Kongsberg Autochief Man MC Engines Instruction Manual
Kongsberg Autochief Man MC Engines Instruction Manual
Kongsberg Autochief Man MC Engines Instruction Manual
Kongsberg AutoChief®C20
MAN MC Engines
Fixed Pitch Propeller
Kongsberg AutoChief®C20
MAN BW MC Engines
Fixed Pitch Propeller
Instruction Manual
316458/C
October 2008
Document history
Document number: 316458
Rev. A November 2007 Update from AA-00381–C
Rev. B February 2008 Correction: command transfer
Rev. C October 2008 Maintenance section, structure update and indexing
The reader
This instruction manual for the AutoChief®C20 Propulsion Control System is intended as a guide for the
ships personnel while operating the engine on a daily basis in transit between ports, assuming a standard
configuration for MAN BW MC Engines with Fixed Pitch Propeller. Any significant changes in system
parameters and maintenance should be handled by design and installation engineers at the shipyard, in
accordance with installation drawings applicable to the vessel.
Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.
Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.
Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com
Instruction Manual
Table of contents
Admonitions .............................................................................................................6
Glossary....................................................................................................................7
1 ABOUT THIS MANUAL ....................................................... 9
2 FUNCTIONAL DESCRIPTION............................................ 10
2.1 Remote Control System Functional Description....................................................10
2.2 AutoChief®C20 Control Panel (ACP)...................................................................13
Display ...................................................................................................... 14
Multifunctional knob................................................................................... 14
Cancel functions ......................................................................................... 15
Alarm Acknowledge and In Command functions .......................................... 15
2.3 AutoChief®C20 Combined Lever and Telegraph Unit (LTU)...............................16
Lever Function ........................................................................................... 16
Emergency Stop Pushbutton ........................................................................ 17
Sub-Telegraph Functions ............................................................................. 17
Command transfer Functions ....................................................................... 18
2.4 AutoChief®C20 Bridge Wing Control Unit (BWU) .............................................19
Lever function ............................................................................................ 19
Indicators ................................................................................................... 20
Panel dimming and lamp test ....................................................................... 20
Command Transfer functions....................................................................... 21
Safety functions.......................................................................................... 22
2.5 AutoChief®C20 Pushbutton Telegraph (PBT) ......................................................24
2.6 AutoChief®C20 Start/Stop & Speed-set lever.......................................................25
2.7 AutoChief®C20 Order Printer ...............................................................................26
2.8 Indication Panel Unit..............................................................................................27
Engine Indicators........................................................................................ 27
Auxiliary blower control ............................................................................. 29
2.9 Emergency control El.box standard .......................................................................30
2.10 Remote control system functions ...........................................................................32
Engine state, start Interlock/Fail/Block ......................................................... 32
Sequential Diagram..................................................................................... 34
Starting the Main Engine............................................................................. 34
Reversing thrust.......................................................................................... 36
Stopping the Main Engine ........................................................................... 37
Engine operation modes .............................................................................. 38
VIT/FQS control function ........................................................................... 42
Remote control system auxiliary functions ................................................... 44
RPM control function.................................................................................. 45
Limiters ACP display.................................................................................. 53
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Kongsberg AutoChief®C20
4 316458/C
Instruction Manual
Engine Modes............................................................................................. 97
Engine Limiters .......................................................................................... 98
Parameter Change..................................................................................... 100
User Access.............................................................................................. 102
Lever fine tuning....................................................................................... 104
Lever calibration....................................................................................... 106
4 MAINTENANCE .............................................................. 109
4.1 Preventive maintenance........................................................................................ 110
Maintenance intervals ................................................................................110
Weekly maintenance ..................................................................................110
3–monthly maintenance .............................................................................110
6–monthly maintenance .............................................................................111
Yearly maintenance....................................................................................111
4.2 Troubleshooting.................................................................................................... 112
Troubleshooting Distributed Processing Units..............................................112
Troubleshooting for AutoChief®C20 Control Panel (ACP)...........................114
Troubleshooting the Servo System (DSU and ELACT) ................................115
4.3 Replacement of Units ........................................................................................... 116
Safety Rules ..............................................................................................116
HMI units of the AutoChief®C20 Propulsion Control System ......................117
Distributed Processing Units, MEI, DGU, ESU, dPSC, RPMU .....................118
Motor Control Unit in the Digital Servo Unit (DSU) ................................... 121
Printers .................................................................................................... 122
ELACT .................................................................................................... 123
5 AS BUILT CONFIGURATION .......................................... 124
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Kongsberg AutoChief®C20
Admonitions
The following admonitions found throughout this manual mark special messages to alert
the user of specific information concerning of the personnel, the equipment or the process.
WARNING
Text set off in this manner provides a warning notice that failure to
follow the directions in this WARNING can result in bodily harm or
loss of life and/or extensive damage to equipment.
Caution
Text set off in this manner provides a warning notice that failure to follow
the directions in this CAUTION can result in damage to equipment.
Note
Text set off in this manner presents clarifying information or specific instructions
pertinent to the immediate instruction.
