Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
Remote control system for marine propulsion plant
NORISTAR 2000
Technical description
0.
General information
The NORISTAR 2000 system is designed to provide automatic open-loop and closed-loop control of
marine propulsion plants, specifically for the control of:
Controllable pitch propellers
Clutch control
Reverse/reduction gear
NORISTAR 2000– C
providing control of a proportional action way valve
NORISTAR 2000- K
Providing control of clutches /gears
NORISTAR 2000– G
providing control of a speed controller
The system is type-tested to GL, LRS, ABS (PDA), RINA and BV and meets class requirements according to AUT24 and UMS.
1.
Technical data
Main supply:
Battery supply:
Operating temperature:
Degree of protection:
Vibrations:
Inputs and outputs
Central unit PS4-341-MM1
Dec. expansion board EM4-101-AA2
(3 ea.)
Dec. expansion board EM4-201-DX2
(2 ea.)
Local expansion board LE4-116-XD1
(3 ea.)
Signal forms
Input voltage
Input current
Output voltage
Load capacity of binary outputs
14.02.07
24V DC
24V DC +30/-25% non-interruptible
0 – 70°C
GL: Environment C
IP 20 / with cubicle IP 55
0.7g
2 analog inputs
1 analog output
16 binary inputs
14 binary transistor outputs
8 analog inputs
4 analog outputs
16 binary inputs
16 binary transistor outputs
0 – 5V
0 – 10V
+/- 5V
+/- 10V
0 (4) – 20 mA
0 – 10V
+/- 10V
I < 0.5A
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 1/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
2.
Network of the PLC components
3.
3.1.
Physical design
Storage-programmable control (SPC)
The system has main supply and battery supply, and both supplies are controlled by remote control.
The storage-programmable control (SPC) system is located in the central control cubicle in the
ECR and consists of the PS4-341-MM102 central unit with ZB4-901-SF2 EEPROM. Stored in the central unit is the control program, both in the battery-backed RAM and the EEPROM (memory card MC).
Also installed in the door of this control cubicle is the service panel (black-and-white).
A local control box is located in the engine room. This cubicle includes the pitch control amplifier
and the pitch measurement system.
The EM4-101-AA2, EM4-101-DX2 and LE4-116-XD1 distributed-type expansion boards fitted on a
chassis are accommodated in the ECR console.
The Bridge console has the distributed and local expansion boards EM4-101-AA2, EM4-201-DX2
and LE4-116-XD1 installed in a interface box.
For the maximum possible inputs and outputs, please refer to Section 1.
A type LOGO (Siemens) mini-controller serves for back-up control, it is also located in the central
control cubicle in the ECR.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 2/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
3.2.
Panels
The scope of supply includes four operating panels, one each for installation in the ECR console, in
the bridge console, and at the port and starboard wings. In addition to the control levers, the operating panels contain all control and indicating elements required for the operation of the vessel.
The service panel is located in the central control cubicle in the engine control room (ECR) and linked
by means of cables to the SUCOM-A-interface (RS 232 C) of the SPC system. This panel provides
comprehensive facilities for commissioning and diagnosis of the equipment.
4.
4.1.
Functions
Start-up and transfer of control between control positions
Upon switching on of the power supply, the control system takes 10 to 15 s for initialisation. This
involves reading out of all parameters from the EEPROM and making them available in the RAM both
for program processing and for the service panel.
If the LOCAL/REMOTE selector in the door of the local control cubicle is set at LOCAL and the engine is also in LOCAL, the system cannot be operated from any control position. Moving the selector
to REMOTE causes the transfer to be prepared for. Depending on the requirements of the manufacturers of the engine and controllable pitch propeller equipment, an interchange of binary signals takes
place which, when completed, results in the REMOTE CONTROL ACTIVE signal being issued.
Depending on the position of the ECR/BRIDGE selector, transfer of control is offered visually and
audibly to the ECR or to the control position on the bridge. On the panel of the control position selected, the HORN will be sounded and the control position lamp (ECR, BRIDGE) as well as the TAKE
OVER COMMAND lamp will be flashing. On the panels of the non-offered control positions, the indicating lamps of the offered control position will be flashing. The transfer is effected by the TAKE
OVER COMMAND button if the control lever is at neutral. The TAKE OVER COMMAND lamp will
go off, the control position lamp (ECR or BRIDGE) will change to steady light and the HORN will be
silenced. The previously offered control position will now be active. The active control position will also
be indicated at the inactive control positions.
