPM, the hydraulic pressure in the winch motors will automatically be increased to maximum to reduce motor RPM. At the same time the Speed Control will adjust manoeuvre valves on the topical motor units to Stop-Position. A Brake On order will be given simultaneously to reduce the RPM under the preset limit. If this happens one should increase the motor pressure a little next time when similar operations is to be carried out, to prevent damages on winch motors caused by too high revolution speed. Towcon Monitoring System will warn the operator about high motor RPM. Please study the Users Instruction for the Towcon. Segment of Alarm picture in Towcon.
By reducing the RPM limit on the Towcon Monitoring System, overspeed protection can easily be tested. PREP. BY: MFH DATE
:11.02.04
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Fax. +47 70 20 86 00
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17
Calibrating Joystick for speed control of winch.
Entering "Cal mode" Make sure that all speed control levers are positioned to Stop-position. Press - and hold - "Lamp Test" and "Cal mode" buttons on the operator panel. All the lamps on the panel will be lit/blinking. Release buttons when all lamps but "Cal mode" is out. This should take approx. 3 seconds. The red “Cal mode” lamp will flash. - You have successfully entered "Cal mode" Sections of Control Panel : Illustration only ! Equipment on various vessels may look slightly different. To enter “Cal-Mode” : Press “CAL MODE” and “LAMP TEST” switches simultaneously for at least 3 sec. As you release the switches the “CAL MODE” button will be lit. To leave “Cal-Mode” : Do as described to enter Cal-Mode, press the switches simultaneously for about 3 s. As you release the switches the “CAL MODE” button will be shut off. Conditions:
All main pumps must be stopped, and brakes must be engaged to enter cal mode.
Commencing calibration of levers Move speed lever that you want to calibrate off centre and press "Cal Mode" button at the same time. If the movement is correct the panel will give feedback with blinking with all lights. - Release button. Move speed lever to hoist/lower. Panel should be blinking when lever is moving towards end position. The blinking indicates that "new" values are stored in memory. Move once again to hoist/lower. If no blinking is to be seen, release speed lever, and repeat "Commencing calibration of levers" for all applicable actuators. Leaving "Cal mode" Make sure all speed levers are released to Stop-position. Press "Cal Mode" button. There should be no blinking in any lamp. If blinking, repeat "Commencing calibration of levers". When finished - press - and hold - "Lamp Test" and "Cal mode" buttons on the operator panel. After approx. 3 seconds all the lamps on the panel will be lit/blinking. Then release buttons. You have successfully left "Cal mode", normal operation can now take place. PREP. BY: MFH DATE
:11.02.04
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
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NOTICE ! This procedure have to be performed if changing hardware in the PLC system or on the operator panel. When new "WRC-cards" are replacing old ones, please study WRC-manual for information regarding calibration on the WRC card. To calibrate chair speed lever, activate a drum from chair. Chair has to be active.
18
Calibrating Knob for Tension Control of winch.
Entering "Cal mode" Make sure that all tension control knobs are adjusted to middle pressure, position 5,5 on scale. To enter Cal-Mode follow procedure as described for calibration of speed control, see section 1.14 Sections of Control Panel : Illustration only ! Equipment on various vessels may look slightly different. To enter “Cal-Mode” : Press “CAL MODE” and “LAMP TEST” switches simultaneously for at least 3 sec. As you release the switches the “CAL MODE”-button will be lit. To leave “Cal-Mode” : Do as described to enter Cal-Mode, press the switches simultaneously for about 3 s. As you release the switches the “CAL MODE”-button will be shut off. Conditions:
All main pumps must be stopped, and brakes must be engaged to enter cal mode.
Commencing calibration of levers Move tension controller you want to calibrate clockwise and press "Cal Mode" button at the same time. If the movement is correct the panel will give feedback with blinking with all lights. - Release button. Turn knob clockwise to max ( 10 ) ; counter clock to minimum ( 1 ) ; and then back to middle. Panel should be blinking when knob is rotating towards end positions. The blinking indicates that "new" values are stored in memory. Repeat adjustment middle-max-min-middle. If no blinking is to be seen, repeat "Commencing calibration” for all applicable tension controllers. Leaving "Cal mode" Before leaving ”Cal-Mode”, make sure that all tension control knobs are adjusted to middle position. Press "Cal Mode" button. There should be no blinking in any lamp. If blinking, repeat "Commencing calibration". Leave “Cal-Mode” as described for calibration of speed control. PREP. BY: MFH DATE
:11.02.04
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
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NOTICE ! Before entering and leaving ”Cal-Mode” adjust tension controllers to middle pressure. This procedure has to be performed if changing hardware in the PLC system or on the operator panel. To calibrate chair tension knob, activate a drum from chair. Chair has to be active.
PREP. BY: MFH DATE
:11.02.04
PAGE OF
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
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APPENDIX : Appendix Description
Document
A B C D E
815-015 812-180GB 814-269 819-005GB 819-018GB
User Manual - TOWCON NT User Instructions for WRC1021B Operating Instruction, Tension Control Winch Operators Chair User Instruction – Radio Controller
PREP. BY: MFH DATE
:11.02.04
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USER INSTRUCTION Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REMOTE CONTROL SYSTEM PROMAR HULL NO. 12 INS
REV
819-067GB REPL. BY :
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Doc. name: C:\Program Files\Adobe\Acrobat 4.0\PDF Output\819-005GB.DOC
Print date: 08 December 2004
OPERATION INSTRUCTION WINCH OPERATORS CHAIR SECTION 0 - TABLE OF CONTENTS : Section
0 1 2
Section Description
Table of contents Use of Winch Operators Chair Remote Control Operation
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
Document
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SECTION 1 - USE OF WINCH OPERATORS CHAIR TABLE OF CONTENTS : Chapter
Chapter Description
Document
Page
1.1 1.2 1.3 1.4 1.5
Table of contents. Preparing operation. Activate Winch Operators Chair. Short pauses. “Parking” the Winch Operators Chair .
819-005
2 2 3 3 4
1.2
Preparing operation.
Before starting pumps, one should always make sure that the brakes are engaged and that there are no open valves, filters etc., due to maintenance or other work, and that all personnel are warned about the possibility of being injured by chains, wires etc. because of the winches being in use. Illustrations : Please notice that this is a general instruction which applies to several installations. Because of this illustrations/pictures in this document may show details slightly different from the equipment delivered to some vessels. IMPORTANT ! Please note that for you safety the portable control panel system is made "fail to safe". I.e. if any communication failure with the portable control panel should occur, the winch pumps will stop. NOTE : Never switch off or disconnect the portable winch control panel before the command has been transferred back to the wheel house
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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Activate Winch Operators Chair.
The most typical functions that may be controlled from the Winch Operators Chair are control of pull capacity and rotation speed on the most important winches onboard. As the chair is likely to be the preferred option for operation during long hours, it has higher ranking than the bridge control panel, and the Activate Switch is placed on stb armrest. You should always be seated in the chair before activating the controls, and it is recommended that all tension control knobs, both on armrests and on control panel, are adjusted to maximum before activating the Operators Chair. Push the “Active”-button, and it will change from yellow to green, indicating that the chair is now ready for use. Observe that all other buttons will still have yellow light. This is so because you’ve not yet actually taken command of any remote control function. As soon as you select an optional function, that button will change to green colour. There is normally one speed control joystick and one tension control knob on each armrest, but this may vary. Which winches that may be controlled are indicated by text on the push buttons, and it is possible to control speed on one winch and tension on another at the same time even if they are controlled from the same armrest. This may often result in very many possibilities, so take care when you choose! Stb Armrest
Port Armrest
Typical examples of panels on Stb and Port Armrest. Push the “Active”-button, and it will change illumination colour from yellow to green indicating that the chair is now ready for use.
