Scana

Scana Volda as
Hamneg. 24, P.O.box 205, N-6101 Volda, Norway
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01
Service (after office hrs.): +47 478 24 365
www.scana.no, e-mail: [email protected]

6. Remote control and electrical equipment

ELECTRONIC REMOTE CONTROL SYSTEM

See enclosed documentation
 Scana Mar-El

ELECTRONIC REMOTE CONTROL SYSTEM

FOR
PROPULSION

Scana Mar-El type no.: Neptune CPP-23/C23

Scana Mar-El plant no.: 2440-41

Customer: Scana Volda

No. 1664-65

Yard: Ebin S/A

EB-004
 General Information
1 Generell informasjon

Installation and Interface Manual

Installation Guidelines
2 Installasjon og interfacemanual
Retningslinjer for installasjon

User's Manual
3 Brukermanual

Service Manual
4 Servicemanual

System Drawings
5 System tegninger

Miscellaneous
6 Diverse

10
 General Information
1 Generell informasjon
 Fncrony AccnprANCETnsr

f Scana IlIar-El
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Sysrnvr

It is herebycertified that this systemandall partsof it is testedandcalibratedin

accordancewith ScanaMar-El's test procedures,andthat all testsand calibrationsare
carriedout successfu
lly.

Scana
Mar-Er
o?eno.: N.En.tl.yf-..Slf....1-!-:.+.
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Scana pluo,'
Mar-Er no.,.L.!.i!.L..
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Date:

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 Parts list - Main parts – Scana Mar-El Electronic Remote Control System

Parts list - Main parts – Scana Mar-El Electronic Remote Control System

Scana Mar-El type no. Neptune CPP 23/C23

Scana Mar-El plant no. 2440-2441

System type Simplex Duplex Other:

Automatic load control Yes No

Manouver stations
Main panel bridge No.'s: 1
Slave panel bridge No.'s: 1
Engine room panel No.'s: 1

Computer cabinet (MEPU) No.'s: 2

Actuators / output units

Pitch actuator No.'s: 2 MAC-102-xxxxxx CRAB-12 SVO delivery
Pitch output to hydraulic valve(s) No.'s: ON/OFF Proportional
RPM actuator No.'s: MAC-51 Other:
I/P-converter, RPM No.'s: 6111 (0,5-5,5 Bar) Other:
Electronic RPM order signal No.'s: 2 4-20mADC Other:
Clutch output No.'s: 2 24VDC (sol. valv.) Other:

Feedback potentiometer pitch D20493 D22860 Other: SVO delivery

Sensors / input units

Pick-up Bi5-M18-AD4X Ni8-M18-AD4X Other: SVO delivery
Fuel sensor Bi10-M30-LIU Other: 4-20mA

Other / additional description Softclutch.

Interface for joystick + DP.
"Common control transfer"
Standby pump control

w:\anlegg\beskriv\neptune main parts list\neptune main parts list 2440-41.doc 09.01.06 Page 1 of 1
 Scana Mar-El type: Scana Mar-El plant no: Customer Customer ref.
Neptune CPP 23/C23 2440-41 Scana Volda A/S 1664-65

Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
Electronic cabinet

C12 MP600-2 Back-up Controller U2 Setup Parameters Backup 01.10 131205 / KIH
C12 MP600-2 Back-up Controller U3 Program Backup Controller 01.10 131205 / KIH
C12 MP600-2 Back-up Controller U6 Logic 01.01 020300 / KIH
C6 MP501-X Main Controller U10 Logic 01.02 290501 / KIH
C6 MP501-X Main Controller U11 Logic 01.01 171298 / KIH
C6 MP501-X Main Controller U12,U16 Program Main Controller 01.58 120206 / KIH
C6 MP501-X Main Controller U19 Setup Parameters Main 01.58 120206 / KIH
C3 MPS200 Power monitoring U5 Logic 01.04 180401 / KIH
C11 MPS405 PWM driver U4 Controller program N/A N/A
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
Main panel

C2 MP600-1 Main Controller U2 Setup Parameters Panel 01.08 131205 / KIH

C2 MP600-1 Main Controller U3 Program Main Panel Controller 01.08 131205 / KIH
C2 MP600-1 Main Controller U6 Logic 01.01 080300 / KIH
C1 MPS110-X Interface card U13 Program Main Backup Controller 01.02 071005 / KIH
C1 MPS110-X Interface card U14 Logic 01.02 261000 / KIH
C3 CANtrak C3 Program Display Unit 01.04 060202 / KIH
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
ECR Panel

C2 MP600-1 Main Controller U2 Setup Parameters Panel 01.08 131205 / KIH

C2 MP600-1 Main Controller U3 Program Main Panel Controller 01.08 131205 / KIH
C2 MP600-1 Main Controller U6 Logic 01.01 080300 / KIH
C1 MPS110-X Interface card U13 Program Main Backup Controller 01.02 071005 / KIH
C1 MPS110-X Interface card U14 Logic 01.02 261000 / KIH
C3 CANtrak C3 Program Display Unit 01.04 060202 / KIH
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
C2 MP600-1 Main Controller U2 Setup Parameters Panel 01.08 131205 / KIH
Slave 1

C2 MP600-1 Main Controller U3 Program Main Panel Controller 01.08 131205 / KIH
C2 MP600-1 Main Controller U6 Logic 01.01 080300 / KIH
C1 MPS110-X Interface card U13 Program Main Backup Controller 01.02 071005 / KIH
C1 MPS110-X Interface card U14 Logic 01.02 261000 / KIH
C3 CANtrak C3 Program Display Unit 01.04 060202 / KIH
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
C2 MP600-1 Main Controller U2 Setup Parameters Panel N/A N/A
Slave 2

C2 MP600-1 Main Controller U3 Program Main Panel Controller N/A N/A

C2 MP600-1 Main Controller U6 Logic N/A N/A
C1 MPS110-X Interface card U13 Program Main Backup Controller N/A N/A
C1 MPS110-X Interface card U14 Logic N/A N/A
C3 CANtrak C3 Program Display Unit N/A N/A
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
C2 MP600-1 Main Controller U2 Setup Parameters Panel N/A N/A
Slave 3

C2 MP600-1 Main Controller U3 Program Main Panel Controller N/A N/A

C2 MP600-1 Main Controller U6 Logic N/A N/A
C1 MPS110-X Interface card U13 Program Main Backup Controller N/A N/A
C1 MPS110-X Interface card U14 Logic N/A N/A
C3 CANtrak C3 Program Display Unit N/A N/A
- Unit Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
- Display repeater 1 C3 Program Display Unit N/A N/A
- Unit Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
- Display repeater 2 C3 Program Display Unit N/A N/A
 Installation and Interface Manual
Installation Guidelines
2 Installasjon og interfacemanual
Retningslinjer for installasjon
 Installation and Interface manual Neptune PCS - CPP version

Installation and Interface manual Neptune PCS - CPP version

(PCS = Propulsion Control System.)

Important documentation and drawings for installing the Neptune propulsion control system are:
1. The installation and interface manual - this manual
2. Installation guidelines Neptune propulsion control systems
3. Cableplan Neptune propulsion control system, drawing no. 016-XXXX (individual for each system)
4. Mechanical drawing computer cabinet Neptune, drawing no. 058-XXXX (different versions exists)
5. Mechanical drawing manoeuvre panel Neptune, drawing no. 058-XXXX (different versions exists)

All installations, mechanical and electrical, are to be done according to these documents. Note that all vessels are not
necessarily equipped with all propulsion and manoeuvring units described in the Neptune documentation (in such cases
connect all that exists/are specified).