If transfer of control is by means of the ECR/BRIDGE selector from an already active control position (ECR or BRIDGE), the only difference from the procedure described above is that control lever
synchronism has to be established between the active and offered control positions and in that the
active control position remains active until the selected control position has completed the transfer.
The control position lamps will indicate the status on all three panels: The lamps of the offered control
position will be flashing, the lamps of the active control position will show steady light.
Instant transfer of control between the three bridge control positions is possible by pressing the
respective TAKE OVER COMMAND button, provided lever synchronism exists. The associated TAKE
OVER COMMAND lamp will then show steady light. Failing lever synchronism, this lamp will continue
flashing after pressing the button until lever synchronism has been established. It will then change to
steady light. The active wing control position is shown on the BRIDGE console.
4.2.
Operation
If the ECR is the active control position, setting of the speed setpoint from idling to maximum speed
(100%) is possible by means of the speed control potentiometer. With the CRPM (CONSTANT
SPEED) button operated, the speed setpoint corresponds to the parameterizable preselection. The
pitch setpoint can be preselected between –100% and +100% by means of the pitch control lever. A
parameterizable operation program provides minimum-stress runup in a manner that the speed setpoint follows the speed control lever with a time delay.
Load limitation is possible by means of the parameterizable LOAD LIMIT potentiometer from the ECR.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 3/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
If the bridge is the active control position, the value selected by the combined control lever is translated by means of a parameterizable program each for speed and pitch into a load value (load demand) each, as a function of time. The program for pitch variation is the same as used in the ECR.
In the COMBINATOR MODE (CRPM lamp extinguished), the load value is translated according to the
two combinator curves for speed and pitch into a speed setpoint and a pitch setpoint.
According to the owner specification, the pitch/speed variation pattern exhibits two special features:
1. The rate of speed increase and decrease is invariably faster than the rate of pitch variation.
2. In the case of fast changes of direction by means of a bridge control lever (ahead – astern or
astern – ahead), the speed will only follow the control lever in respect of the absolute value.
This eliminates the need for the speed to be reduced to idling!
In the CONSTANT SPEED MODE (CRPM lamp lit), the speed setpoint corresponds to the constant
value. The load value (load demand) will in this case, too, be translated into a pitch setpoint according
to another combinator curve. CPP control send out a signal CONST.RPM SELECTED, the main
switchboard will replay with a hold on when the main shaft alternator breaker is ONLINE.
Provision has been made for a display of the lever value of the active control position; the signal
being available from appropriate terminals on the terminal bar. In addition, arrow lamps are provided
to indicate the movement of the control levers required at the inactive control positions to establish
lever synchronism. These lamps will not light on the panel at the active control position.
Protection of the engine from overloading is provided by a programmed load controller (PIcontroller). This controller will intervene to reduce the manipulated variable (pitch setpoint) if actual
engine injection exceeds a setpoint. In the COMBINATOR MODE, this setpoint is generated by the
injection limit curve from the actual engine speed and, in the CONSTANT SPEED MODE, by an empirically parameterizable fixed point because speed drops are to be avoided. The setpoint is limited by
the LOAD LIMIT or, respectively, SLOW DOWN (overriding) potentiometer settings.
Where two separate potentiometer are provided to sense the current pitch (actual pitch) value, it will
be possible in the event of a fault for remote control to change from one value (actual pitch) to the
other value (pitch backup). While this will not eliminate the fault, it will permit continued troublefree
operation of the remote control system.
4.3.
Main Clutch Control
Operation of the clutches is possible from both control control positions, provided it is active.
Permissives for clutch engagement are:
- Firing speed < clutching speed (adjustable) < rated speed,
- Actual pitch = 0,
- Feedback from disengaged clutch,
- No emergency stop imposed by safety system,
- Remote control on,
- Control position active.
Upon pressing the CLUTCH IN push-button, the lamp in this button will be flashing and the main
clutch will be engaged. Clutch feedback will cause the CLUTCH IN lamp to change to steady light.