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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Short pauses.
Generally the operator should never leave the chair when it is activated, though occasionally this may be necessary. Be aware that there is a risk that someone by an accident may nudge one of the speed joysticks when moving around in the narrow area around the chair and the control desks on bridge. Never leave the Winch Operators Chair when it’s activated unless you are certain that all other personnel on bridge are informed about the risk of unintentional rotation of drums if they in any way touch joysticks on armrests !
1.5
“Parking” the Winch Operators Chair
When the Winch Operators Chair is to be “parked” this is done simply by pressing the “Pause”button on stb armrest. Before this is done it is a good habit to always set tension controllers on both armrests and control panel to max adjustment. If “Pause”-button is pressed, all orders controlled from chair will immediately be transferred to joysticks and tension knobs on control panel. If the tension controllers activated on chair do not have an adjustment equal to that of the control knobs on panel, it won’t be possible to “park” the chair, and the indication lamp on armrest and on panel will blink. Adjust the knob on panel to match adjustment of the knob on armrest. If possible, it is recommended to adjust all tension control knobs, both on armrests and on control panel, to maximum before “parking” the chair. This is the safest way of doing the “command change”, and it’ll ensure no trouble when you want to leave the chair. Study the chapter describing “Limitation of Maximum Pull” in the Operation Instructions for Remote Control functions. Tension control knobs on chair and on panel must be adjusted to equal setting before attempting to “park” Winch Operators Chair. Equal Adjustments : Control Knob on Chair and knob on Control Panel.
Tension Control Knob on control panel belonging to the selected tension option from armrest on chair.
Press the “Pause”-button to switch off all control options on Winch Operators Chair.
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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SECTION 2 - REMOTE CONTROL OPERATIONS TABLE OF CONTENTS : Chapter
Chapter Description
Document
Page
2.0 2.1 2.2 2.3
Table of contents Rotate the Winch. Operating Spooling Devices. Limitation of Maximum Pull
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5 5 6 7
2.1
Rotate the Winch.
It may be possible to remote control rotation of one special winch both from bridge and from a Portable Controller on deck, as well as from the Winch Operators Chair. As mentioned in chapter 1.3 the chair has higher ranking than the Control Panel on bridge, but it can’t take command from a Portable Controller. Control of a winch that’s occupied by a portable controller may be prepared by selecting it on a armrest, but you’ll not actually get control of the winch before the command is transferred back to bridge. Push buttons on the armrests will clearly indicate which winches you may control from the Operators Chair. Select by pressing a button, and when it changes colour from yellow to green, the joystick is ready for operation. To control another winch, simply release the joystick and press another button. To pay out, push lever firmly ahead. To haul in, pull lever firmly towards you. Avoid any quick movements on control levers to minimize stress on generators, pipes, pumps and other hydraulic equipment, and to make winch operations as quiet as possible. Releasing the lever will make the winch stop, as the lever automatically returns to stop position Illustration shows part of stb armrest. Notice that you can’t select control of a winch unless the chair is activated. Chair will keep command of the last selected winch until it is “parked” by the operator pressing “Pause”-button.
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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Operating Spooling Devices.
The spooling devices are operated by use of small push buttons on the speed control joysticks. This makes it possible to operate both Hoist/Lower and spooling at the same time by using only one hand. Observe that joystick will always control spooling on the winch that is selected to have its speed controlled from the armrest. Make spooling device move to stb by pressing the left push button at the front of the joystick head, or use the right button to make it move in port direction. Spooling rollers may be separated to allow bigger attachments through by pressing the left button at the rear side of the joystick’s head simultaneously with either the Stb-button or the Port-button. Opening is achieved by moving stb roller to stb direction or port roller to port direvtion one at a time. The right side-button is pressed simultaneously with either the Stbbutton or the Port-button to close spooling device. Also when closing the device, the rollers are moved one at a time. Observe that spooling device may not be opened to maximum distance between rollers if device is to near end position. In that case move device a little to centre before making a new attempt to gain maximum opening once more.
Spool STB : Press left button on front of grip. Spool PORT : Press right button on front of grip. Opening Spooling Device : Move Stb Roller to stb by pressing left front button and left rear button simultaneously. Move Port Roller to port by pressing right front button and left rear button simultaneously. Closing Spooling Device : Move Stb Roller to port by pressing left front button and right rear button simultaneously. Move Port Roller to port by pressing right front button and right rear button simultaneously
Illustration : Typical Part of Port Armrest
OBSERVE ! There is several types of spooling devices, which do not necessarily have all the same functions. One type may be opened and closed as described above, while another type have fixed distance between rollers and can’t be opened at all. Another variant is that the rollers may be separated as described, but the device will close by the movement of the rollers when normal spooling is resumed. Please study the Operation Instruction for Remote Control to see which applies to that specific vessel.
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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Limitation of Maximum Pull.
It is possible to control the power on some of the winches by limiting the oil pressure in their hydraulic motors. Pressure is controlled by a knob marked Tension Control, which is most likely to be found both on armrests on the Operators Chair as well as the Control Panel. Select which winch you want to control by pressing one of the push buttons below the knob. The push button change colour from yellow to green to confirm your choice. If you press a button and it starts blinking, you are then denied control of the tension adjustment because the controls on armrest and Control Panel are not adjusted to equal pressure. Adjust the knob on armrest equal to the knob on control panel and press the push button once more. If the knob on armrest is already operating tension control for one winch, you’ll also have to check that the corresponding knob on panel is adjusted to equal value before attempting to take control of another winch. Please find more about tension control in the Operation Instructions for Remote Control. To limit the pressure, turn knob counter-clock. To increase pressure, turn knob clockwise. Please notice that you may not see the pressure increase on panel meters or bar graphs etc even if you adjust the knob. This is so because the pressure will never exceed what is necessary to cope with the present torque on hydraulic motors.
Illustration : Typical Part of Port Armrest PLEASE NOTICE : If chair is already controlling tension on one winch, both the corresponding knob on control panel and the knob for the new winch you want to take control of must be adjusted equal to the knob on chair before a change will take place !
Illustration above : Control knobs on Control Panel. Left knob : winch is controlled from chair Right knob : winch is controlled from panel.
It is recommended to always adjust all tension control knobs on panel to maximum before activating the chair, and to adjust knob on armrest to maximum each time a new winch is selected.
WINCH OPERATORS CHAIR OPERATION INSTRUCTION REMOTE CONTROL
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OPERATION INSTRUCTION RADIO REMOTE CONTROL - WINCHES
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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SECTION 0 - TABLE OF CONTENTS
SECTION 0 - TABLE OF CONTENTS ..............................................................................................2 SECTION 1 - USE OF RADIO CONTROLLER ...............................................................................3 1.1 Preparing operation......................................................................................................................3 1.2 Test Control Unit .........................................................................................................................3 1.3 Activate Radio Controller............................................................................................................3 1.4 Short pauses in use of Radio Controller ......................................................................................4 1.5 Shut off Radio Control System....................................................................................................5 1.6 Operating at “Slow Motion”. ( Optional ) ..................................................................................5 1.7 Using the Radio Controller connected by cable...........................................................................5 SECTION 2 - REMOTE CONTROL OPERATIONS .......................................................................7 2.0 Rotate the Winch. ........................................................................................................................7 2.1 Operating Spooling Devices. ( Optional )...................................................................................7 2.2 Emergency Stop ...........................................................................................................................9 2.3 Emergency Release. ( Optional ) .................................................................................................9
IMPORTANT ! Please note that for you safety the portable control panel system is made "fail to safe". I.e. if any communication failure with the portable control panel should occur, the winch pumps will stop. NOTE 1: Never switch off or disconnect the portable winch control panel before the command has been transferred back to the wheel house NOTE 2: Wireless winch control panels will give low battery warning at approx. 15-20 minutes remaining capacity. If the low battery alarm goes off during operation, interrupt the winch operation immediately and transfer the command back to the wheel house. Change battery before the wireless control panel is used again.