6 316458/C
Instruction Manual
Glossary
ACC20 AutoChief®C20
ACK Acknowledge
ACP AutoChief Control Panel
BWU Bridge Wing control Unit
CAN Controller Area Network
DPU Distributed Processing Unit
ECR Engine/Electric Control Room
ESU Engine Safety Unit
FPP Fixed Pitch Propeller
FQS Fuel Quantity Setting
GMT Greenwich Mean Time — see also UTC
I/O Input/Output
KM Kongsberg Maritime
LCD Liquid Crystal Display
LED Light Emitting Diode
LTU Lever Telegraph Unit
MCR Maximum Continuous RPM
MEI Main Engine Interface unit
NOx Nitrogen Oxides (combustion gasses)
PBT PushButton Telegraph unit
PCS Propulsion Control System
PSS Process Segment Starcoupler Module
RPM Rotations pr Minute
SHD SHutDown
SLD SLowDown
UPS Un-interruptible Power Supply
UTC Coordinated Universal Time — similar to Greenwich Mean Time
VIT Variable Injection Timing
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About this manual
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Kongsberg AutoChief®C20
2 FUNCTIONAL DESCRIPTION
10 316458/C
Functional Description
Dual CAN
CONTROL ROOMStart/Stop
Indicating Panel
Control Room Manoeuvring Unit speedset Unit
Lever 1
0
9
8
7
6
5
4
3
2
1
START
AHD
STO
P
START
AST
1
2
3
4
5
6
7
8
19
0
Dual CAN
ENGINE ROOM
Main Engine
Slow Digital
Engine Safety
down Governor
Interface Unit
Unit
nn. RAI16 MEI ESU
DGU
Servo
Unit
Electric
Local Control Panel Actuator Dual RPM
Units
with Engine Telegraph (Including
overspeed
system)
RPM
Detectors
vs060006m
MAN B&W MC
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Kongsberg AutoChief®C20
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Functional Description
Functions Indications
• Alarm ackn./sound off • Analogue RPM and
set-point
• Changing of parameters
• Analogue start air pressure
• Backlight dimming
• Current main engine state
• Start blockings
• Shutdown/slowdown
• General alarm indication
• Wrong way alarm
• Wrong way
• Bump-less control transfer
• Cancel
shutdown/slowdown
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Kongsberg AutoChief®C20
Display
The ACP LCD display is the main interface between the
operator and the system to be monitored. All interaction such
as monitoring of starting air pressure, main engines RPM and
load, adjustment of operational parameters and displaying of
safety related and conventional alarms are carried out with the
aids of this display.
HOME
Set
Limiter
Lim.
Curves
Show
Limiters
Load
Program
Home
ACP LCD display, using the Rotary Knob below. When a menu
Shut
Down
Slow
Down
EMG
stop
RPM
detector
Home
Misc2
Order VIT Param Engine
Dimming
Date & User Home
Available mimic pages and messages are described in section
Guide to the Graphic Pages on page 84
Printer Setting Change data Time Access
A photo sensor located on the lower left side help adjust the
background light, which can also be adjusted manually.
Multifunctional knob
14 316458/C
Functional Description
Cancel functions
The cancel functions available on the AutoChief®C20 control
panel are:
Cancel SHD only cancellable Shut Downs will respond to this
function.
Cancel SLD only cancellable slow Downs will respond to this
function.
Cancel limits is used to cancel RPM, fuel and load limiters which
is active in the remote control system.
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Kongsberg AutoChief®C20
Lever Function
The telegraph handle enables an operator on the bridge to be
in direct command of the ship by allowing speed and rotation
control of the engine. Communication is established between the
bridge, the engine room and local stand via the telegraph system.
The lever operates in eleven fixed steps, where each step
represents an RPM/Thrust command in ahead or astern direction.
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Functional Description
Sub-Telegraph Functions
The sub-telegraph functions are used to inform the engine crew
about the subsequent need for propulsive and electric power.
Indications
The LED indicator is lit to indicate sub-telegraph mode.
At Sea
The operator on the bridge is informing that all systems has to be
prepared and set-up for seagoing.
Stand By
The operator on the bridge is informing that all systems have
to be prepared for stand by and engine prepared for start. It
may also inform the crew that the vessel is entering channel or
harbours where special attention has to be made to the machinery
or steering plant.
FWE (Finished with engine)
The operator on the bridge is informing that there will be no
need for propulsive power. To secure that the engine cannot be
started unintentionally some safety actions has to be done by
the engine crew.
When the above actions is made and the corresponding conditions
is fulfilled the FWE Lamp in the sub telegraph will get a steady
indication light.
If these actions is not done an alarm will be released called FWE
Loop abnormal.
Functions
The pushbuttons are used for sub-telegraph mode transfer.
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Kongsberg AutoChief®C20
Bridge
The operator on the bridge/wheelhouse is controlling the engine
via the automatic Remote Control System.
ECR
The engine control room personnel have control of the engine.
Local
The engine room personnel have control of the engine from the
local control system.
Indications
• The push-button LED indicator is lit with a steady light to
indicate control position.