Note that this document is for general help, and is not intended as the detailed installation documentation for the
system. The installation shall be done according to the cable plan, which is the most important installation document.
In case of disagreements between the cable plan and other documentation, the cable plan is the valid one.

Note that to fully comply with EMC-standards all cables must be screened and it is very important to follow the
'Installation guidelines Neptune propulsion control systems'.

1 General description

The Neptune propulsion control system CPP version controls main engine rpm, propeller pitch and clutches. Different
operating modes to suit the vessels different operating conditions may be implemented. Up to eight control stations can
be included.

The Neptune propulsion control system consists of the following main units:
1. Computer cabinet.
2. Manoeuvre panel (one or more, up to eight).
3. Necessary sensors and actuators.

2 Mounting

All units must be mounted according to general requirements and classification society requirements for equipment
onboard vessels. Se also 'Installation guidelines Neptune propulsion control systems'.

2.1 Computer cabinet

The computer cabinet must be mounted indoor, and is normally mounted easily accessible in the engine control room
(ECR) or on the main bridge.

Pay special attention to grounding of cable screens.

2.2 Manoeuvre panels

The manoeuvre panel(s) are designed for fixed mounting (portable and drop-in versions are available). See cut-out
dimensions in the mechanical drawing for mounting as fixed or drop-in. No drilling, screwing etc. into the unit may be
done.

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 Installation and Interface manual Neptune PCS - CPP version

The standard manoeuvre panel(s) are intended for indoor mounting. A version with additional sealing in front is
available for outdoor mounting/use. It must then be arranged with cover and heating (not included), and the panel must
be cleaned and dried thoroughly after being exposed to rain, water, sea spray etc.

Connection to the main or ECR manoeuvre panel is necessary during system set-up and tuning. The panels must be
mounted so the service connector for connection of the PC for system set-up and tuning is easily accessible.

3 External connections

The propulsion control system interfaces sensors and actuators and other systems (e.g. alarm plant, main engine
governor, main switchboard etc.). Alarm outputs are normally connected to the vessels alarm system.

All external equipment and units are connected to connection terminals in the computer cabinet. Below are all external
connections described in detail (actuators, sensors etc. within the scope of supply are internal connections).

Note that all connections are necessarily not present on all systems, see the system cable plan for details (drawing no.
016-XXXX). The descriptions below are given as guidings. In case of other description than in the cable plan, e.g.
different terminal numbers etc., the cable plan is valid.

See installation requirements in the installation guidelines and the cable plan. Note specially that connected units must
not generate transients, e.g. connected solenoids, relay coils etc. must have transient arrester.

3.1 Power supply

Power supplies:
Term. no. Signal Miscellaneous
X1-1 +24VDC supply 1
X1-2 024VDC supply 1
X1-3 +24VDC supply 2
X1-4 024VDC supply 2

The two supplies must be completely separate and capable of delivering min. the required continuos rating each (the
required min. ratings are given in the cable plan, drawing no. 016-XXXX).

3.2 Alarm outputs

The system has the following alarm outputs:

Term. no. Signal Miscellaneous
X2-1 Potential free NC contact
Alarm voltage failure – Output
X2-2 Open contact indicates alarm
X2-3 Potential free NC contact
Alarm system failure – Output
X2-4 Open contact indicates alarm

3.2.1 External alarms

All alarms from gearbox and propeller shaft must be active in all running modes, including normal, PTI, boost etc.

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 Installation and Interface manual Neptune PCS - CPP version

3.3 Gear and propeller system

Interface signals to the gear and propeller system.

3.3.1 Servo oil pressure

Pressure switch sensing the servo oil pressure:

Term. no. Signal Miscellaneous
X7-1 Potential free NC contact
Servo oil pressure – Input
X7-2 Closed contact when no pressure

3.3.2 Clutch indication

Pressure switch sensing the clutch pressure:

Term. no. Signal Miscellaneous
X7-8 Potential free NO contact
Clutch pressure – Input
X7-9 Open contact when no pressure

3.3.3 Clutch in/out

Output to solenoid valves operating the clutch:

Term. no. Signal Miscellaneous
X7-3 Output – Clutch in 24VDC max 2A
X7-4 Common
X7-5 Output – Clutch out

3.4 Main engine

Interface signals to the main engine (governor, diesel control, safety system).

3.4.1 Speed setting signal

Speed setting signal to main engine governor (evt. via I/P-converter):

Term. no. Signal Miscellaneous
X8-1 Order signal – Output signal Galvanically isolated
X8-2 Order signal – Common/reference Configurable to 4-20mADC / 0-10VDC

3.4.2 Fuel rack position

Sensor for the fuel rack position or engine load signal:

Term. no. Signal Miscellaneous
X8-3 Sensor input – Sensor power Must be galvanically isolated
X8-4 Sensor input – Sensor signal Configurable to 4-20mADC / 0-10VDC
X8-5 Sensor input – Sensor common/reference

3.4.3 Interlock start main engine

Output signal to interlock starting of main engine:

Term. no. Signal Miscellaneous
X8-6 Potential free NC contact
Interlock start main engine
X8-7 Open contact when possible to start

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 Installation and Interface manual Neptune PCS - CPP version

3.5 Main distribution board (main switchboard)

Interface signals to the main distribution board.

3.5.1 External rpm order

Input for potential free potentiometer track:

Term. no. Signal Miscellaneous
X9-1 Sensor input – Sensor power Must be potential free
X9-2 Sensor input – Sensor signal
X9-3 Sensor input – Sensor common/reference

3.5.2 Shaft generator load

Input for electronic shaft generator load signal:

Term. no. Signal Miscellaneous
X9-4 Sensor input – Sensor signal Must be galvanically isolated
X9-5 Sensor input – Sensor common/reference Configurable to 4-20mADC / 0-10VDC

3.5.3 Constant rpm mode engaged (shaft generator mode)

Output signal to interlock the shaft generator:

Term. no. Signal Miscellaneous
X9-6 Potential free NC contact
Interlock shaft generator
X9-7 Closed contact when possible to engage the shaft gen.

3.5.4 Shaft generator engaged

Input signal to lock the remote control system to the shaft generator mode:
Term. no. Signal Miscellaneous
X9-8 Potential free NC contact
Shaft generator engaged
X9-9 Closed contact when shaft generator engaged

3.6 Miscellaneous

Signals that may be used for several functions.

3.6.1 Pitch limit

Activates a preset (adjustable) pitch limit, i.e. load limit.

Input signals to activate pitch limits:

Term. no. Signal Miscellaneous
X10-1 Potential free NC contact
Pitch limit 1
X10-2 Closed contact to engaged the pitch limit
X10-3 Potential free NC contact
Pitch limit 2
X10-4 Closed contact to engaged the pitch limit

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 Installation and Interface manual Neptune PCS - CPP version

4 Internal connections and set-up

Connection of internal signals. Connect as described in the cableplan. Note that the internal network has a theoretical
maximum cable length of 1200 meters. Also note that there are two independent networks, each with its own power
supply (one main network and one back-up network).

Set-up consists of termination of network.

4.1 Network termination

The internal network must be terminated in each end. It must be guided as one line, i.e. no branches are allowed.