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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SECTION 1 - USE OF RADIO CONTROLLER
1.1
Preparing operation
Before starting pumps, one should always make sure that the brakes are engaged and that there are no open valves, filters etc., due to maintenance or other work, and that all personnel are warned about the possibility of being injured by chains, wires etc. because of the winches being in use. Please observe that it is not possible to control all functions from the Radio Controller. Starting pumps, releasing brakes etc must most likely be carried out by personnel on bridge before winch can be controlled from deck. Illustrations : Please observe that this is a general instruction that applies to several installations. Because of this illustrations/pictures in this document may show details slightly different from the equipment delivered to some vessels.
1.2
Test Control Unit
Before taking the Radio Controller into use the battery condition should always be checked. If “Battery” –lamp changes colour from green to red, it’s time to recharge the battery. To secure reliable operation the battery should always be replaced by a fully charged one before using the controller. Battery is not necessarily fully recharged even if battery indicator comes on with green light. Green light indicates only that voltage is adequate for proper operation. Please insert a newly recharged battery every time new work is to be started. Battery OK !
1.3
If battery indicator changes to red light, switch off unit as described below as soon as possible! !
Battery voltage low !
Activate Radio Controller
All winch operations should be supervised by personnel on bridge, and it is only possible to activate Radio Controller if this is cleared by setting selector switch on control panel to Deck Operation. Find more about “Command Change” between bridge and deck in the Operation Instruction for Remote Control. If permission to operate winch from deck is approved, and selector switch is in position Deck, the Radio Control System can be activated by switching on power for the Radio Receiver.
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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This is done by the “Activation Switch”, which is an illuminated rocker switch mounted in a small junction box. The “Activation Switch” is normally placed near the deck entrance. Activate the Portable Controller by turning the Key-switch to position ON ( 1 ). Then the “Start-switch” must be pushed within 5 seconds to avoid an emergency stop. When controller is ready for use the “In Command” –lamp will be illuminated.
Switch on Radio Receiver with the “Activation on Switch”
Key-switch should be removed from controller and kept in a safe place when system is not in use.
“Start”-button is normally found on the right side of the Radio Controller. “Start”-button is marked by a symbol illustrating a horn ( audible alarm ) Switch on controller by with the key-switch, and push “Start”-button within 5 seconds. Controller is ready for use when the “In Command” –lamp is illuminated
1.4
Short pauses in use of Radio Controller
If Radio Controller is not needed for a while it should be switched off to save battery capacity. Push the “Start”-button and turn the key-switch to switch off the controller. If you forget to push the “Start”-button before switching off the controller, this will cause an Emergency Stop. Likewise Emergency Stop will take place if you wait more than 5 seconds after pushing the “Start”-button before switching off the unit. When the controller is needed simply activate it once more as described above. Never leave the Radio Controller out of reach or out of sight when it is activated! If battery capacity gets too low the controller will automatically be shut off, which will cause an Emergency Stop !
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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1.5
Print date: 08 December 2004
Shut off Radio Control System
If winch operation requiring the Radio Controller is terminated, the Radio Control System should be shut off immediately. Switch off the Controller as described above to avoid an unintended emergency stop. Switch off power for Radio Receiver by setting the Activation Switch to position “Off”. Set the selector on control panel on bridge to position Bridge. When controller is not in use the key should be removed and stored in a safe place.
1.6
Operating at “Slow Motion”. ( Optional )
If winch operation should be carried out with very little wire speed, it is possible to ensure that full speed is not available just by selecting “slow motion” on the radio controller. Switching between normal speed and slow motion, or vice versa, can be done at any time. When slow motion is selected max hoist/lower on joysticks on controller will not give max speed order to the remote control system. This will secure that max speed on winch is not possible as long as “Slow Motion” is selected. Speed reduction for slow motion operation may be adjusted as described in the “Operating Instructions” delivered by the radio control manufacturer, but it is recommended to leave this as adjusted by the Rolls Royce supervisor.
Normal function
“Slow Motion”
Select normal function or “Slow Motion” whenever you want.
1.7
Using the Radio Controller connected by cable.
Even though the radio signals do not reach more than approx. 100 metres it may sometimes be advisable to use the radio controller connected by cable to avoid interference on other systems. The Radio Control System for winch will not be jammed by other radio systems, but there is no guarantee that the winch radio won’t influence other systems. Especially when the ship is in a harbour, very close to other vessels, or at a yard for maintenance etc., it may be a chance that other radio systems are in use at the same time.
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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Connect control cable before switching on the receiver or the controller. When cable is connected in both ends, the controller will be activated and used exactly in the same way as if it where operating by radio signals. Switch of system as described in chapter 1. 6 before disconnecting the cable.
Connection point on Controller is normally protected by a plastic cap.
Cable between Deck Connection and Receiver should not be disconnected. The cable may however easily be disconnected at the receiver cabinet. When cable is not connected, the protecting cap should always be attached.
NOTICE ! Cable to be connected between Controller and Connection Point on deck before system is activated. Protection cap on Controller and Connection Point must always be in place when cable is not connected !
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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SECTION 2 - REMOTE CONTROL OPERATIONS
2.0
Rotate the Winch.
Radio Controller may contain joysticks for remote controlled speed on several winches, but the directions given for correct use are the same for all. To pay out, push lever firmly ahead. To haul in, pull lever firmly towards you. Avoid any quick movements on control levers to minimize stress on generators, pipes, pumps and other hydraulic equipment, and to make winch operations as quiet as possible. Releasing the lever will make the winch stop, as the lever automatically returns to stop position. If it is essential that the winch doesn’t rotate too fast it is possible to limit the order given from Radio Controller. Even if joystick is moved to full-speed position this will then only result in a reduced speed order to the Remote Control System. Please find more about this in section 1.7 Please notice that it is necessary to have the Servo Pump in service to operate as described above.
Before rotating any winch, be sure that the precautions mentioned in chapter 1.2 concerning security of crew are carried out.
2.1
Operating Spooling Devices. ( Optional )
The spooling devices are operated by tilting the speed control joysticks to either left or right. This makes it possible to operate both Hoist/Lower and spooling at the same time by using only one hand. Remember that Spooling Servo Unit must be started. Make spooling device move to stb by pressing the joystick to the left, or press it to the right to make it move in port direction. Joystick may be moved both forward/backwards and sideways simultaneously, or the spooling device may be moved stb/right when the winch is stopped. Spooling rollers may be separated to allow bigger attachments through by pressing the “Open-Close”switch to position Open simultaneously by tilting the joystick either left or right.
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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Opening is achieved by moving stb roller to stb direction or port roller to port direction one at a time. Close spooling device by pressing joystick to left or right simultaneously as the “Open_Close”-switch is held in position Close. Also when closing the device, the rollers are moved one at a time. Observe that spooling device may not be opened to maximum distance between rollers if device is to near end position. In that case move device a little to centre before making a new attempt to gain maximum opening.
The Open-Close –switches will return to neutral position when you release them. Keep it in Open /Close position simultaneously to pressing joystick to the left/right.