• The push-button LED indicator is flickering and a buzzer
will sound when a control position is requested but not yet
accepted.
Functions
• Command transfer request and acknowledge.
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Functional Description
Lever function
NAV.F ULL
The manoeuvre lever on the bridge wing unit is divided into the
FULL same steps as the bridge lever.
HALF
SLOW Indications
D.SLOW
• Illuminated scale showing each lever position.
STOP
Functions
D.SLOW • Combined speedset and telegraph setting.
SLOW
HALF
• An electric shaft function will move lever in centre bridge.
FULL
EM.AST.
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Indicators
The BWU C20 includes indicators for start air pressure and
engine rpm. The indicators are operative whether the wing
20
control station is in command or not.
Indications
0 40 • Start air pressure instrument, indicates available starting air
S TA RT A IR P RE S S URE
pressure
rpm
-100 100
The Lamp Test button is for checking all indicator lights and
LAMP
TEST
Led’s in the BWU panel.
Indications
• LED indicator is lit as long as pushbutton is pressed.
Functions
• By pressing “+” button intensity will be enhanced.
• By pressing “-“ button intensity will be reduced.
• By pressing Lamp Test the lamp test will run until lamp test
is pressed once more.
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Functional Description
Indications
• Green LED illumination when bridgewing is in command.
Functions
• Command Transfer activation.
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Kongsberg AutoChief®C20
Safety functions
The Safety functions in the BWU are divided in two sections,
Shut Down and Slow Down.
Shut Down Warning
SHD
NONE
CANCEL
Whether it’s a cancellable or not cancellable shut down individual
SHD
indicator Led’s will be illuminated. Both shut down functions
CANCEL-
ABLE have a pre-warning time (normally 8 sec.s). The led indicator
will flicker during the pre-warning time.
SHD
ACTIVE
Cancel Shut Down
CANCEL The pushbutton will, when activated, cancel shut downs which
SHD
are pre-defined as cancellable.
Shut Down Active
The Led is lit when the shut down is active.
Slow Down Warning
SLD
NONE
CANCEL
Whether it’s a cancellable or not cancellable shut down individual
SLD
indicator Led’s will be illuminated. A cancellable function is
CANCEL-
ABLE
provided with a pre-warning time, while a not cancellable will
activate immediately.
SLD
ACTIVE
Indications
• If the push-button is pressed and the cancel function is
activated the LED indicator activates a fixed red light.
• If the push-button is pressed again the cancel function is
switched off and the LED indicator starts flickering if the
Safety function is still active, and extinguishes if the safety
function is not active.
Functions
• Press pushbutton once for activation.
• Press pushbutton again for deactivation.
Over-speed
A separate indicator for over-speed shut down is provided. If the
engine is over-speeding the safety system will stop the engine.
The lever has to be set to stop and the engine has to be re-started.
22 316458/C
Functional Description
Functions
• Press pushbutton once for main engine emergency stop
• Press pushbutton again for reset.
Function is further described in Emergency Stop switches on
page 55
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Kongsberg AutoChief®C20
24 316458/C
Functional Description
Functions
• Lever for selecting start ahead or start astern and setting rpm
command by moving the lever within the scale 1 – 10 in ahead
or astern direction.
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Kongsberg AutoChief®C20
26 316458/C
Functional Description
Engine Indicators
FUEL Indicates that the fuel cam is positioned for ahead running.
CAM
AHEAD
FUEL Indicates that the fuel cam is positioned for astern running.
CAM
ASTERN
LIM.IN Pushbutton with indicator to cancel limiters in governor in ECR control.
GOV.
CANC.
SLOW Indicates the slow turning is activated. (optional function)
TURNING
TURNINGIndicates that the turning gear is mechanically engaged. (Start Block
GEAR condition)
ENG.
TURNINGIndicates that the turning gear is disengaged.
GEAR
DISENGAGED
316458/C 27
Kongsberg AutoChief®C20
MAIN Indicates that the main start valve is set to service position.
START
VALVE
IN
SERVICE
MAIN Indicates that the main start valve is set to blocked position.
START
(Start Block condition)
VALVE
BLOCKED
GOV. Indicates that the governor is engaged and connected to the fuel linkage.
ENGAGED
START Indicates that the start air distributor is set to blocked position. (Start Block
AIR condition)
DISTR.
BLOCKED
SLOW Indicates that slow down is activated.
DOWN
ACTIVE
SLOW Pushbutton with indicator for cancelling of Slow Down in ECR Control.
DOWN
CANCEL
SHUT Indicates that shut down is activated.
DOWN
ACTIVE
SHUT Pushbutton with indicator for cancelling of Shut Down in ECR Control.
DOWN
CANCEL
BRIDGE Indicates that the control position is from bridge ACP.
CONTROL
ECR Indicates that the control position is from the engine control room ACP.
AUTO
CONTROL
ECR Indicates that the control position is from the engine control room manual
MANUAL controls.
CONTROL
LOCAL Indicates that the control position is from the local control stand.
CONTROL
LAMP The pushbutton “Lamp test” is for testing all Led indicators in the engine
TEST indicator field.