The network has two possibilities regarding units in each end:

1. Manoeuvre panel in one end and the main computer in the other
2. Manoeuvre panels in each end

Termination of the network are always done in the two units being in the ends, and nowhere else. I.e. the two "end units"
shall have network termination and no others.

The system is factory preset to possibility 2 above if an ECR panel is included, otherwise it is factory preset to
possibility 1. The figures below shows the network schematically:

Manoeuvre panel in one end and the main computer in the other:

Network termination Network termination

Main
computer
cabinet Manoeuvre Manoeuvre Manoeuvre
panel panel panel

Manoeuvre panels in each end:

Network termination
Network termination
Main
computer
Manoeuvre cabinet Manoeuvre Manoeuvre
panel (ECR) panel panel

The network termination consists of two 120Ω resistors. Manoeuvre panels: one connected between X1-3 and X1-4, the
other between X2-9 and X2-10. Main computer cabinet: one connected between X4-3 and X4-4, the other between X4-9
and X4-10.

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 Installation Guidelines
Neptune Propulsion Control Systems

INSTALLATION GUIDELINES
NEPTUNE PROPULSION CONTROL SYSTEMS

1 General

1.1 Environment conditions

Ambient temperature : +5°C to +55°C.

Humidity : Up to 100% RH noncondensing.

Vibrations: Frequency range 2 - 300Hz.

Amplitude 1 mm (peak value) below 13,2 Hz.
Acceleration amplitude 0,7g above 13,2 Hz.

Ventilation: The equipment should be installed in such a way that free air circulation is
maintained.

1.2 Electrical requirements

DC voltage power supplies: 24V DC (+20%, -10%).

Two or more independent power supplies may be required (see the specific system documentation).

2 Mounting

2.1 General

The equipment must be protected against dust etc. when mounting. This also applies when other installation
work near the equipment is done.

2.2 Mechanical installation

While planning the mounting positions, cable length must be considered.

2.2.1 Operator panels

Mount indoor.

Sealed option can be supplied.

2.2.2 Cabinets, incl. main computer cabinet

Mount in a place where it can be easily accessed in order to make service easy, and so that the equipment
is protected against damage.

Check that the door can be fully opened, that the interior can be easily accessed and that free air
circulation are maintained when cooling fans are mounted.

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 Installation Guidelines
Neptune Propulsion Control Systems

2.2.3 Main terminal block and terminal lists

Mount in a place where it can be easily accessed in order to make service easy, and so that the equipment
is protected against damage. The main terminal block is usually mounted inside the main computer
cabinet.

Cables should be routed in such a way that access to the main terminal block and other equipment is easy.

3 Wiring and connections

3.1 Cable types

Cable dimensions will always be given in a cableplan distributed with each installation. The cable plan describes
which cables that should be grouped into multicables. Multicables should be of collective screened type. The
cables should meet the requirements of the installation environment (i.e. heat, humidity etc.).

Typical minimum requirements for cables in different applications:

Category Min. dimension Remarks
24VDC power 2,5mm2, Screened,
but max. drop at peak load < 6% multi-stranded
Serial communication 0,5mm2 twisted pair Screened,
multi-stranded
Input / output signals 0,5mm2 Collective screened,
multi-stranded
Electromechanical actuators 1mm2, Collective screened
Solenoid valves but max. drop at 24VDC < 6% multi-stranded
External relays etc.

3.2 Cable routing

The various differing categories of cables should be separated from each other.

3.3 Grounding

3.3.1 Equipment

All parts should be grounded. Use the screw provided for this, marked with a ground mark. Where
possible connect a copper strand from this screw to the main computer cabinet, otherwise connect a
copper strand to a proper grounding point. Use a copper strand with min. dimension 2,5mm2.

The main computer cabinet should be grounded to a proper grounding point using copper strand with
min. dimension 10mm2.

3.3.2 Cables

Screens should be grounded at the main computer cabinet. In non metallic vessels (e.g. GRP boats),
screen should be grounded in both ends.

Screens should be guided unbroken. In connection boxes they should be guided further on by terminal
blocks. Pig tails should be no longer than 50mm.

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 User's Manual
3 Brukermanual
 User's manual Neptune Propulsion Control Systems – CPP version

User's manual Neptune Propulsion Control Systems – CPP version

Type: Propulsion control system for safe and secure vessel control. Different operating modes to suit the
vessels different operating conditions. Up to eight control stations.

Functions: Control of pitch main propulsion propeller(s).

Control of main engine(s) rpm.
Control of main clutch(es).
Automatic load control for protection of the main engine(s).

Main units: 1 off Computer cabinet – MEPU.

1 to 8 off control stations.
Miscellaneous sensors and actuators.

Documentation: Installation and interface manual Neptune Propulsion Control Systems.

User's manual Neptune Propulsion Control Systems (this manual).
Service manual Neptune Prop. Control Syst. (incl. commissioning, tuning and trouble shooting).
System drawings.
Special documentation referred in the individual manuals.

System drawings: See drawing list.

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 User's manual Neptune Propulsion Control Systems – CPP version

1 General

The total system consist of one or several control station(s), a computer cabinet with electronic cards – the MEPU, and
miscellaneous sensors and actuators The control station(s) are the systems operating unit(s), they are the only units used
during normal operation. If required portable or drop-in versions are also available. All system settings and adjustments
are carried out from a standard MS-Windows PC running a special program called MarWin (available from Scana
Mar-El). Connections to peripheral units, sensors, actuators and other systems are via the computer cabinet.

The vessels propulsion units are controlled from the control stations order lever and push-buttons. Operating
information (e.g. propeller pitch, rpm etc.), warning and error messages are shown on the operating stations graphic
display.

Optimal safety is obtained by a main system and an independent back-up and instrumentation system. Different
versions of the back-up system is available, from the standard push-button operated system to a sophisticated hot back-
up system.

2 Control stations

All user interface during normal operation are via units on the control station(s). The control stations are equipped with
all push-buttons, order levers, graphic display etc. necessary for system control and status. In addition a back-up system
and an extensive warning and error checking system are included.

If a portable control station is included, the standard version is splash proof and should normally be used indoor. If used
outdoor and exposed to rain or water, it must be dried and cleaned thorough immediately.

2.1 Control and status units

The control stations are equipped with an order lever (bridge panels, ECR panels have orderpotentiometers), a graphic
display, push-buttons and indicators. There are backlighting in all units, including the graphic display and the push-
buttons. The backlighting and the light in the indicators may be adjusted to suit the surrounding lighting conditions.

Unit description (note that all units will normally not be present on all control stations, see the specific layout):

• MANOEUVRE HANDLE
Main unit for controlling the vessels propulsion. Controls the main engine rpm and the propeller pitch. Versions for
combinator control (simultaneous control of both the engine rpm and propeller pitch according to the combinator
curve with only one lever) or separate control of engine rpm and propeller pitch (one order lever for each). Systems
with the latter may have a combinator mode, in with case the pitch lever will be the combinator lever and the rpm
lever will be out of function. The text in front of the manoeuvre handle informs about the direction and which lever
controls what.

• GRAPHIC DISPLAY
The systems information centre. During normal operation are operating and status information like propeller pitch,
rpm and other relevant information shown. Guiding and helping information are shown when useful for the
operator. Output unit of the extensive warning and error checking system.

• IN COMMAND
Push-button with light for command transfer. Light in the button indicates that the panel is in service (only lit at one
panel at a time).