Move spooling device to stb or port by pressing the joystick sideways as indicated on the controller.
NOTICE ! There are several types of spooling devices, which do not necessarily have all the same functions. One type may be opened and closed as described above, while another type have fixed distance between rollers and can’t be opened at all. Another variant is that the rollers may be separated as described, but the device will close by the movement of the rollers when normal spooling is resumed. Please study the Operation Instruction for Remote Control to see which applies to that specific vessel
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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2.2
Print date: 08 December 2004
Emergency Stop
If something unexpected or dangerous should occur, which entails that the winches must be stopped immediately, there is an Emergency Stop Switch on the Radio Controller. Please observe that an Emergency Stop caused by switch on Radio Controller may not stop all pumps. However, all pumps used for winches controlled from the Radio Controller will be stopped. Please take time to examine this before starting any winch operations. There is also one Emergency Stop Switch placed on a small junction box in a convenient place on deck, as well as a switch on the control panel on bridge. Please ensure that the crew are informed about their whereabouts before any winch operations are started.
Section of Portable Controller. Illustration only ! Red button = Emergency Stop Pushing down one of these switches will stop the Servo Unit and Main Pumps, make the manoeuvre valves on winches go to Stop Position, and engage all remote controlled brakes.
2.3
Emergency Release. ( Optional )
If something unexpected or dangerous should occur, causing the winches to release the load immediately, there is an Emergency Release Switch on the Control Panel on bridge. There is also one switch placed on deck. Please make sure that the crew are informed about their whereabouts before winch operations are started. One should however be aware of the rather serious consequences that using these switches may have on the ship, crew and equipment. Because of this the switches are protected against being activated by accident. Pull the switch actuator upwards and tilt it forwards to activate. Activating Emergency Release will smoothly engage the brakes, with a rather weak force, but just enough to prevent uncontrolled rotation on drum resulting in wire injury.
Section of Control Panel. Illustration only !
WARNING ! Observe that if function is reset this may result in the brake being engaged. ( if it was engaged when the Emergency Release was activated ) If done while there is load on wire this may cause serious damages to winch equipment, towing wire, ship, and even expose crew members to great danger.
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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2.4
Print date: 08 December 2004
General Alarm Lamp ( Optional )
Some situations will cause Remote Control or TOWCON System to alarm the crew on bridge by audible or visual alarm signals. This may be alarm lamps on control panels or texts on the TOWCON Monitor. These alarms are not available to the person who is operating the Radio Controller on deck, but he will on some devices get a general alarm, telling that something unexpected has happened. If the alarm lamp on the Radio Controller is lit, the winch should be stopped immediately and the bridge crew in charge should be consulted for further information.
Stop all winch operations and contact personnel on bridge if the Alarm-lamp is lit !
HETRONIC OPERATION INSTRUCTION REMOTE CONTROL INS
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Rauma Brattvaag™ Lubricants - Hydraulic oil: ISO VG100 Winches and Cranes Hydraulic Main System
Remote Controls
Lubricants
V.I. P.P. Enclosed gears
Types R8 – R11 – R12
Type of oil
V.
F.1 Unitractor 20w/40 Agip OSO 46
122 130 145 106
-27 Agip Blasia 237 -20
1) Grease
Agip GR MU3
Bartran HV100
100 133
-33 Energol GR-XP 320
Energrease MM-EP2 Bartran HV15
15
155 -51
Supreme Five Star 100w-40 20w-40
Multifak EP2
Rado Oil HDZ15
16
155 -51
88 187 126 128
-30 -24
Hyspin AWH-M100
100 130
-30 Alpha SP320 Alphasyn HG320
Meropa Lubricant 320
Spheerol EPL2 2) APS 2 Grease
Powerdraulic
90 136
Estela H120
145 120
Rando HDZ100
100 142
-33 Meropa 320
Visga 100
100 106
-33 Epona Z 320 Epona SA 320
2)
-33 Spartan EP 320 Spartan SEP 320
2)
-40 Giran 320 Giran S 320
2)
Univis N100 Hydran HV100
97 150 99 154
Hydraulic Oil AW100 100
1)
-25 Centlube G76 20 Engranasjes HP6 Lissur Engranasje 633
15
150 -51
14
140 -35
Arga L2 Arga EP2
Estela H20
16,8 150 -45
Multifak EP2 Starfak EP2
Rando HD215
15
155 -48
Epexa 2
Visga 15
15
150 -45
Beacon EP2
Univis N15
14
150 -45
Ceran WR2
Hydran HV22
21,5 158 -46
Hydraulic Oil AW22
22
95
Mobil DTE 11M
16
151 -58
HydraWay HVXA15
16
144 -45
Mobil DTE 18M Mobil DTE 19M
102 127 150 121
-40 Mobilgear 632 -37 Mobil SHC 632
Mobillux EP2 2) Mobilith SHC 460
Hydra Way HVXA100
100 190
-33 Load Way EP320 Mereta 320
2)
Hydro MV100
100 137
-30 Optigear BM 320 Optigear HT 320
Tellus Oil T100
100 154
Rando HD Z100
100 142
Klübersynth GEM4-100
100 >140
UniWay EP2N
1) Products listed in columns “Enclosed gears” and “Bearings” may deviate from those stated on lubrication chart for the particular plant. In such cases the latter shall take precedence. Open gear lubricants, see lubrication chart for the particular plant.
14,2 103 -35
Olista Longtime 2
Hydro 22
23
106 -26
Tellus Oil T15
15
153 -51
Rando Oil HDZ15
15
155 -48
2)
Polylub GA 352 P Crucolan 22 2) Staburags NBU 12K
23,0 90
2) Synthetic oil, recommended for winch gear operation in Arctic area. Notes in tables: V = Viscosity cSt / 40°C V.I. = Viscosity Index P.P. = Pour Point in °C
Rolls-Royce Marine AS Deck Machinery – Brattvaag Årsundveien 24, N-6270 Brattvåg Norway
-18
Philube Grease EP2 Magnus Hydraulic A75
-36 Omala Oil 320 SRS 4000 Paolina 320/Omala HD320 2) -33 Meropa 320 Multifak EP2 Starfak EP2 Klüberoil GEM 1-320 -45 Klübersynth GEM 4-320
V.I. P.P.
Nevis 3
EP2 Grease
-20 IBL Gear Oil Sp90
16,5 150 -50
Hyspin AWH-M15
-18 Gear Lube 6EP
160 137
V.
Agip Arnica 625
Regulus A 2 EP
95
Magnus Hydraulic A700
Type of oil
Tel. +47 70 20 85 00. Fax +47 70 20 86 00 E-mail: [email protected] Homepage: www.rolls-royce.com
-22
Rauma Brattvaag™ Lubricants - Hydraulic oil: ISO VG100 Hydraulisk olje
Hydraulic oil
Oljen er en av vinsjeanleggets hovedkomponenter, og må derfor velges og behandles deretter. Følgende krav stilles til en hydraulikkolje:
The oil is one of the most important components of a winch installation, and must be chosen and considered with this in mind. The following requirements must be met:
1. Viskositetsindeksen må være over 120. 2. Olje må ha høy skjærstabilitet. 3. Oljen må ha tilsetninger som hindrer slitasje, rust og skumdannelse. 4. Oljen må ha lang brukstid, - tåle varme og fuktighet. 5. Lav luftløselighet og evne til raskt å skille ut luft. 6. Oljen må ha gode smøreegenskaper.