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Functional Description
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30 316458/C
Functional Description
316458/C 31
Kongsberg AutoChief®C20
Start Blocked
The Start Blocked input may contain a various amount of start
interlocks. Which signals to be implemented are for the owner
or shipyard to decide. If however this input is active the actual
items in the interlock circuit has to be cancelled before a start
can take place.
3 start failures
If the engine fails to run on the first start attempt, a total of 2
repeated starts will be performed by the control system. If 3 start
attempts are made and the engine didn’t start the message 3 Start
Failures will be announced. To reset this function the manoeuvre
lever has to be set to Stop
32 316458/C
Functional Description
Engine tripped
Engine has tripped because of a shut down detected and created
by the safety system.
Details to be found in the alarm list on the Safety system mimic
pages.
Governor disconnected
When the engine is operated from the local control stand and fuel
control is carried out manually the Electric fuel actuator has to be
de-clutched from the fuel linkage system. If the Actuator is not
engaged to the fuel linkage, starting is inhibited.
316458/C 33
Kongsberg AutoChief®C20
Sequential Diagram
In the Seq. Diagram it is possible to monitor the different
sequences during start, stop and reversing. Led indicators will be
lit according to actual state in a sequence.
Slow turning
If the engine has been stopped for a certain time (normally 30
minutes), the first start will include one revolution with slow
turning of the main engine. When a start order is given from
bridge (by setting the bridge lever from stop to any position
ahead (or astern) the slow turning valve will be activated, and a
limited amount of starting air will be supplied to the main engine,
the engine will rotate slowly on starting air.
When one revolution is completed, the engine will be started in a
normal way. Slow turning indication will be shown in the control
room and bridge ACP. If one revolution with slow turning is not
accomplished within the correct time, alarm Max slow turning
time is released in control room and bridge.
It’s also possible to perform slow turning on demand. This is
done by activating the function in the ACP mimic Engine modes.
Normal start
Starting of the main engine is performed when the bridge lever is
moved from stop to any position in ahead (or astern direction).
The system will activate the starting air solenoid valve, and
starting air is supplied to the engine. System will at the same
time give a fixed starting-speed set-point to the governor. When
the engine speed has reached the start-air / fuel change over level,
starting air will be switched off, and fuel will be supplied. The
starting-speed set-point will be kept for 6 seconds (adjustable),
and then the speed set-point to the governor will be adjusted in
accordance with the set-point of the bridge lever.
34 316458/C
Functional Description
Restarting
If the engine fails to start (run on fuel) after the starting air is
switched off, the system will automatically try to restart the
engine. Indication for repeated starts will show on bridge and
ECR. The starting speed set-point to the governor will at the
second (and third) starting attempt be higher (heavy start), and
the fuel limiters for scavenge air and torque in the governor will
be cancelled. If the second start also fails, the system will try a
third start. After 3 failed starting attempts, start fail alarm will
be released.
Heavy start
Heavy start is a automatic function activated in two segments
of the propulsion control system. Firstly in the remote control
system as a heavy start RPM set-point, thereafter as a higher
pump index set-point to the fuel actuator. The Heavy start
function is automatically activated if the crash astern function is
activated.
Starting failure
Starting failure is detected when one of the following conditions
occurs, and is indicated on ECR and Bridge ACP.
• 3 starts failed
• Start too long
• Slow turning failed
Start too long means engine is unable to reach the
start-air/fuel-change level within a specific time period.
Start failures are reset by setting the manoeuvring lever to stop.
Running
The signal Running is indicated when the engine is running on
fuel.
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Kongsberg AutoChief®C20
Reversing thrust
Reversing
Engine thrust is reversed automatically to ahead (or astern)
direction from bridge by setting the bridge handle from stop to
any position in ahead (or astern) direction.
For Fixed Pitch Propeller (FPP) installations a reversing sequence
will be carried out prior to the starting sequence in opposite
direction. If the engine is running above the brake air level, then
brake air will be supplied when engine has reached the brake
air rpm level, in order to perform the reversing sequence as fast
as possible.
Crash astern
Crash manoeuvring means quick reversing of the engine thrust
from ahead to full astern, and used in emergency situations which
are most likely observed from bridge or bridgewing.
• Initiated when the bridge lever is moved from Ahead to
Emergency Astern position, according to a set of parameters.
• Crash Astern indication on bridge and engine control room
ACP.
• Stop signal will be given to the main engine.
• Engine speed will be reduced to brake air level.
• Engine will be reversed, and start air will be supplied.
• Heavy start and cancel limiters signals will be given to the
speed control system.
• When the speed reaches the fuel/start air change level in
astern direction, the start air will be switched off, and fuel
will be supplied.
• Engine RPM will be increased to Emergency Astern
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Functional Description
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38 316458/C
Functional Description
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Kongsberg AutoChief®C20
• When the engine speed reaches the over-speed level, the fuel
will be cut-off, the engine speed will decrease.
• When the engine speed reaches reset level, fuel will be
supplied, and the engine will be running at this level.
• To reset, move speed-set lever back to reset level and move
handle to desired RPM.