• BRIDGE CONTROL
Push-button with light for command transfer between the bridge and ECR (Engine Control Room). Light indicates
that the bridge is in command.

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 User's manual Neptune Propulsion Control Systems – CPP version

• ECR CONTROL
Push-button with light for command transfer between the bridge and ECR (Engine Control Room). Light indicates
that the ECR is in command.

• EMERG. MAN CHANGE

Push-button. When this button is pressed together with the 'ECR Control' button, the engine room
receives control.

• BACK-UP
Push-button with light for activation and deactivation of the back-up system, must be pressed together with the
'Acknowledge' push-button to activate/deactivate (deactivation can only be done from the panel where the main
system is in command). Light indicates that the back-up system is active.

• ACKNOWLEDGE
Push-button with light for acknowledging alarms (presses together with 'Back-Up' to activate/deactivate the back-up
system). Further information is given in the graphic display.

• PITCH AHEAD
Only active while the back-up system is on. The propeller pitch increases ahead as long as the button is pushed.

• PITCH ASTERN
Only active while the back-up system is on. The propeller pitch increases astern as long as the button is pushed.

• CLUTCH ACTIVATE
Push-button with light for interlocking the 'Clutch In' and the 'Clutch Out' push-buttons (to avoid unwanted
operation). Must be pressed prior to these to make them active. The light is on/flashes as long as the function is
active.

• CLUTCH IN
Push-button with light for engaging the clutch, interlocked with 'Clutch Activate'. Steady light indicates that the
clutch is engaged.

• CLUTCH OUT
Push-button with light for disengaging the clutch, interlocked with 'Clutch Activate'. Steady light indicates that the
clutch is disengaged.

• COMBINATOR
Push-button with light for activation and deactivation of the combinator mode. Light indicates that the combinator
mode is active. In the combinator mode is the pitch lever the combinator lever and the rpm lever has no function.

• LIMIT RPM
The engine speed can be varied between two preset limits with the rpm lever. Normally shaft generator mode, then
the limits correspond to 50 and 60Hz.

• LOCAL CONTROL PITCH

Push-button with light that switches off the electrical field in the stepping motor. The pitch actuator can then be
operated by hand. The light is also lit when the actuator field is switched off caused by too low servo oil pressure.

• LOAD INCREASE
Push-button with light for increasing the max. pitch up to the max. limit preset in the system.

• LOAD REDUCE
Push-button with light for reducing the max. pitch below the max. limit preset in the system (setting a new
temporary max. limit / operator controllable pitch reduction).

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 User's manual Neptune Propulsion Control Systems – CPP version

• LIGHT UP
Increases the light in the indicators (push-buttons) and the backlighting (push-buttons etc.). Lamp test if pressed
together with 'Light Down'. The backlighting in the graphic display is adjusted separately, see section below.

• LIGHT DOWN
Decreases the light in the indicators (push-buttons) and the backlighting (push-buttons etc.). Lamp test if pressed
together with 'Light Up'. The backlighting in the graphic display is adjusted separately, see section below.

During change of state, the light in the corresponding unit will flash (if the change of state time is long enough). 75%
duty cycle indicates it is going from on to off and 25% from off to on.

2.1.1 Adjusting the graphic displays backlighting and contrast

The backlighting and the contrast for the graphic display are adjusted by the five circular buttons marked F1 to F5 just
below the graphic display itself.

Pressing F5 brings up a menu from which the backlighting and contrast can be adjusted, see the figure below:

The line at the bottom describes the function of the different keys F1 to F5:
F1 Light down (darker)
F2 Light up (brighter)
F3 Contrast down ("brighter")
F4 Contrast up ("darker")
F5 Exit (leaves the menu and goes back to normal mode)

The bargraph in the middle of the screen shows the current setting, and changes from 'Contrast' to 'Lighting' as the
appropriate keys are pressed.

2.2 Display messages

The graphic display shows operation and status information during normal operation. It is also the output unit of the
extensive warning and error checking system. The system gives as far as possible self-explanatory information,
messages, warnings etc.

During operation are useful information and help given, e.g. during command transfer are help for equalling the order
levers etc. given.

When the back-up system is active this is shown in the display. If the back-up system was activated automatically due
to a system error, a descriptional message is given. The bargraph giving the propeller pitch will still be shown.

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The figure below shows the different parameters and status information presented in the display during normal
operation.

Pitch order Command position

Pitch feedback Propeller shaft speed

Engine speed

Engine load

Pitch reduction

Pitch feedback Operating mode

System status

• PITCH ORDER is the order given by the pitch (combinator) order lever.

• PITCH FEEDBACK is the actual pitch value. It is shown by both a bar graph and a numeric value.

• COMMAND POSITION shows which station that is in command (whether the station is in command or not is also
shown by the light in the 'In Command' push-button).

• PROPELLER SHAFT SPEED is the actual speed of the propeller shaft. Normally measured by a rpm pick-up.

• ENGINE SPEED is the actual engine speed. Normally calculated ('Propeller shaft speed' x 'Gear ratio'). If the clutch
is disengaged are three dashes shown ('- - -'), indicating that the number is not available.

• ENGINE LOAD is the actual load of the prime mover/main engine as calculated by the automatic load control
system.

• PITCH REDUCTION shows if and how much the pitch is reduced. The pitch may f.inst. be reduced by the
automatic load control system, by a fixed or an analog pitch reduction, by the load of the main switchboard etc.

• OPERATING MODE shows which is active at the moment. Normally also shown by light in push-buttons for
selecting the different modes. Most common modes are 'Combinator', 'Individual', 'Shaft gen.', 'Const. rpm' and
'Local Control'.

• SYSTEM STATUS gives information about the systems condition (healthy, non-serious error etc.).

If guiding, warning, error messages etc. shall be presented, a message window covering hole or parts of the graphic
display is shown (the pitch feedback will be shown as long as possible, i.e. as long as an input value is available). Note
that some messages require to be acknowledged by pressing the 'Acknowledge' push-button.

2.3 Command transfer

When the Neptune propulsion control system includes more than one control station, a command transfer system with
shifting by identical lever positions is included for the bridge panels, and by acknowledging push-buttons between
bridge and ECR.

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The bridge panels have an 'In command' push-button with light which is lit on the panel in service/command and off on
all other stations. ECR panel in command is indicated by light in the 'ECR Control' push-button.

Only one control station can at any time be in command. The command can be transferred from any bridge station to
any bridge station. Command transfer between bridge and ECR is done between the main panel bridge and the ECR
panel.

2.3.1 Command transfer between bridge panels

Responsibility change between the panels on bridge consists of the push-button with light 'In Command' on all panels
and an electronic system.

When voltage is applied to the system, the main panel will be in charge.

The command is transferred according to the procedure below:

1. Press and hold the 'In command' push-button on the control station where the command is wanted. The light
in the 'In command' push-button starts flashing indicating that a command transfer is in progress.
2. Move the order lever to the same position as the one on the station in service. Help for finding the position is
given in the display.
3. When the two orders are equal the command is transferred. The light in the 'In command' push-button is lit
on the new panel in service, and switched off on the panel which was in service.
4. Release the 'In command' push-button.

Since the command is only transferred at identical orders, the risk for giving unwanted manoeuvres are completely
eliminated. The procedure for transferring the command is also very easy and quick to carry out.