1. Viscosity index above 120. 2. High shear stability. 3. Contain additives preventing wear, corrosion foaming. 4. Be of type longlife and withstand heat and humidity. 5. Have low solubility in air and ability to release air. 6. Have good lubrication qualities.
and
Valg av hydraulisk olje Oljens tykkelse står i nært forhold til anleggets virkningsgrad. En tynn olje vil således redusere virkningsgraden ved høye temperaturer. På den annen side kan en tykk olje medvirke til vanskeligheter under oppstarting av et anlegg ved lave temperaturer. Det er derfor svært viktig at oljen tilfredstiller de krav som er nevnt foran.
Choice of hydraulic oil The viscosity of the oil is closely related to the efficiency of the installation. A thin oil will reduce the efficiency at high temperatures. On the other hand a thick oil will cause difficulties when starting an installation at low temperatures. It is therefore essential that the oil meets the above mentioned requirements.
Skifting av olje
Oil change
En hovedregel er at oljen alltid må skiftes dersom noen del av de hydrauliske komponenter har vært kjørt ned. Det er ellers vanskelig å gi generelle retningslinjer for når den hydrauliske oljen bør skiftes. For å sikre kontinuerlig og sikker drift anbefales imidlertid en periodisk prøvetagning f.eks. en gang pr. år, for analysering av oljens tilstand. Prøven tappes direkte fra den sirkulerende oljen mens denne er varm, og bør være på minst ½ liter.
The hydraulic oil has to be changed if a brake down or an extraordinary wear of the hydraulic components has taken place. It is otherwise difficult to give general rules when oil should be changed. To ensure continuos and troublefree operation, it is recommended that samples should be taken at regular intervals, for instance once a year, for analysing the condition of the oil. The sample must be taken when the oil is circulating and warm and the test quantity should be at least ½ litre.
Viktig: Emballasjen må være helt ren, og korkes straks prøvekannen er påfylt.
Important: Put the sample in an absolutely clean bottle and cork it.
Fettsmøring av vinsjer Det er viktig at det smøres regelmessig. En smørerutine bør legges opp, og smøreintervallet bestemmes av hvor ofte vinsjene er i bruk. Smøring bør utføres når vinsjene er i gang. Ved siden av å smøre har fett også en tettende funksjon. Det er derfor viktig at også vinsjer som i lengre perioder er ute av drift blir smurt regelmessig for å hindre korrosjon på lagrene fra inntrengende sjøvann. Fett med ulike såpebaser er vanligvis ikke blandbare. Innhent derfor godkjenning fra fettleverandøren eller Ulstein Brattvaag om man vil skifte til en annen type fett med en annen såpebase.
Grease lubrication of winches Regular greasing is vital. A greasing schedule should be drawn up, and the intervals determined by the operation time and/or frequency use of the winches. Greasing should take place when the winches are running. In addition to its lubrication function, grease act as a sealer. It is therefore important that winches being out of use for a short or long period are greased regularly to prevent corrosion of the bearings caused by penetration of seawater. Greases based on different soap bases will usually not mix. Get the approval from grease supplier or from Ulstein Brattvaag if you wish to change to a type of grease with a different soap base.
Rolls-Royce Marine AS Deck Machinery – Brattvaag Årsundveien 24, N-6270 Brattvåg Norway
Tel. +47 70 20 85 00. Fax +47 70 20 86 00 E-mail: [email protected] Homepage: www.rolls-royce.com
Instruction
Rauma Brattvaag™ Flushing - Main System
1. Before oil filling
3. Flushing oil
Verify controlled and cleaned piping to piping diagram. This to be done by one of our Commission engineers.
Specified main oil according to our oil chart.
2. Drying
5. Flushing oil speed
Blow thouroughly through with dehuminified, filtrated compressed air.
Reynoldsnumber Re>3500 is recommended. When using the main pumps, the temperature should be increased to 50 - 60 centigrades.
4. Flushing Pumps Main system pumps, or external pumps.
6. Flushing time - 30 minutes. Hammer on pipes during flushing. No motors to be used. Open and clean filters. - Repeat for 30 minutes, clean filters again. - Turn the motors a few turns. - Repeat flushing until filters are clean, for a further 3 hours. 7. Cleanliness level of oil - Recommended to ISO 4406 code 19/14 (NAS 10) - Max content of water in oil 0.1% volume. - Verification to be done by analyzing an oil sample.
Prepared by/date: KL / 24.08.01
Approved by/date: KL / 24.08.01
Instr. No. 814-613GB Rev. =
Page 1 of 1
Lubrication instruction for chain driven spooling devices:
Lubricate monthly with SHELL Alvania EP2 (TF)*
Oil quantity – According to instruction Oil type - SHELL Tivela Oil SA*. Change oil after the running in period of 50/100 hours. Then after every 2500 hours or one year
Lubricate monthly with SHELL Alvania EP2 (TF)*
Gliding surfaces: Always covered with grease to prevent rusting (SHELL Alvania EP2 (TF)*) Chain: Cover with Techtyl Threads: Protect with Densotape
* or corresponding Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Lubrication instruction for chain driven spooling 11.06.03 devices
Page 1 of 1 Rev.
I.P. Huse A/S N-6487 Harøy, Norway
414558
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Lubrication instruction for brakes:
Protect threads with Densotape
Lubricate brake bolts monthly with SHELL Alvania EP2 (TF)*
Lubricate brake bolts monthly with SHELL Alvania EP2 (TF)*
*SHELL Alvania EP2 (TF) or corresponding Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Lubrication instruction for brakes 11.06.03
Page 1 of 1 Rev.
I.P. Huse A/S N-6487 Harøy, Norway
414559
=
Lubrication instruction for bushings on drive gear and claw coupling:
Expose lubrication nipple by moving the coupling in OUTposition. Lubricate monthly with SHELL Alvania EP2 (TF), or corresponding.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Lubrication instruction for bushings on drive 13.06.03 gear and claw coupling.
Page 1 of 1 Rev.
I.P. Huse A/S N-6487 Harøy, Norway
414561
=
Lubrication instruction for roller bearings:
Lubrication of roller bearing: Lubricate once a year with SHELL Alvania EP2 (TF), or corresponding.
Lubrication of labyrinth: Lubricate monthly with SHELL Alvania EP2 (TF), or corresponding.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Lubrication instruction for roller bearings. 13.06.03
Page 1 of 1 Rev.
I.P. Huse A/S N-6487 Harøy, Norway
414562
=
Lubrication instruction for flexible roller coupling:
Special valve
Regular lubrication nipple
Lubricate monthly through the two lubrication nipples with EP grease Din51818 NLGI grade 0. Fill on both sides until the valves bleed oil. The total quantity of the coupling is approximately 7 kg.
IMPORTANT! If the coupling does not have the special valves, unscrew one of the lubrication nipples to avoid overpressure. (See specific instruction for roller coupling in instruction manual.)
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Lubrication instruction for flexible roller coupling 07.07.03
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I.P. Huse A/S N-6487 Harøy, Norway
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414584
FLUSHING WITH FILTER NET” IN UBR-FILTERS:
FILTER
Type N7A N8A N9A * * * *
FILTER NET
MAX. OIL FLOW
Art. no. 393-636-02 393-636-01 393-636-00
OIL TEMP. Min. / max. °C 15 / 60 15 / 60 15 / 60
L / min 3000 1800 6000
Do not flush with max. oil flow when oil temperature is lower than 15qC. Flushing with high oil temperature is favourable. Change filter net once or several times during flushing, due to the oil cleanness. Remove filter net after flushing.