Permissives for the clutch disengagement are:
- Actual speed < clutching speed,
- Actual pitch = 0
- Remote control on,
- Control position active,
Upon pressing the CLUTCH OUT push-button, the lamp in this button will be flashing and the clutch
will be disengaged. An emergency stop applied by the safety system will produce the same result.
Loss of clutch feedback will cause the CLUTCH OUT lamp to change to steady light.
CLUTCH ENABLE will be signalled if permissives for engagement or disengagement are met and the
opposite clutch status exist. If the main clutch fails to reach the selected status within 20 s (adjustable), main clutch error will be signalled.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 4/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
4.4.
PTI Mode Operation
In PTI Mode the main switchboard will give CPP control a signal that the APS/PTI system is selected.
CPP control uses this signal to de-activate the main engine load control and to activate the overload
protection to give both indication and pitch reduction.
APS/PTI system will allow use of the analogue load signal 4-20 mA. Also with this system CPP control
install a separate pitch curve for the PTI Mode which has to benefit to set the maximum useable pitch
in PTI Mode to the maximum lever position.
The installing parameters and the calibration of the load signal will be done during sea trials.
4.5.
Errors
All individual errors of the SPC are combined in a group error signal to be fed together with the main
and battery power failure to the ship alarm system. According to the error category, the safety system
can intervene by means of a SLOW DOWN binary signal (reducing to +/-60%) or a SHUT DOWN
(EMERGENCY STOP) binary signal.
The error analysis is to be performed on the service panel in the ECR.
An additional display is provided by means of LED indications of binary outputs on the central unit. For
this purpose, open the control cubicle in the ECR and check the two bottom rows of green LEDs on
the D1 unit. The meanings of these LEDs are as follows:
st
From left
1 LED
th
5 to 8 LED
th
group error (ON is ok.)
error code (ON/OFF alternating is ok.)
All error codes are scanned once every second. If no error exists, scanning will proceed without any
st
interruption. If an error occurs, the 1 LED will go out and the scan will stop at the corresponding error
th
code. Continuation of the scan can be enforced by applying a 24 V pulse to the 0.8 input (9 connection at top) (DIAGNOSIS button). The scan will then again stop at the next existing error with the associated code.
The error codes mean: 1 – LED on, o – LED off, - – LED on or off.
o--o--o--o--o--o--o--o--o--o--o--o--o--o--o---
----------------------------------------------
----------------------------------------------
oooo
1ooo
o1oo
oo1o
1o1o
o11o
111o
ooo1
1oo1
o1o1
11o1
oo11
1o11
o111
1111
Error analog actual values (fuel ME, speed, pitch, pitch backup)
Error analog values ECR (lever pitch, poti speed, load limit)
Error analog values BRIDGE (levers bridge, wing pt/stbd)
Error pitch (actual/desired difference)
Error date synchronisation
Error transfer parameters
Error central unit (memory card/power failure)
Error decentral expansion boards
Error local expansion boards
Error SG 2000
Error power supply ECR/BRIDGE (not used)
Error analog output desired pitch
not used
not used
Error main clutch
Attention! When a bus connection error between central unit PS4-341-MM102 and local expansion
board LE4-116-DX1 or betw. dec. expansion board EM4-201-DX2 and local expansion boards LE4116-XD1/LE4-108-XR1 is detected, this is an important error (1 o o 1 Error local expansion boads).
Please remove this error only after switching off of the power supply.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 5/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
st
On removal of the errors, the 1 LED will come on again. For continuation of the scan, see above. In
the case of errors of the central unit and/or expansion boards, acknowledgement is necessary on the
central unit after errors have been removed. To this end, open the door in the right-hand part of the
central unit and operate the small switch at the top right once.
If the SPC should require a battery change, this should be carried out with the control system on
by trained personnel. Any change of the EEPROM must also be carried out only by trained personnel but in this case it is absolutely necessary that the control system be deenergised.
4.6.
Backup control
In an emergency situation or if any faults should have developed in the remote control system,
it will be necessary to change to backup control (switch on the appropriate panel at ON).
The backup control can be activated only from the activated control stand (bridge or engine
control room). It is not possible to switch on the backup control i.e. from bridge, if bridge is not
selected.
An indication of which panel is in operation is provided by means of the BRIDGE/ENG.
CONTROL ROOM BACKUP ON lamp on each of the two panels.