The responsibility is transferred in the same way between all bridge panels. The lamp 'In command' will only be lit on
the panel which is in command, and only one panel can at any time be in command.

2.3.2 Command transfer between bridge and ECR

The responsibility change system between bridge and ECR consists of the push-buttons with light 'Bridge Control' and
'ECR Control', and a buzzer on each of the panels.

When power is applied, the responsibility is always on bridge. The 'Bridge Control' lamp are lit on both panels.

To change responsibility both operators must press their respective buttons. If one operator uses his button alone, light
and sound indication will show on both panels until the other operator acknowledges the changeover (or the button is
released without changeover).

In case of emergency, the ECR can take control without the bridge acknowledging. I.e. emergency take over to the
ECR.

Emergency take over procedure:

1. In the ECR press and hold down the 'ECR Control' push-button.
2. Press the 'Emerg. Man. Change' push-button (give a "false" acknowledge).
3. The ECR is now in command, release the push-buttons.

3 The rpm system

The vessel has one main engine and the rpm can be controlled from all panels. The rpm varies from idle to full with
lever movement from mid-position to full ahead or full astern.

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There is also a "Constant rpm mode", which can be activated on the engine room panel. In this mode the rpm is
controlled from an external potentiometer mounted on the main switch board. When the "Constant rpm mode" is
chosen, the system gives a closed contact to the main switch board.

When the shaft generator is engaged the system receives a closed contact from the main board, which locks the
"Constant RPM mode" (and if necessary activates it first).

It is not possible to disengage the "Constant rpm mode" when the shaft generator is engaged.

Output from the remote control system is normally a 4-20mADC signal to the governor on the main engine. This signal
is delayed to give a ramp signal to the engine governor. The ramp is adjustable from 0 sec. to about 100 sec. for a 0% to
100% rpm order.

4 The pitch system with automatic load control

Control of pitch from order lever on control station. Either combinator control or separate control of pitch and rpm.

The ECR panel has a function for pitch/load reduction of abt. 20% from max. pitch ('Load Reduce' and 'Load Increase').
This is used with heavily loaded vessel, rough weather conditions or if the engine needs protection.

The pitch deflection is achieved by an electromechanical stepping motor operated pitch actuator with built-in feedback
unit mounted on the gear, normally type MAC-102-D20493. The actuator has a maximum stroke length of 100 mm,
force and operating speed are adjustable.

If a system failure occurs, an alarm light will be lit and a buzzer will sound. At the same time the command will
automatically be transferred to the push-button operated back-up control. The back-up control system can also be
activated by a push-button. If it is necessary to operate the pitch manually at the gear, the actuator must be deenergized
by operating 'Local Control Pitch' push-button on the ECR panel.

The propeller pitch will be shown continually on the indicators. The indicators are scaled in percent of max. adjusted
pitch.

To ensure that the pitch manoeuvre system is interlocked when the servo oil pressure is low, an external contact from a
pressure switch on the gear is needed. The switch gives an open contact with normal pressure and a closed contact with
low pressure. The pressure switch is delivered from the gear supplier. The switch is mounted to sense the pressure both
from the main pump and from an auxiliary pump. A safety device is added to disconnect this function when the clutch
is engaged.

The engine load is monitored by the automatic load control. If the preset load limit is reached, the engine load is
automatically decreased to prevent overload situations. The system receives a galvanically isolated signal from the fuel
sensor on the fuel rack to indicate motor load condition. The rpm of the propeller shaft is measured by an initiator. Both
these parameters are inputs to the automatic load control system.

In case of shaft generator, the system also receives a signal indicating the generator load (0-10VDC). This signal will
give an analog (continual) reduction of the pitch to help distributing the load.

Two preadjustable pitch reductions are available. These are operated by potentialfree contacts. Normally the reductions
would be activated in advance of a known increase in engine load. If the change in the load condition is small the
automatic load control system will handle the situation by itself.

The system has no external outputs.

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5 The clutch system

The clutch is controlled by push-buttons on the manoeuvre panels. One push-button for 'Clutch In' and one for 'Clutch
out'.

The clutch system is interlocked with "zero pitch", and has two inputs for external interlocking. External interlocking
via NC potentialfree contact, strapped if not in use.

The system has options for astable or bistable output. Output: NO potentialfree contacts for PLC or 24VDC to solenoid
valves.

Output from a potentialfree change-over contact gives information about the clutch (in/out). Normally used to interlock
starting of the main engine.

To get a true indication for the clutch, the system needs a potentialfree NO contact from a pressure switch sensing the
clutch pressure. The pressure switch is delivered by the clutch supplier. The switch must be adjusted so that it is
activated when the clutch is engaged. It shall then give a closed contact.

The system has an input, from a potentialfree contact, used to disengage the clutch. ("Clutch out from diesel control").
This is normally open, closed to clutch out.

6 Operation

The system controls the vessels propulsion units by input from the operator via levers and push-buttons.

Note that during all normal operation the main engine must be running. It is not possible to control the propeller pitch
unless the main engine or the standby pump is running.

6.1 Operating modes

Depending on the actual system, several operating modes are available:

1. Combinator
2. Individual
3. Shaft generator
4. Const. rpm

6.1.1 Combinator

The propeller pitch and prime mover/main engine rpm are controlled according to the combinator curve.

If the system is equipped with separate order levers for pitch and rpm, the pitch lever will be the combinator lever, and
the rpm lever will have no function.

6.1.2 Individual

The system is equipped with separate order levers for pitch and rpm for independent control.

6.1.3 Shaft generator

Mode for shaft generator. May be fixed or floating frequency depending on the vessels equipment.

Fixed frequency. The engine is set to a preset rpm (normally adjustable with a potentiometer in the main switchboard to
adjust the frequency). The pitch/combinator lever controls the propeller pitch, the rpm lever (if any) has no function.

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Floating frequency. The pitch lever controls the propeller pitch. The rpm lever controls the rpm between two preset
rpm's, normally corresponding to 50 and 60 Hz.

6.1.4 Const. rpm

The engine is set to a preset rpm. The pitch/combinator lever controls the propeller pitch, the rpm lever has no function.

7 Alarms

The system has two alarm outputs:

1. Power failure alarm
2. System failure alarm

These are normally connected to the vessels main alarm system.

In addition are alarms and warnings that are not critical for the system given internally. Both these and the system
failure alarm are controlled by the internal fault monitoring system.

Internal alarms and warnings are given at the control panels, by text messages in the graphic display, by litting the
'Acknowledge' lamp/push-button and by sound in the buzzer. Alarms are acknowledged by pressing the 'Acknowledge'
push-button.

7.1 Power failure alarm

The system is equipped with voltage failure alarms, both the 24VDC supply voltages and the internal operating
voltages are monitored.

If either of the voltages should fail, an alarm via an open potential free contact is given (normally connected to the
vessels alarm system).

The LED's in front of the filter and voltage monitoring card (mounted in the main computer cabinet) shows status of the
external voltages/power supplies.

7.2 System failure alarm

The system is equipped with a fault monitoring system which continuously monitors the systems and react in case of a
malfunction. The external output of the fault monitoring system is the 'System failure'.

In case of a serious system failure, an alarm via an open potential free contact is given (normally connected to the
vessels alarm system), alarm is given on the manoeuvre panels with light and sound, and the command is transferred to
the back-up system.

The pitch indication system will still be working, since it is a part of the back-up system and also has and its own
independent track on the feedback potentiometer.