INSTALLATION OF “FILTER NET” INTO RAUMA-BRATTVAAG FILTERS: 1. Shut off, drain and open the filter. 2. Pick out the magnetic rod and the filter insert, and clean both. (Fig. 1) 3. Fit the filter net inside of the filter insert. 4. Mount the magnetic bar back into the filter insert without displacing the filter net, and in such a way that the guide rings clamps the filter net in upper and lower edge. (Fig. 2) 5. Split the filter net in upper edge and bend out before mounting back into the filter house.
Filter net Filter Insert Fig. 1
Filter Insert
Magnetic rod
Filter insert with magnetic rod and filter net.
Filter net
Filter net Magnetic rod
Fig. 2 PREP. BY: G.H. DATE
: 17.02.03
PAGE OF
1 1st
FILTER NET
Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
REPLACES:
395-502GB
USER INSTRUCTION INS
REV
REPL. BY :
This document and its contents shall not be made available to any third party without written permission from Rolls-Royce Marine AS.
B
For å forsikre seg om at tannklaringer på vinsjer er etter våre spesifikasjoner, skal denne prosedyre brukes: To ensure that the tooth engagements on winches are according to our specification, this procedure shall be used: A. Når vinsjen blir montert under produksjon. When the winch is assembled in the workshop. B. Når vinsjen skal installeres ombord. When the winch is installed on board the ship. C. Dersom tannhjul eller drev må skiftes. When gear wheel or pinion shall be replaced. A. Montering under produksjon: 1. Sjekk i tabell på tegning 44361 for å finne ut hvilke toleranser som gjelder for den riktige modulen. 2. Bruk metall-shim som tilsvarer ca midt i mellom maksimum og minimum i tannklaringstabellen (eks: 0.5mm – 1.0mm, bruk 0.75/0.8mm shim). 3. Sett opp tannhjul og drev mot hverandre slik at disse nesten er i inngrep mot hverandre. Legg shimet mellom tanninngrepet på belastningssiden, det vil si hivesiden og begynn å stille drevet mot tannhjulet helt til shimet sitter fast i tannflankene (se bilde 1)
A. Assembly in factory 1. Use the table on drawing 44361 to find the correct limits for this module. 2. Find shim that is in the middle between max. and min. in the table (i.e. 0.5mm – 1.0mm, use 0.75/0.8mm shims). 3. Place the gear wheel and pinion against each other until nearly engaged. Put the shims between the teeth on the load side and begin to adjust the pinion against the gear wheel until the shims is stuck between the teeth (picture 1)
Bilde 1 / Picture 1
Sale and service: Rolls-Royce Marine, Dep.: Deck Machinery - Brattvaag, N-6270 Brattvåg, Norway. Prosedyre: Justering og kontroll av tannklaring mellom tannhjul Draw. H.E.S. Page 1 of 3 og drev 12.11.98 Procedure: Adjustment and control of tooth engagement between gear wheel and pinion
Rev. c
I.P. Huse A/S N-6427 Harøy, Norway
412857
4. Kontroller at shimet sitter fast på begge sider av drevet slik at det ikke er skjevhet mellom tannflankene. 5. Bruk en følekniv på andre siden av tanninngrepet for å forsikre deg om at det ikke er glipe i mellom tannflankene (Minst av: Tannbredde/1000 eller 0.2mm). Bruk her en følekniv som er så tynn som mulig (eks. 0.05mm). (se bilde 2) 6. Dersom glipen er større en kravet i punkt 5, må det legges mellomlegg under lagerflaten på den siden som det gliper for å heve drevet til det blir rett (glipen mellom tannflankene minker). Det er nå viktig at drevet blir justert mot tannhjulet slik at shimet som ligger mellom tanninngrepet fremdeles ligger fast på begge sidene. 7. På alle tanninngrep kontrolleres det at tanntopper på hjul eller drev ikke overfører hele lasten ved tennenes inneller utløp. Toppavletting utføres iht instruksjon 410720-2 hvis inngrepet ikke er OK. 8. Målte klaringer og skjevheter mellom tannflanker noteres og signeres i tannklaringsskjema for gjeldende vinsj av montør og kontrollør.
4. Check that the shim is stuck on both side of the pinion and there is no obliquity between the tooth flanks. 5. Use a sensing knife on the other side of the tooth engagement to ensure that there is no gap between the tooth flanks. (Smallest of: Flankwidth/1000 or 0.2mm) Use a sensing knife as thin as possible (ex.0.05mm).(see pic. 2) 6. If the gap is bigger than specified, shims have to be put under the bearing house on the gap side, for removing the gap (the gap between the tooth flanks decrease). It is extremely important that the pinion should be adjusted against the gear wheel so the shims still is stuck between the tooth engagement on both sides. 7. Check that the teeth tips on pinion and wheel are not transmitting the tooth pressure when entering and leaving the engagement. If so, tip relief shall be done according to instruction 410720-2. 8. Measured clearances and obliquity’s between tooth flanks to be noted and signed on relevant form by installer and inspector.
Bilde 2 / Picture 2
Sale and service: Rolls-Royce Marine, Dep.: Deck Machinery - Brattvaag, N-6270 Brattvåg Norway. Prosedyre: Justering og kontroll av tannklaring mellom tannhjul Draw. H.E.S. Page 2 of 3 og drev 12.11.98 Procedure: Adjustment and control of tooth engagement between gear wheel and pinion
Rev. c
I.P. Huse A/S N-6427 Harøy, Norway
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B. Kontroll av tanninngrep: 9. Roter vinsjen slik at tannhjul og drev står i fast inngrep mot hverandre i hiveretning. 10. Kontroller om det er gliper i mellom tennene i inngrepet (se bilde 3) og jamfør i ”Instruction manual” om glipen er innenfor kravene som er gitt. 11. Bruk følekniv på tanninngrepets bakside og sjekk hvor stor klaring de er mellom tennen (se bilde 4). Pass på å kontroller begge sidene for å konstatere eventuelt hvor stor skjevhet det er i tanninngrepet. Resultatet registreres iht punkt 8. 12. Ved feil tannklaring eller for skjevt inngrep, må drev-arrangementet løsnes og lagerstopp flyttes eller forandres. Jamfør tannklaringsskjema i ”Instruction manual”. Følg videre denne prosedyren fra punkt 2 til 8.
B. Checking tooth engagement 9. Rotate the winch so the gearwheel and pinion is standing engaged in heave direction. 10. Check if there is gap between teeth (see picture 3) and check against the instruction manual if the gap is between tolerances. 11. Use a sensing knife on the tooth engagements backside and check how big free space there are between teeth (see picture 4). Check both side how big obliquity there is in the tooth engagement. The result shall be noted according to point 8. 12. If there is wrong clearance or obliquity teeth engagement, the pinionarrangement must be loosened, and bearing stops moved/changed. Check the gear wheel clearance form in “Instruction manual”. Use this procedure further from point 2 until 8.
C. Utskifting av tannhjul/drev: 13. Under skifting av tannhjul/drev, må prosedyren følges fra punkt 9 til 12 i tillegg til punkt 7.
C. Replacement of gear wheel/pinion 13. When replacing gear wheel/pinion, the procedure must be followed from point 9 until 12, in addition to point 7.