NOTE: Constant speed (100%) will be instantly provided as a fixed default settingfor the speed
setpoint. The current pitch setpoint will be taken over unchanged for the time being.
Variation of the pitch with backup control active is possible by means of the AHEAD/ASTERN
joystick.
The remote control system and the control position will be in the standby mode.
Reactivation of the remote control system is possible only if and when backup control has
been switched off (switch on the corresponding panel at OFF). On the panel at the control position that was active before backup control was brought in, the HORN will sound and the TAKE
OVER/IN COMMAND lamp will flash. Transfer of control will be effected by pressing the TAKE
OVER button.
Prior to reactivation of the remote control system and transfer of control to the previously active control position, it is necessary to adjust the pitch control lever at the indicated control
position to the actual pitch in order to ensure bumpless pitch transfer. The selected lever value
or, respectively, constant speed is applied as the speed setpoint.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 6/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
5.
5.1.
Service panel
Function and page layout
The versatile, multi-language (black-and-white) display serves to visualise signals and operating
statuses as well as to change any parameters that are important for the commissioning, maintenance
and operation of the equipment. In addition, it is used for fault identification. Using the internal error
logic, the display shows operating statuses, error conditions and alarms in clear text.
Page layout
The indications of date/time and user rights as well as
FORWARD/BACKWARD ARROWS are provided on each page.
Level 0:
Level 1:
Level 2:
Page 3.1.:
Page 3.2.:
Page 3.3.:
Page 3.4.:
Page 3.5.1.:
Page 3.5.2.:
Page 3.6.:
Page 3.7.:
Page 3.8.:
Page 3.9.:
Level 3:
P. 3.4.1.1.:
P. 3.4.1.2.:
P. 3.4.1.3.:
P. 3.4.2.1.:
P. 3.4.2.2.:
P. 3.4.2.3.:
P.3.4.3.:
P.3.4.4.1./2.:
P.3.4.4.3./4.:
14.02.07
the
START or
MENU
and
- Start screen
Date/time, logo ZF MARINE, plant description, START button;
- Selection
Buttons for date/time, display, language, parameters, service + commissioning, alarm
list, trend, login/logout, ? (help);
- System settings
Settings of date/time, change winter/summer time, boot display (warm start)
- Display settings
Contrast adjustment, brightness adjustment;
- Language setting
System languages are German, English;
- Display of parameter settings
Buttons for control lever calibration, calibration of engine/propeller inputs, calibration
of engine/propeller outputs, operation program, combinator mode, constant mode,
limiter, load distribution, load control, pitch control, monitoring parameters, storing parameters;
- Service + commissioning
Password entry for operator and service;
- Display of parameter settings (corresponds to page 3.4)
- Alarm list
Individual alarm acknowledgement, change-over of current/historical alarms, acknowledgement of all alarms;
- Trend display
- Password entry (corresponds to page 3.5.1.)
- Project information
- Service/control lever calibration
Control lever for pitch_bridge, wings;
- Service/control lever calibration
Control lever for pitch_ECR;
- Service/control lever calibration
Control potentiometer speed_ECR;
- Service/analog inputs
incoming values load and pitch;
- Service/analog inputs
incoming values load limit and pitch backup;
- Service/analog inputs
incoming current control values lever/poti ecr bridge
- Service/analog outputs
Analog output of pitch_desired;
- Service/operation program
delay program pitch (ahead/astern increase/decrease speed);
- Service/operation program
delay program speed (increase/decrease speed);
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 7/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
P.3.4.5.1./2.:
S.3.4.6.1.:
P.3.4.7.1./2.:
P. 3.4.8.:
P.3.4.9.1.-4.:
P.3.4.10.
P.3.4.11.:
P.3.4.12.1.-3:
P.3.4.13.1.:
5.2.