8 Miscellaneous

After power up and after a reset of the main computer will alarm be given and the back-up system be active. Command
can be taken at any control station by pressing the 'In Command' push-button on bridge panels or the 'ECR Control' on
the ECR panel, the push-button must be held down until indication is given in the corresponding light. The rpm will
then be set to the settings (order lever positions) at the control station that is given the command. The pitch will still be

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controlled by the back-up system, deactivate the back-up system to control the pitch by the main system. If a message is
still shown on the graphic display, acknowledge it by pressing the 'Acknowledge' push-button.

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4 Servicemanual
 Service manual Neptune Propulsion Control Systems – CPP version

Service manual Neptune Propulsion Control Systems – CPP version

This manual describes the commissioning, system set-up, tuning, troubleshooting and eventual special procedures in
accordance with the Neptune Propulsion Control Systems – CPP version.

In addition to this manual the following documentation are available and essential:
1. Installation and interface manual Neptune Propulsion Control Systems
2. User's manual Neptune Propulsion Control Systems
3. System drawings
4. Special documentation referred in the individual manuals

The individual hardware modules included are described in the system drawings.

1 General description

Neptune Propulsion Control Systems is a propulsion control system for safe and secure vessel control. Different
operating modes to suit the vessels different operating conditions are implemented. Up to eight control stations may be
included.

The Neptune Propulsion Control Systems – CPP version consists of the following main units:
1. Computer cabinet - (MEPU)
2. 1 to 8 control stations
3. Miscellaneous sensors and actuators

Further description regarding the functionality, different modes etc. of the Neptune Propulsion Control System is given
in 'User's manual Neptune Propulsion Control Systems'.

2 Commissioning - mechanical and electrical checks

This section describes check points and procedures special for commissioning the Neptune. System set-up and tuning
are described in the next section.

The first points to check out during commissioning is to control that all installation requirements are fulfilled, see the
systems installation documentation and go carefully through this.

2.1 Mechanical checks

The mechanical and visual checks must be carried out to ensure proper installation of the system in regard of vibrations,
EMC consideration etc.

2.1.1 Computer cabinet (MEPU)

The computer cabinet, MEPU, is normally mounted on the bridge (vessels with separate engine control room might have
the computer cabinet mounted there, but mounting easily accessible on the bridge is recommended). In the lower end of
the computer cabinet are the screw terminals for interconnections of the system and for connections to other equipment
(i.e. main engine governing system, alarm plant, sensors and actuators etc.).

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Checkpoints to pay special attention to:

1. Check that the cabinet is well mounted regarding fastening and vibrations. Vibrations must be kept at the
lowest possible level, the cabinet must be mounted so further vibrations do not occur.
2. If the temperature might rise above 55°C a cooling fan must be mounted.
3. Electrical sources of disturbance nearby (VHF, intercom etc.) must be shielded.
4. Check that there are no waste from drilling etc. inside the cabinet. Do also check the electronic cards.
5. Check that all cables and conductors are well fastened, that they do not touch any sharp edges and that they
do not have sharp bends.
6. Check that all conductors into the terminal block are marked with correct numbers and that the fastening
screws are well tightened.
7. Check that the cable screens are properly grounded (using the special grounding clamp).

2.1.2 Control stations

The control stations are mounted at selected places on the vessel according to the wanted control and manoeuvre
positions.

Checkpoints to pay special attention (to be carried out for all control stations):
1. Check that the control station is well mounted regarding fastening and vibrations.
2. Check that there are no waste from drilling etc. on the screw terminals/connectors.
3. Check that all cables and conductors are well fastened, that they do not touch any sharp edges and that they
do not have sharp bends.
4. Check that all conductors into the screw terminals/connectors are marked with correct numbers and that the
fastening screws are well tightened.
5. Check that the cable screens are properly grounded (using the special grounding clamp).
6. Check that the network is only terminated at the last control station.

2.1.3 Cables and electrical conductors

Checkpoints to pay special attention:

1. Check that all cables and conductors are well fastened, that they do not touch any sharp edges and that they
do not have to sharp bends.
2. Check that all conductors not in use are individually isolated and well fastened.
3. Check that the cables are not mounted nearby electrical sources of disturbance.
4. Check that all conductors into the terminal lists/blocks are marked with correct numbers.
5. Check that shielded cables between different equipment have the screen connected to ground in one end only.
6. Check that the screen is guided unbroken through connection boxes, terminal lists etc.
7. Check that pig tails are no longer than 50mm for any screen.

2.2 Electrical checks with no power applied

Before power is applied to the system check carefully that all connections are correct. Damage to the system may occur
if malconnections exits when power is applied. Potentiometers and other sensors must be checked specially careful.

Most of the measurements are done inside the system, on the screw terminals/connectors in the computer cabinet or
conductors connected to this.

2.2.1 Earth fault 24VDC system

The measurements are carried out on the terminal block in the computer cabinet (MEPU) with all fuses in the power
supply connection terminals removed. They are done on the inside of the fuse connection terminals, on the consumer
side, for all 24VDC power supply circuits.

If an earth fault is discovered, one and one lead connected to the 24V-system is removed until the fault disappears. The
earth fault is then in connection with the lead last removed. Be aware of that more than one earth fault may occur.

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Checks to be carried out:

1. Measure between 024V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower
value indicates an earth fault.
2. Measure between +24V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower
value indicates an earth fault.

2.2.2 Earth fault 5VDC and ±15VDC system

The measurements are carried out on the screw terminals/connectors in the computer cabinet (MEPU) with all fuses in
the power supply connection terminals removed. The system drawing for this shows where the voltages are located.

If an earth fault is discovered, one and one lead connected to the 5V/±15V-system is removed until the fault disappears,
do first remove units connected with connectors. The earth fault is then in connection with the lead last removed. Be
aware of that more than one earth fault may occur.

Checks to be carried out:

1. Measure between +5V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower value
indicates an earth fault.
2. Measure between 015V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower
value indicates an earth fault.
3. Measure between +15V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower
value indicates an earth fault.
4. Measure between -15V and the hull using an ohm meter. The reading should be more than 3MΩ. Lower value
indicates an earth fault.

2.2.3 24VDC power supplies

Measurements that must be done for each of the power supply circuits before connection:
1. Check that the supply voltage is within the range 24VDC -10%/+20% (21,6VDC - 28,8VDC).
2. Measure between each of the power supplies and the hull using a voltmeter. Check that the reading counts
upwards to infinitely or downwards to zero, if a stable voltage is measured it indicates earth fault in the power
supply circuit.

2.2.4 Internal connections

Check carefully that all connections between the units listed below are correct:
1. The main computer and the control stations.
2. Between each control station.

2.2.5 External connections

Check carefully all connections to external equipment, i.e. the main engine governing system, alarm system, sensors,
actuators etc.

Check carefully the requirements listed below:

1. Digital inputs: connections to digital inputs shall be potential free contacts only.
2. Digital outputs: potential free contacts. Max. ratings resistive load are 24VDC/0,5A, 220VAC/0,1A (other
than resistive loads are considerably less). If connected to a relay coil or similar (inductive) load, a spark
quenching device/transient arrester (protection diode) must be installed on the consumer side.
3. Digital outputs power: potential free contacts. Max. ratings resistive load are 24VDC/3A, 250VAC/2A (other
than resistive loads are considerably less). If connected to a relay coil or similar (inductive) load, a spark
quenching device/transient arrester (protection diode) must be installed on the consumer side.
4. Analogue outputs: ±10VDC, max. output current 1mA. Galvanic isolation is normally installed. These may be
configured to other signals than ±10VDC to suit the connected systems (e.g. ±5VDC or 0-10VDC), check
that correct signal levels are configured.