Bilde 3 / Picture 3
Bilde 4 / Picture 4
Sale and service: Rolls-Royce Marine, Dep.: Deck Machinery - Brattvaag, N-6270 Brattvåg Norway. Prosedyre: Justering og kontroll av tannklaring mellom tannhjul Draw. H.E.S. Page 3 of 3 og drev 12.11.98 Procedure: Adjustment and control of tooth engagement between gear wheel and pinion
Rev. c
I.P. Huse A/S N-6427 Harøy, Norway
412857
For å forsikre seg om at vinsjer blir opprettet og faststøpt etter våre spesifikasjoner, skal denne prosedyre brukes: To ensure that aligning and pouring of winches are according to our specification, this procedure shall be used: A. Oppretting av vinsj
A. Aligning of winch
B. Forbereding for støping.
B. Preparing of pouring
C. Støping.
C. Pouring.
D. Forspenning av festeskruer.
D. Preloading of holding down bolts.
E. Kontroll av tanninngrep.
E. Checking tooth engagement.
A. Oppretting av vinsj
A. Aligning of winch.
1. Påfør slippmiddel på justeringsskrue. (Figur 1)
1. Apply release agent to adjusting screw. (Figure 1)
2. Vinsjen rettes opp ved hjelp av Justeringsskrue på vinsjeramme. På tunge vinsjer kan det være vanskelig å heve vinsjen. Da må Justeringsskruen skrues så langt ut at oppretting skjer ved senking.
2. Winch to be aligned by adjusting screw on winch frame. On heavy winches it can be hard to raise the winch. Then the screws must be adjusted so that aligning can be done by lowering the winch.
3. Tannklaring rettes opp etter ”prosedyre for justering og kontroll av tannklaring mellom tannhjul og drev". I.P.Huse tegn. Nr. 412857 Avsnitt B. Sjekk tabell på tegn. 44361 for å finne tannklaring for den aktuelle modul.
3. Tooth engagement to be adjusted by following ”procedure for adjusting and control of tooth engagement between gearwheel and pinion”. I.P.Huse draw. No. 412857 section B. Use the table on drawing 44361 to find the correct limit for this module.
4. Avstand mellom dekk og vinsjeramme skal være ca. 25 mm.
4. Distance between deck and winch frame shall be ca. 25 mm.
Sales and service: Ulstein Brattvaag A/S, N-6270 Brattvåg Norway.
Prosedyre: Oppretting og faststøping av vinsj Procedure: Aligning and pouring of winch
Draw. K.M 14.01.99
Page 1 of 3 Rev. a
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B. Forbereding for støping.
B. Preparing for pouring.
5. Støpeområdet må rengjøres. Rust, olje, fett, glødeskall og maling må fjærnes. NB! Epoxy primer (20-25 µm) trenger ikke å fjernes.
5. Pouring area to be cleaned from rust, oil, grease, mill scale and paint. NOTE! Epoxy primer (20-25 µm) is allowed.
6. Påfør slippmiddel på demningen. Punktsveis på plass demningen slik at det blir enkelt å tømme støpemiddel i demningen (figur 2).Tett med egnet kitt.
6. Add release agent on dam plate. Tack weld dam plate in place so that pouring can be done easily (figure 2). Seal the dam plates with sealing compound.
7. Sett bolter godt innsmurt med slippmiddel i boltehull, eller bruk gummislanger e.l.
7. Insert bolts applied with release agent or rubber tubes into the boltholes.
C. Støping.
C. Pouring.
8. Påse at temperaturen på støpemiddel og fundament er i henhold til anbefaling for aktuelt støpemiddel.
8. Temperature on foundation and resin has to be according to recommendation for actual resin.
Figur 1 / Figure 1 Sales and service: Ulstein Brattvaag A/S, N-6270 Brattvåg Norway.
Prosedyre: Oppretting og faststøping av vinsj. Procedure: Aligning and pouring of winch.
Draw. K.M 14.01.99
Page 2 of 3 Rev. a
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9. Bland herder i henhold til anbefaling for aktuelt støpemiddel.
9. Add hardener according to recommendation for actual resin.
10. Tøm støpemiddel i demningen kort tid etter blanding i den laveste side av hver chock. Høyde på støpehode bør vere min.20 mm (figur 1).
10. Pour the resin shortly after mixing into the lower end of each chock. Height of overpour should be min. 20 mm. (figure 1)
D. Forspenning av fundamentbolter.
D. Preloading of holding down bolts.
11.Påse at støpemiddel er herdet iht leverandørens anbefalinger.
11. Check that resin is completely cured according to recommendation from supplier.
12. Fundamentbolter kan ikke forspennes til mer enn 80% av ”normal” forspenning. Dette for å unngå ”knusing” av chock. Se tabell nedenfor. Bolt dimensjon Forspenning M36 2100 Nm M30 1200 Nm M24 600 Nm
12 Foundation bolts can not be preloaded to more than 80% of ”normal” preloading. This to avoid ”crushing” of chock. See table below. Bolt dimension Preloading M36 2100 Nm M30 1200 Nm M24 600 Nm
E. Kontroll av tanninngrep.
E. Checking tooth engagement.
13. Kontroller Tannklaring etter ”Prosedyre for justering og kontroll av tannklaring mellom tannhjul og drev”. Tegn. 412857 avsnitt B.
13. Check tooth engagement by following ”Procedure for adjusting and control of tooth engagement between gear wheel and pinion”. I.P.Huse draw. No. 412857 section B.
Figur 2 / Figure 2 Sales and service: Ulstein Brattvaag A/S, N-6270 Brattvåg Norway.
Prosedyre: Oppretting og faststøping av vinsj. Procedure: Aligning and pouring of winch.
Draw. K.M 14.01.99
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Instruction for adjustment of brakes:
1) Release brake by putting brake handle on control desk to OFF-position.
2) Tighten tension rod until brake band is clamping brake drum.
3) Adjust support until clearance between support and brake band is about 0,5 mm.
For adjustment of brake band support bearings, see instruction nr 412176
Note! Adjustment will alter due to brake lining wear and must be periodically checked.
4) Unscrew the tension rod until brake drum is just running free from the brake
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Instruction for adjustment of brakes 12.06.03
Page 1 of 1 Rev.
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Spoling av wire / Spooling of wire: •
•
•
•
Festing av wire ende: Wire enden festes til trommelen i henhold til instruksjon 28065A. Valg av høyre- eller venstre-slått wire bør gjøres i henhold til plassering av wire feste (se fig.1). Første omdreininger: Wire festet har begrenset holdekraft. De første omdreininger spoles derfor med forholdsvis lav kraft. Denne økes progressivt for hver omdreining. På grunn av friksjon mellom wire og trommel kan full kraft påføres etter om lag 10 omdreininger. Passende påspolingskraft er 10% av normal arbeidskraft. Spoling av første wire lag: For å unngå problemer med spoling i høyere lag, er det viktig at første wire lag er tett spolt. Dette kan gjøres ved bruk av spoleapparat og/eller ved hjelp av gummiklubbe. Åpninger mellom turnene må ungås da dette kan medføre at høyere lag kan trenge ned i mellom og skade wiren. Bøying av wiren: Når wiren skal spoles på vinsjetrommelen, sørg for at den bøyes i samme retning som på lagringstrommelen. Unngå S-bøyer, som kan forstyrre wire konstruksjonen (se fig.2). Avstanden til lagringstrommelen bør være så stor som mulig slik at innløpsvinkelen blir liten.
•
•
•
•
Wire fastening: The wire shall be fastened to the drum according to instruction 28065A. Selection of right-hand or left-hand lay wire should be done according to location of wire fastening (see fig.1). First wraps: The wire fastening has limited holding capacity. The first wraps shall therefore be spooled with low force increasing progressively for each wrap. Due to friction between wire and drum, full load can be applied after 10 wraps. Adequate tension during spooling is 10% of normal working load. Spooling of first layer: To achieve good spooling, it is important to make a tight first layer. A spooling device and/or a rubber sledgehammer can be used for this purpose. Openings between wraps must be avoided to prevent other layers to penetrate and damage the wire. Bending of wire: When spooling onto the winch drum, make sure that the wire is bent in same direction as on the pay-off reel. Avoid S-shapes, which can damage the wire construction (see fig.2). Distance to pay-off reel should be as big as possible in order to reduce the fleet angle.