There is an upper speed limit for this function (adjustable). The
upper limit is provided to avoid fluctuation between over-speed,
and stop.
Note
MAN B&W does not approve this function, however it is provided
as an option.
40 316458/C
Functional Description
Dead Band
The dead band function reduces the motion of the actuator. A
rpm dead band is set by parameters, as default it’s set to 2 rpm.
That means +- 2 rpm. During normal operation the speed control
system will use a reduced gain in this area, causing the governor
to act slower when the rpm variations is less than +- 2 rpm.
When the dead band mode is selected the gain is zero in this area,
the governor will not act at all. The dead band can be adjusted
up to 15 rpm.
316458/C 41
Kongsberg AutoChief®C20
The system uses the charge air pressure and the engine speed
as input signals to this control function, in order to control the
VIT+FQS actuator placed on the main engine in accordance with
specified curves.
VIT+FQS is controlled on the engine using the engine
manufacturers controls.
42 316458/C
Functional Description
VIT Normal
During VIT Normal mode the system is using charge air pressure
and main engine speed as reference to make the correct action
on the output to the VIT actuator. There are two curves which is
used together to make the output for Normal VIT function they
are illustrated on the drawing below:
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Kongsberg AutoChief®C20
44 316458/C
Functional Description
RPM detection
The AutoChief®C20 is equipped with two independent RPM
measurement systems. These systems will at all time ensure
correct reading of the RPM pickups and give alarm in case of
irregularities.
The AutoChief®C20 governor system receives the engine actual
RPM from the AutoChief®C20 RPM detection system on a
direct serial communication line RS422, and as back-up from the
AutoChief®C20 CAN communication line.
The figure below shows the basic components for the RPM
control system.
ACP DGU
Electric actuator
RPMD
Pick-ups RPME RPME
316458/C 45
Kongsberg AutoChief®C20
Regulator functions:
• Controlling speed of the main engine based on set-point from
lever in control.
• Protecting the engine from overload.
• Constant fuel mode (Increases the dead band for speed
regulation).
• Load dependent cylinder lubrication.
Actuator functions:
• Setting the fuel rack in the correct position based on the order
from the governor unit.
• In case of major failure, to block fuel in order to maintain
speed and thrust.
Governor management:
• In bridge control, the governor is managed by the remote
control system.
• In control room control, the governor is managed either by the
AutoChief®C20 telegraph lever or the separate control room
manoeuvring handle.
46 316458/C
Functional Description
RPM limiters
For protecting the engine and its accesories against thermal stress
and destruction and unnecessary wear and tear some fixed RPM
Limiters are included in the system.
Load program
When setting the bridge handle to Navigation Full position, load
program will be activated. This will be indicated as Load up
program active on the ACP. The purpose of this function is to
prevent engine internal temperatures (i.e liners and pistons), from
increasing too fast when higher load is applied.
When MCR is obtained the Load up program active indication
will disappear.
The same function may also apply for the opposite purpose.
When reducing speed from Navigation Full to full ahead the load
down function is activated, slowly decreasing the speed to allow
the engine to cool down.
If the bridge lever is set to a position below Full ahead before the
load down program is finished, the program will automatically
be cancelled.
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Kongsberg AutoChief®C20
Slow-Down
A slow down is caused by a input signal detected by the slow
down module. If such a signal is detected, the safety system will
send a speed reduction request to the remote control system. The
speed set-point will after a pre-warning time be reduced to the
pre-defined slow down level.
48 316458/C
Functional Description
If the engine RPM run within the critical (or barred) speed ranges
too long time, indication for Critical RPM will be shown on the
ACP.
There are two critical RPM zones available, a ‘high’ and ‘low’,
each having an upper and lower limit adjustable in engine
parameters. These are displayed in red on the RPM indicator.
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Kongsberg AutoChief®C20
Acceleration limiter
The acceleration limiter defines maximum acceleration and
retardation in RPM/seconds.
Minimum RPM
The minimum RPM limiter defines the lowest RPM possible for
running of the main engine. If the manoeuvre lever or fine tuning
RPM control is set below this limiter the main engine will be
running according to the setting done in this defined parameter.
50 316458/C
Functional Description
Fuel limiters
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Kongsberg AutoChief®C20
Power loss
Fuel rack will be blocked in last position in order to maintain
speed and thrust.
When power is restored the governor will check actual engine
speed and speed set point. And then automatically restore normal
regulation.
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Functional Description
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54 316458/C
Functional Description
316458/C 55
Kongsberg AutoChief®C20
Note
Emergency Stop switches are hardwired directly to the engine
safety system and function is designed to shut down the engine
as fast as possible.
All switches must be in inactive position before the main engine
can be restarted.
56 316458/C
Functional Description
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Kongsberg AutoChief®C20
Note
Please refer to the DPU Maintenance Manual 313675 and
datasheets for details regarding different DPUs.
58 316458/C
Operation
3 OPERATION
• Bridge
• Bridge Wings
• Engine Control Room
• Local Control Stand
The operational description is built on the case that the engine
shall be started, stopped and propeller to provide ahead and
astern thrust from each control location. Normal events during
these operations are described. More advanced operations are not
covered in this chapter.