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2.3 Electrical checks with power applied

When all the checks in the procedures above are carried out, power can be applied to the system. Note that the system
shall be powered from two completely separate and independent supplies.

Be absolutely certain that all connections are correct before applying power, specially connections to potentiometers.

When power is applied, check that the functions are correct. I.e. move the levers and check that the pitch/rpm
deflections etc. are correct.

If the function check are carried out successfully, the system is ready for tuning which are done during sea trial.

3 System set-up and tuning

This section describes the system set-up and tuning of the Neptune. All adjustments are to be carried out during sea trial
with all units in operation.

All the system settings, tuning and adjusting of the Neptune propulsion control system are carried out from a standard
MS-Windows PC running MarWin (a special program for communicating with Neptune).

3.1 MarWin – MS-Windows program for set-up, tuning and diagnostics

MarWin is the program for set-up, tuning and diagnostics of the Neptune propulsion control system. MarWin runs on a
standard MS-Windows PC.

MarWin is developed as a user-friendly self explanatory program utilising the standard MS-Windows interface. It is
recommended that the user has some experience with MS-Windows PC's.

3.1.1 Connecting the PC

The Neptune is equipped with a special service connector located on the underside of the main panel. The connector is a
standard 9-pin male D-sub connector, interface is according to RS-232. Use a standard null-modem cable (female
connector in both ends, all pins connected) to connect to a PC.

3.1.2 Cable description

The cable for connecting the PC to the Neptune must have 9-pin female D-sub connectors in each end, and be wired
between them as described below:
1. Pin 2 to pin 3
2. Pin 3 to pin 2
3. Pin 5 to pin 5
4. Pin 7 to pin 8
5. Pin 8 to pin 7

In addition the following wirings between the two connectors can be present: pin 1 to pin 1, pin 4 to pin 6, pin 6 to pin 4
and pin 9 to pin 9.

Note that no internal wirings in the same connector must be present, e.g. pin 7 must not be wired/connected to pin 8 in
the same connector etc.

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3.1.3 Communication parameters

Communication parameters are:

1. Baud rate: 19200
2. Data bits: 8
3. Parity: None
4. Stop bits: 1

3.1.4 Starting MarWin

When the PC is connected, the MarWin program can be started. MarWin is a MS-Windows program, end hence started
in the standard MS-Windows way.

3.1.5 Passwords and access levels

The system has several password protected levels. When started, the access level is the lowest. Selecting password level
is done by a menu choice in MarWin. The table below gives the different access levels etc.

Description of access levels:

Access level Password Access
0 None, automatically entered Read only of parameters/values on the system
when starting MarWin. bus.
1 MAR-EL The most common parameters to tune/adjust.
2 MAR-EL 2 All above, plus some vital system parameters.
3 For service engineers only. Service engineer level.

Once the password for the selected access level is granted, are all parameters fetched from the Neptune main computer.

3.2 Simplified setup of pitch

Sometimes, after a normal commissioning, there may be a need for small adjustments of pitch position. The ship may
behave differently through different loading conditions, or there might have been work done on the pitch servo system.
In such cases the use of a PC and the MarWin program is not always a practical solution, and a simplified setup of pitch
positions is available. This procedure makes it possible to store an offset for each of the zero pitch-, full ahead- and full
astern positions. The actual parameter-values stored through MarWin are not changed. The maximum offset is limited to
±15% from the actual parameter-value. There are no limits on how often the procedure is repeated. It would normally be
a good idea to clear the offset-values the next time a full setup is made using MarWin.

Caution: The following procedures involve changing the pitch while the engine is running. This may be
dangerous unless done properly. Always check with equipment suppliers before applying
changes.

The procedure is basically the same for all three positions. Find the (new) correct position, and operate a switch to tell
the system to store the current offset. Both the control system and the indicator system will be updated.

3.2.1 Correcting zero pitch

1. Use the pitch lever to find the pitch position which is correct for zero pitch.
2. Stop the pitch actuator from moving by activating "Pitch actuator release"-button (ECR-panel)
3. Return pitch lever to zero.
4. Operate the "Store Offset"-switch in the CPU-cabinet for a minimum of 3 seconds.
5. Check that LED-display shows "8", then return to "5". Observe the status message in the panel display(s).
6. Acknowledge the change by pressing "Acknowledge"-button to silence the alarm.
7. Release the pitch actuator by de-activating "Pitch actuator release"-button (ECR-panel).
8. Test the new offset. (Repeat the procedure if not satisfied) .

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3.2.2 Correcting pitch ahead

1. If possible, use the pitch lever to find maximum pitch.

2. If you need more than the current 100% pitch, you will have to activate the "Pitch actuator release"-button
and then manually operate the actuator (handwheel) until correct position is found.
Take care not to overload the engine. Always check with engine supplier.
3. (If not already done in the step above), stop the pitch actuator from moving by activating "Pitch actuator
release"-button (ECR-panel).
4. Put the lever in the 100% ahead position.
5. Operate the "Store Offset"-switch in the CPU-cabinet for a minimum of 3 seconds.
6. Check that LED-display shows "8", then return to "5". Observe the status message in the panel display(s).
7. Acknowledge the change by pressing "Acknowledge"-button to silence the alarm.
8. Release the pitch actuator by de-activating "Pitch actuator release"-button (ECR-panel)
9. Test the new offset. (Repeat the procedure if not satisfied).

3.2.3 Correcting pitch astern

1. If possible, use the pitch lever to find maximum pitch.

2. If you need more than the current 100% pitch, you will have to activate the "Pitch actuator release"-button
and then manually operate the actuator (handwheel) until correct position is found.
Take care not to overload the engine. Always check with engine supplier.
3. (If not already done in the step above), stop the pitch actuator from moving by activating "Pitch actuator
release"-button (ECR-panel).
4. Put the lever in the 100% astern position.
5. Operate the "Store Offset"-switch in the CPU-cabinet for a minimum of 3 seconds.
6. Check that LED-display shows "8", then return to "5". Observe the status message in the panel display(s).
7. Acknowledge the change by pressing "Acknowledge"-button to silence the alarm.
8. Release the pitch actuator by de-activating "Pitch actuator release"-button (ECR-panel).
9. Test the new offset. (Repeat the procedure if not satisfied).

3.2.4 Clearing the offset values

1. Switch off all power to the system.

2. Activate the "Store Offset"-switch in the CPU-cabinet.
3. Turn on power to the system.
4. Release the "Store Offset"-switch in the CPU-cabinet.
5. All the three offset values in both control system and indication system are now cleared.

3.3 Set-up and tuning procedures

The system set-up and configuration must be carried out before the sea-trial, while all tuning are carried out during the
sea trial.

The normal procedure for set-up and tuning is:

1. Carry out the system set-up.
2. Control all interface signal to connected equipment.
3. Tune the parameters as good as possible alongside the key.
4. Do the final parameter tuning (load adjustments etc.) during sea trial.
5. Check the different control positions.

If all necessary information are known, point 1. above is done during the factory set-up and tests.