Fig.1
Fig.2
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Instruksjon for spoling av wire. 14.08.01 Instruction for spooling of wire.
Page 1 of 1 Rev.
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Fastening the wire clamp: When clamp is in right position (umbrako screws facing the drum flange), crosstighten the four M12 umbrako screws to about (85Nm).
The wire rope can not go more than 25mm through the wire clamp.
Drum attachment: Inserting the wire clamp:
Securing the wire clamp:
1) Loosen screws
1) Crosstighten the six M30 Umbrako screws to max 2079 Nm (See instruction 213901).
2) Adjust the spring loaded screw until the clamp can be opened by hand. 3) Push wire rope with wire clamp through the rectangular hole. (umbrako screws facing the drum flange!) Make sure clamp is locked against the ratchet and locking edge!
2) Tighten to 220 Nm 3) Tighten the ”spring screw” so that it is not protruding into the drum area.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Instruction for wire fastening, drawing 213901 25.06.03
Page 1 of 1 Rev.
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Instruction for emergency brake: Manometer 1
Manometer 2
Remote controlled brake:
Adjustment of ”Remaining brake pressure” from the accumulator:
Valve A and B to be closed and valve C open.
1) Run the brake ON and OFF several times by the remote control until the accumulator opens the valve (pos 6) and manometer 1 is showing max pressure in the accumulator.
Manual emergency brake: ON: Close valve C and B, open valve A and operate hand pump until manometer 2 shows 70 bar.
2) Put the brake ON and push the quick release button.
OFF: Open valve B.
3) Apply desired ”Remaining brake force” to the winch drum and open gas valve (pos 4) on the accumulator until the drum just start to rotate. See also next page.
Quick release: The power supply to both solenoids on brake control valve (pos 5) is cut off. The spool then goes to middle position, and oil pressure from the accumulator (5-25 bar) goes via the shuttle valve to the brake cylinder and thus giving ”Remaining brake force”.
If the gas pressure is too low, the accumulator must be recharged with nitrogen. Charging equipment CGH3000 PR Hydraulik A/S. The accumulator is charged to 25 bar at delivery.
Valve A
Valve B
Valve C
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Instruction for emergency brake 08/12/03
Page 1 of 2 Rev.
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414580 page 2 of 2
Repair of chain wheel: 1. Chain wheel and the around area have to be cleaned for dirt and humidity. 2. Control the materials for cracks with (PT) before the repair work starts:
Surface crack
Spray on penitrate
Remove penitrate
Inspection
3. Place the grinding and marking template on chain wheel and mark the repair area.
Grinding template
Marking template for hard facing pocket
4. Remove the marked material with carbon air cutting, approximately 10 mm depth. 5. Grind the surface (min. 1mm) to remove carbon remains.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. TF Repair of chain wheel 03.07.03
Page 1 of 3 Rev.
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Chain wheel Ordinary filling metal Filler pass 6. If the pocket is more than 10 mm deep, weld bottom with ordinary electrode before filler pass.
Rest filling with hard weld
7. Before welding is started, adjust the welding point into vertical or a 45° position, and preheat according to welding procedure H-197 (page 3). 8. Weld with filler pass until depth of pocket is approximately 4-8mm. Use the template to control that the thickness is reached. 9. Weld the top layer with Castolin 6450 or Cavitec SMA, until surface is barely covered (1-2 mm oversize). 10. Grind to remove superfluous materialand smoothen surface before putting it back to service. NOTE! If the surface is not smooth after grinding, the chain may be damaged and will also wear out more quickly. Examine the entire area for cracks, using dye penetrant method. Never use magnetic powder for crack detection on stainless steel in combination with carbon steel.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. TF Repair of chain wheel 03.07.03
Page 2 of 3 Rev.
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414581 page 3 of 3
Installation and dismantling of chain wheel with hydraulic jack, drawing 311999:
1) Clean and oil shaft and distance ring well. Make sure you have got the right distance ring for the specific chain wheel (ref. 211132).
2) Put on the gasket.
3) Install the centre bolt and the guiding plate at the shaft end.
4) Enter the chain wheel on to the guiding plate. Rotate the chain wheel to align the hexagon surfaces.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Installation and dismantling of chain wheel with 09.07.03 hydraulic jack, drawing311999
Page 1 of 3 Rev.
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414589
5) Install the triangle plate and the hydraulic jack. If the chain wheel is hard to move, dismantle and check for sharp edges.
6) Remove guiding plate, grease shaft end and install stop plate.
3) Use a crane to secure and lift the chain wheel during dismantling.
Dismantling 1) Remove stop plate and install guiding plate. 2) To release the chain wheel from the shaft, it may be necessary to rotate the chain wheel in lowering direction.
4) Install jack and the triangle plate as shown to pull off the chain wheel.
Sales and service: Rolls-Royce Marine AS, Dep.: Deck Machinery - Brattvaag Draw. AL Installation and dismantling of chain wheel with 09.07.03 hydraulic jack, drawing311999
Page 2 of 3 Rev.
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414589
414589 page 3 of 3
How to order spare parts When the parts you want to order are identified (example how to use the Instruction Manual, see section 1). Your order to ROLLS-ROYCE Marine AS should if possible contain the following elements: q q q q q q q q q q q
Ship name Plant No.: A...............(see back cover of Instruction Manual) Contact person buyer/ship owner Delivery address/consignee Delivery time wanted Delivery terms Way of transportation Invoice to Item No. of the ordered parts Assembly drawing No. Name plate data of main components E-mail address: [email protected]
Identification of winch equipment by Name plates: Winch units
Rauma Brattvaag
Rolls-Royce Marine AS N-6270 Brattvaag - Norway
Rauma Brattvaag
FORDELINGSKODE: DA PREP. BY: TBA DATE
:12.01.1994
PAGE OF
1 3rd
BESTILLING AV RES. DELER HOW TO ORDER SPARE PART Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
INS
REPLACES: REV
812-012 REPL. BY :
This document and its contents shall not be made available to any third party without written permission from Rolls-Royce Marine AS.
D
Pump units:
Rauma Brattvaag
FORDELINGSKODE: DA PREP. BY: TBA DATE
:12.01.1994
PAGE OF
2 3rd
BESTILLING AV RES. DELER HOW TO ORDER SPARE PART Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
INS
REPLACES: REV
812-012 REPL. BY :
This document and its contents shall not be made available to any third party without written permission from Rolls-Royce Marine AS.
D
Example how to identify Spare Parts When Assembly Drawing with the requested part have been located in "Section 6", find Item ID in the enclosed Parts List. Here illustrated with Bearing block drawing no. 396-571, and sliding bearing with Item ID no. 266-321-14 as pos. no. 2 in Parts List.
Recommended spare parts are marked "R" in the Part Lists.
FORDELINGSKODE: DA PREP. BY: TBA DATE
:12.01.1994
PAGE OF
3 3rd
BESTILLING AV RES. DELER HOW TO ORDER SPARE PART Rolls-Royce Marine AS Dept. Deck Machinery - Brattvaag Tel. +47 70 20 85 00
Fax. +47 70 20 86 00
INS
REPLACES: REV
812-012 REPL. BY :
This document and its contents shall not be made available to any third party without written permission from Rolls-Royce Marine AS.
D