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Kongsberg AutoChief®C20
60 316458/C
Operation
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Kongsberg AutoChief®C20
Stop engine
Note
Emergency Stop switches are hardwired directly to the engine
safety system and function is designed to shut down the engine
as fast as possible.
All switches must be in inactive position before the main engine
can be restarted. The current status of all emergency stop
switches is displayed in a dedicated mimic picture: Safety System
— Emg. Stop
62 316458/C
Operation
Crash astern
3 At a preset level starting air for start astern will cut in for
reducing the RPM ahead as fast as possible. As soon as the
rotation of the engine ahead is stopped and the engines rpm
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Kongsberg AutoChief®C20
64 316458/C
Operation
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Kongsberg AutoChief®C20
Safety functions
Safety functions are divided in cancellable and not cancellable.
If a cancellable safety function appears follow the description
below. A none cancellable safety function will appear like this:
E ME R GE N CY S TOP
1 To activate Emergency Stop, lift the protection cover
2 Press the pushbutton, and emergency stop is activated.
E ME R GE N CY S TOP
3 To reset emergency stop, press the pushbutton once more,
set the manoeuvre lever in command to stop, then engine
can be started again
Note
Emergency Stop switches are hardwired directly to the engine
safety system and function is designed to shut down the engine
as fast as possible.
All switches must be in inactive position before the main engine
can be restarted.
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Operation
Start conditions
Before starting the engine it has to be prepared for start, and all
start block conditions removed.
Observe theEngine State indication in the IPU Panel for engine
ready to start.
This can also be checked on the ACP Panel in ECR. Since the
starting and stopping of ME is a semi-automatic system for
control of ME in ECR, states on engine is not shown since the
AutoChief C20 system is not in control.
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1 Use the Rotary knob for navigating to the Engine State page.
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Stop engine
Note
Emergency Stop switches are hardwired directly to the engine
safety system and function is designed to shut down the engine
as fast as possible.
All switches must be in inactive position before the main engine
can be restarted.
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Operation
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Cancel Limiters
When the engine is operated from control room, the conventional
remote control system is not in operation. Limiters such as
Acceleration limiter and load program will not be active.
However limiters in the speed control system (Governor) will
work. Use the following procedure to cancel limiters in control
room control:
1 Command given from bridge
2 When the RPM is adjusted and it’s not possible to obtain
requested rpm, a limiter is likely to be active.
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Operation
Local panels
When the engine is operated from the local control stand, orders
for rpm and direction of thrust is given from the bridge. The
telegraph system is active by transmitting orders from bridge
to the local control stand. The order is confirmed at the local
control stand by pressing the pushbutton representing the order
requested from bridge. The panels involved in operating the
main engine from local stand is the Emergency control El.box
and the pushbutton telegraph unit.
2 The Manual fuel control wheel is then used for adjusting the
fuel level according to requested rpm.
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Stop engine
Emergency Stop
EMERGENCY STOP If required Emergency Stop may be activated from local control
stand
1 Open the cover.
2 Press the pushbutton Emergency Stop for stopping the engine
3 For resetting the function press once more and the engine
can be restarted.
Note
Emergency Stop switches are hardwired directly to the engine
safety system and function is designed to shut down the engine
as fast as possible.
All switches must be in inactive position before the main engine
can be restarted.
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Operation
Cancel functions
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The status bar at the top of the ACP mimic will indicate control
position.
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Operation
Bridge
The operator on the bridge/wheelhouse is controlling the engine
via the automatic Remote Control System.
ECR
The engine control room personnel have control of the engine.
Local
The engine room personnel have control of the engine from the
local control system.
Indications
• The push-button LED indicator is lit with a steady light to
indicate control position.
• The push-button LED indicator is flickering and a buzzer
will sound when a control position is requested but not yet
accepted.
Functions
• Command transfer request and acknowledge.
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The grey field below the analogue instruments is the status bar
for indicating alarms. When the alarm condition is acknowledged
the field returns to normal with a grey background only.
When Shaft Generator is engaged, this will be indicated above
the RPM indicator.
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Operation
The lower section of the page is the menu where the operator
does the selection of other pages related to handling alarms,
adjustments of limiters, fine tuning etc. For navigating the ACP
mimic pages, using the Multifunctional Knob (Rotary Knob) the
following illustration may be useful.
Please note that not all options are available on both Bridge and
ECR ACP display, and there may be custom designed mimic
pictures different from standard configuration for MAN BW MC
Engines with Fixed Pitch Propeller.
HOME
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ACP Dimming
Select the Dimming page under the Misc menu.
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Operation
Safety System
From the Home menu, select the Safety System page.
The Home page will remain but the lower section provides a
different set of soft keys.
Use the rotary knob and navigate to Shut Down soft key, and
press the knob once.
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Use the rotary knob to navigate the list to cancel individual shut
down alerts, rather than all by using the SHD button.
Use the rotary knob and navigate to Slow Down soft key, and
press the knob once.