- Service/Combinator mode
Load/speed, load/pitch;
- Service/PTI_Operation ON
Load/pitch;
- Service/constant mode
Load/pitch, constant speed value, overload response time;
- Service/limiter
Increment pitch/speed, dead band lever, dead band lever zero, gear ratio, full scale
deflection, number of teeth/bolts flywheel, firing speed, nominal speed;
- Service/load control
Increase without overload, decrease with overload, slow-down, load limit at n=const.,
load limit curve,
- Graph
Representation diff. Analogue values
- Service/pitch control
Parameters of pitch controller, calibration of control edges;
- Analog input, analog outputs
Overview of analog values;
- Storage of parameters
Buttons for storage: parameter store on MC_Card;
Manipulation
Changing between levels/pages:
Touching the START button on the start page brings up the next lower level of the display. By entering
the appropriate password, access is authorised to change the appropriate parameters. Without entering the password, access to the pages is read-only.
The other levels of the display can be accessed by touching the appropriate button. The MENU button
or the ARROW LEFT button provide access either to the selected level or the next higher level. Where
there are several pages per level, it is possible to have other pages of the level displayed by means of
the ARROW RIGHT or ARROW LEFT buttons.
In the displays of the operation programs, arrows are placed between the columns of the X and Y
parameters. Arrows from 0 to +/- mean increase speed ahead/astern, arrows from +/- to 0 mean
decrease speed ahead/astern.
Parameter changes:
Changes to the parameters will directly affect the SPC program flow and must not be made except on
instruction of the service personnel or by the latter themselves.
5.3.
Parameter setting
Examples for changing parameters
Setting pitch_bridge control lever:
- Perform LOGIN with password.
- Select Control lever calibration, pitch_bridge control lever page.
- Move control lever to zero.
- Read upper momentary value and enter against calibr. 0 %.
- Move control lever right back.
- Read upper momentary value and enter against calibr. -100 %.
- Move control lever right forward.
- Read upper momentary value and enter against calibr. 100 %.
Generally, the y-values will not be changed.
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 8/9
Friedrich Barnewitz Str. 10
D-18119 Rostock
Tel: 0381-5199440 * Fax: 0381-5199444
Mail: design@noris-automation.de
NORIS Automation GmbH
Setting pitch analog input:
- Perform LOGIN with password.
- Select Calibration engine/propeller inputs page.
- Decrease pitch by means of control lever in ECR to minimum.
- Read momentary value and enter against calibr. –100%.
- Increase pitch by means of control lever in ECR to maximum.
- Read momentary value and enter against calibr. +100%.
- Calculate mean of the two values and enter against calibr. 0% (zero pitch).
- Since zero thrust is a more important criterion for the correct setting, it is necessary to reduce
pitch to zero and to observe the propeller wake. The value entered against calibr. 0% should be
corrected (mostly upward, say from 2000 to 2200) until no propeller wake is visible aft.
Generally, the y-values will not be changed.
Calibration of control edges for pitch adjustment:
- Perform LOGIN with password.
- Select Pitch control page.
- Set AHEAD/RIGHT button to ON.
- Increase parameter in steps from 0% until change in pitch takes place.
- Set AHEAD/RIGHT button to OFF.
- Set ASTERN/LEFT button to ON.
- Increase parameter in steps from 0% until a change in pitch takes place.
- Set ASTERN/LEFT button to OFF.
After the change has been made, the parameters are at once contained in the RAM of the SPC and,
consequently, effective in the program. In order to have them available after shutdown again for the
next startup of the control system, it is necessary to store them in the EEPROM (MC memory card).
To do so, select the Store parameters page and operate the button of the storage area. Any error
made during storing will be displayed and the storing operation will then have to be repeated.
Final remarks
All parameters calibrated and set during commissioning are recorded and the date stated in a data
sheet. Any change to the parameters should be recorded in the data sheet in order to be able to restore the previous status in the event of any loss or wrong setting of parameters.
6.
Instructions for commissioning
Commissioning should be performed in two steps.
First of all, make sure that the electrical wiring of the plant components has been correctly made. In
this context, also check all logic functions, such as takeover or lamp test.
Following this, check the function of the speed settings. The speed setpoint is set at 4...20 mA. Idling
corresponds to 4 mA.
As the second step, check the integrity of the complete system with the engine running.
The following parameters must be checked and, if necessary, readjusted according to the attached
data sheet:
- All parameters except those of the operation program.
The following parameters may be changed according to the following data sheet:
- X-values of operation program (indicated in each case starting from 0 in seconds).
Enclosures
Data sheets for parameter setting
14.02.07
NORISTAR 2000, Draw.No. 075.084.00 (ZF Padova S.p.A.)
P. 9/9