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Use the rotary knob to navigate the list to cancel individual slow
down alerts, rather than all by using the SLD button.
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Note
It’s possible to cancel individual shut downs from the Safety
System sub-menu. This can be useful in case of e.g. a known
faulty sensor or maintenance work.
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Note
It’s possible to cancel individual slow downs, from the Safety
System sub-menu. This can be useful in case of e.g. a known
faulty sensor or maintenance work.
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Operation
Sound off
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Alarm ackn
4 Use the rotary knob to navigate to the page Alarm, press the
knob for activating the picture.
5 Observe the Alarm page and verify which alarm conditions
that are present.
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Operation
• Select the Date & Time page under the Misc menu.
• By using the rotary knob each field for adjusting date and time
can be selected.
• When the soft key Set Time is selected the adjustments are
made active.
• Use the Adjust local offset to set the difference (in minutes)
between zero-point reference and your local timezone, and
daylight saving time if in effect.
Note
Universal Time Coordinated is an atomic time standard that has
replaced Greenwich Mean Time as the main reference time scale,
which approximates GMT for the purpose of adjusting local
time according to longitude and daylight saving time. UTC may
also be referred to as ‘Temps Universel Coordonne’ (TUC) or
‘Coordinated Universal Time’ (CUT), and by the military as
‘Zulu time’ (Z).
System logs are displayed with Local Time.
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Engine Data
The settings in Misc Menu — Engine Data page are configured
during commissioning and cannot be changed. The information
includes engine type, propeller type rpm and max continuous
rpm (MRC) and the number of cylinders.
Engine State
The Engine State and start/stop conditions are displayed in the
Engine State page. Conditions are further described in Functional
Description Engine state, start Interlock/Fail/Block on page 32
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Operation
Engine Modes
Select the Engine modes page.
• Press the knob, the indicating field beside the soft key will get
green colour. The operation mode selected is now active.
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Engine Limiters
For protecting the engine and its accesories against thermal stress
and destruction and unnecessary wear and tear some limiters are
included in the system. Limiters are displayed in the Limiters
page and described further in Functional Description RPM
control function on page 45
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Operation
The limiter curve settings can be inspected and adjusted using the
Misc Menu — Parameter Change — ME Governor DGU mimic,
according to guidelines found in section Parameter Change on
page 100
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Parameter Change
The settings in Misc Menu — Parameter Change page are
configured during commissioning and requires higher lever user
access to be changed.
Caution
The user is advised to consult engine manufacturer’s
manual before attempting to adjust parameters.
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User Access
The AutoChief®C20 has 3 levels of access control.
• Press OK in the dialog box. The status field beside the access
level changes to “Active” When the access level is accepted
the other fields on the “User Access” page is available for
adjustments.
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• Use the rotary knob and navigate the Misc menu — Fine
Tuning page.
• Use the rotary knob and navigate to the field for percent
setting.
• Press the knob to be able to adjust the value and use the rotary
knob to adjust the percent setting
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Operation
The start point will be the value representing the preset lever
position. Values above and below the bar-graph is representing
max and min. value for fine tuning.
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Lever calibration
The levers can be calibrated using the Misc menu — Parameter
change pages, as follows, though options available on the screens
may differ due to various engine/propeller configurations.
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14 Repeat 6–9 for Max Ahead, but move the lever as far as
possible ahead, and note the correct values to be 100%
16 Repeat 6–9 for Full Astern, and note the correct values to be
according to settings found/adjusted in step 4 (about –80%)
17 Repeat 6–9 for Half Astern, and note the correct values to be
according to settings found/adjusted in step 4 (about –60%)
18 Repeat 6–9 for Slow Astern, and note the correct values to be
according to settings found/adjusted in step 4 (about –40%)
19 Repeat 6–9 for Dead Slow Astern, and note the correct values
to be according to settings found/adjusted in step 4 (about
–20%)
Move the lever through all 11 steps to verify correct calibration
values. Repeat steps 6–9 in case of incorrect calibration values
(contact service personnel if this does not correct the problem).
The calibration of the Bridge lever is now completed.
Repeat the procedure for other levers if necessary.
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Maintenance
4 MAINTENANCE
This guide explains how to keep the system in good working
order and what to do if the system fails. The following subjects
are covered:
• Preventive maintenance
• Troubleshooting the system
• Unit replacement
• Distributed processing units
This maintenance description is intended for trained maintenance
technicians or engineers with experience in electronic and digital
circuits, computers and electro mechanical design. The level
of information is based on Kongsberg Maritime’s maintenance
philosophy:
The onboard technical personnel shall, with the help of the
documentation and the system’s built-in test functions, be able to
identify malfunctions, locate the fault, and replace major parts,
modules and components on a “Line Replaceable Unit” (LRU)
level. He/she shall however not attempt to repair the LRUs.
Caution
Cleaning with abrasive material or strong chemical
cleaning solutions is not recommended as these may
damage the system.
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Maintenance intervals
Kongsberg Maritime recommends the following preventive
maintenance routine for the AutoChief®C20 Propulsion Control
system:
Weekly: Clean all operator panels with a dry
cloth, and perform a lamptest.
3-Monthly: Clean all filters for units equipped with
fans.
6-Monthly: Check rpm pickups, cables and cable
entrances, electrical screw-terminals,
fuse connections and plug connections.
Yearly: Check and if necessary calibrate the
input sensors and output actuators
according to the manufacturer’s
instructions. Check the batteries in the
UPS.
Weekly maintenance
This maintenance routine applies to units equipped with lamp
test buttons. Pushing lamp test buttons will not interrupt normal
system operation.
1 Clean the surface of the units. Wipe the surfaces with a
clean cloth.
2 Push LAMP TEST.
a All LED’sshould be lit.
b If the test fails, refer to the trouble shooting section.
3–monthly maintenance
Locate the unit(s) equipped with fan(s) and filter(s), take out
the filter and clean it. After cleaning, return the filter to it’s
designated place.
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6–monthly maintenance
Where applicable; check the following parts of the system each
6-month period:
1 Check cables and cable entrances for damage to the cable.
2 Tighten all electrical screw-terminals.
3 Tighten all plug connections.
Visual inspection of system parts is recommended to prevent
malfunctions and to ensure safe operation. For rpm pick-ups :
Remove dirt and check distance, while engine is stopped.
Check the batteries in the UPS, either by using a battery tester or
by letting the system run on batteries for 30 minutes.
Yearly maintenance
Visual inspection of system parts is recommended to prevent
malfunctions and to ensure safe operation. Each year, check
and if necessary calibrate the input sensors and output actuators
according to the manufacturer’s instructions. In general, it is not
necessary to re-calibrate sensors if the input signal is correct.
In particular for the fuel rack : check max fuel position on the fuel
pumps, and adjust max fuel in governor parameter, while engine
is stopped. Also inspect the actuators connection to the fuel rack.
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4.2 Troubleshooting
Green indicates that power is available and red that the power
has wrong polarity.
3 Read the status for each indicator above and check it against
the table below.
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4 Follow the action for the fault you found as described below.
Normal Operation
Indicators lit: Run (Green), Info. (flashing yellow), End Init.
(green) and Power (green). - The unit seems to be working OK.
1 Check the cabling.
2 Restart the unit by turning power off and then on again.
3 If the Remote Operator Station is still reporting an error
replace the module. See procedure below.
No application loaded
Indicators lit: Watch Dog (red), End Init. (green) and Power
(green).
1 Indicates that the distributed processing unit has boot
software installed, but no basic software. Use the Rioload
program to install the appropriate software.
Not initialised
Indicators lit: Watch Dog (red) and Power (green)
1 Return the item to us.
Application stopped
Indicators lit: Watch Dog (red) and End Init (green)
1 Restart the unit by turning power off and then on again.
2 If the WatchDog indicator is still lit replace the module. See
procedure below.
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No power
Indicators lit: None
1 Check power supply and wiring.
2 If the power supply and wiring is OK, replace the module.
Troubleshooting checklist
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Note
All DPUs look very similar. Make sure the replacement unit is
of exactly the same type as the failed unit. Type specification is
available on labels found on each unit.
Safety Rules
Note
Kongsberg Maritime’s health and safety system must be adhered
to at all times.
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Printers
It is recommended that the replacement printer is of the same
make and model as the old one. Do the following:
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ELACT
Perform the following procedure.
1 Replace the ELACT
2 Perform origin teaching (if using position control).
a When replacing the ELACT, the ELACT specific origin
position (Z-phase) may slip, so be sure to perform origin
teaching.
b Refer to the manual for the position controller you use for
how to perform origin teaching.
3 Set up the absolute encoder (ABS).
a If using ELACT with an absolute encoder, when
replacing the ELACT, the absolute data in the absolute
encoder will be cleared, so you need to set up the data
again. Also, the rotation limit data will be different from
before you replaced the ELACT, so initialize the Motion
Control Unit settings.
b For further reference, Check OMRON USER’S
MANUAL MODELS R88M-W_ (AC Servomotors)
MODELS R88D-WT_ (AC Servo Drivers)AC
SERVOMOTORS/SERVO DRIVERS, Revision March
2003
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5 AS BUILT CONFIGURATION
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Index
C
Command Transfer
ACP page, 78
Bridge Wing, 80
Bridge/ECR, 81
Local, 83
Pushbuttons, 18, 21, 79
M
Maintenance, 109
Intervals, 110
Troubleshooting, 112
Unit replacement, 116
Units, 13, 16, 19, 24, 26,
118, 124
R
Remote Control System, 32
Actuator Functions, 46
Alarms, 32
Auxiliary functions, 44
Engine limiters, 45, 53, 98
Engine modes, 38, 42, 97
Engine State, 32, 96
Governor Management, 46
Regulator Functions, 46
Start Fail/Block, 32, 67
VIT/FQS, 42, 97
S
Safety System, 54, 87
Acknowledge, 15, 94
Alarms, 32, 91
Cancel Limits, 15, 61, 93
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©2008 Kongsberg Maritime