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 Service manual Neptune Propulsion Control Systems – CPP version

4 Troubleshooting

Note that during troubleshooting the LED's in the systems are giving a lot of information. There are LED indication on
all digital inputs and outputs in addition to voltage monitoring etc.

4.1 Voltage failure alarm

The LED's in front of the filter and voltage monitoring card (mounted in the MEPU) shows status of the voltages, both
the external power supplies and the internal. Note that all fuses from F1 to F8 are monitored, and a voltage failure alarm
will be given if any of these are blown.

Possible faults and actions:

Symptom Cause Correction
1. Voltage failure alarm. • One of the 24VDC power • Check the fuses on the MEPU.
The system is OK. supply circuits is out. • Control the power supply (24VDC) to the
MEPU.
2. Voltage failure alarm. • One of the internal circuits • Check the fuses on the MEPU.
Parts of the system are "dead". are out.
3. Voltage failure alarm. • Both 24VDC power supply • Check the fuses on the MEPU.
The system is "dead". circuits are out. • Control the power supply (24VDC) to the
MEPU.
• Control if there is a short circuit on the
24VDC supply internally in the system.
• Any of the internal voltages • Check the internal power supply.
are missing.

4.2 System failure alarm

The system failure alarm is asserted when the fault monitoring system discovers a serious internal error. If a back-up
system is included, the command is automatically transferred to this.

System failure alarms may be due to many reasons, and the first thing to do is to check the hardware carefully (specially
feedback-potentiometers). Note that if there also is a voltage failure and the system is "dead", the system failure may be
due to this (no voltage applied).

4.3 No communication with the main computer

If one panel only, or the panel in command gives this error message, it will also cause a system failure alarm.

Possible faults and actions:

Symptom Cause Correction
1. Panel computer presenting: No • The communication between • Check connection of the panel cable (the
communication with main the main computer and the cable with multiplugs) and the cable itself.
computer. panel computer is down. • Check the wiring, connection terminals etc.
• Check the network termination.
• Check the panel itself.

4.4 Codes shown in the 7-segment LED display on the controller card

Valid for MP501 controller card in the control cabinet and MP600 controller card in the panel.

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Code Meaning Cause Correction

• The controller (CPU) • Erroneous program ICs • Check that the program ICs are
do not find the correctly inserted
program • Insert new program ICs
• HW-error on the controller card • Replace the controller card
• Controller card • If this code is present more than a • Check that the program ICs are
starting up (in start-up few seconds there is a HW failure correctly inserted
sequence) on the controller card • Replace the controller card
• Controller card • If this code is present more than a • Check that the program ICs are
starting up (in start-up few seconds there is a HW failure correctly inserted
sequence) on the controller card • Replace the controller card
• Controller card • If this code is present more than a • Check that the program ICs are
starting up (in start-up few seconds there is a HW failure correctly inserted
sequence) on the controller card • Replace the controller card
• Normal • Everything is normal •

• Responsibility shift • Everything is normal, but •

between different responsibility shift between two
control stations in control stations are in progress
progress
• Communication error • Error in the communication • Check that one control station is in
between the control stations(s) and command
the controller card in the control • Check that voltage is applied to the
cabinet control stations
• Check that the communication
connectors are correctly inserted
• Check that the communication cables
are correctly connected and of
correct type (screened twisted pair)
• Check that there are no earth fault on
the communication cables
• Check that the network terminations
(120Ω resistors) are correctly
mounted (see the cable plan)
• Check the flat cables between the
MP501 controller card and the
MPT400 card in the control cabinet
• Replace the MPT400 card in the
control cabinet
• Replace the MPS110 card in the
control station
• Replace the controller card
• Storing pitch offset • Normal while adjusting pitch offset • Check that "Store Offset"-switch is
value values. Should return to "5" in a off.
few seconds.
• Initiating parameters • If this code is present more than a • Check that the setup IC is correctly
in the setup IC few seconds there is a HW failure inserted
on the controller card • Replace the controller card
• Initiating parameters • If this code is present more than a • Check that the setup IC is correctly
in the setup IC few seconds there is a HW failure inserted
on the controller card • Replace the controller card
• Initiating parameters • If this code is present more than a • Check that the setup IC is correctly
in the setup IC few seconds there is a HW failure inserted
on the controller card • Replace the controller card

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 Service manual Neptune Propulsion Control Systems – CPP version

• Error • HW-error on the controller card • Check that the program ICs are
correctly inserted
• Replace the controller card

5 Miscellaneous procedures

In this part procedures that might, but not necessarily must, be carried out are described. THESE ARE CARRIED OUT
DURING FACTORY SET-UP AND SHALL NORMALLY NOT BE DONE LATER.

5.1 Changing the main program - replacement of program memory in the main computer

The Neptune main program (control program) is programmed into two flash memory PLCC ICs located in position U12
(odd/high) and U16 (even/low) on the MP-501 controller board in the main computer cabinet. See the figure of MP-501
for locating the IC.

Fig. 1 Layout MP-501 controller board

Replacement of main program:

1. Switch off the power.
2. Remove gently the PLCCs (flash memory ICs) in locations U12 and U16 using the special PLCC removal
tool.
3. Insert the PLCCs with the new program in locations U12 (odd/high) and U16 (even/low). Check carefully that
they are inserted in the correct location.
4. Turn on the power.
5. Verify that the system is working properly.

Note that it is normally necessary to set-up and tune the system after changing the main program.

The set-up flash located in position U19 on the MP-501 controller board must also sometimes be replaced, most likely
in conjunction with changing the main program. The procedure is the same for changing the main program, apart from
that the IC in position U19 is replaced instead of (in addition to) the ICs in locations U12 and U16. In this case it is
necessary to set-up and tune the system afterwards.

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5.2 Miscellaneous panel computer

This section describes miscellaneous procedures etc. concerning the panel computer.

The manoeuvre panel is equipped with both a main and a back-up computer. These are independent and controls
different units. Most push-buttons and the order levers are connected to the main computer, some push-buttons and the
graphic display are connected to the back-up computer. Some procedures, e.g. setting panel address, must be carried out
for both.

All push-button numbers etc. refer to the figure below:

30 25

29 24

28 23

27 22

26 21 16 17 18 19 20

13 14 15

10 11 12

7 8 9

4 5 6

1 2 3

Fig. 2 Panel layout Neptune with numbered push-buttons/indicators

5.2.1 Setting panel computer address and calibrating order units for the main panel computer

The procedure for setting the address for the main panel computer and calibrating order units is described below:
1. Press end hold down push-button no. 25 while applying power (the push-button must be held down until the
light in some of the push-buttons starts flashing).
2. Set panel address by push-buttons nos. 10, 11, 12, 14 or 15 according to the description below (the chosen
one has steady light, the selectable are flashing):
Push.button no. 10 Slave panel 1
Push.button no. 11 Slave panel 2
Push.button no. 12 Slave panel 3
Push.button no. 14 Main panel
Push.button no. 15 ECR panel
3. Move the order levers to the extreme positions (full ahead, full astern etc) and leave them in the neutral
position (zero pitch, idle speed etc.).
4. Press push-button no. 2.
5. Depending on the result the following is shown:
OK The light in push-button no. 2 is flashing and all others have steady light.
Error All lights are flashing – restart the whole procedure.
6. Press push-button no. 2.
7. Remove and apply power.

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The procedure may be abrupted by pressing push-button no. 24 (note that this is not recommended if on step 3 or
higher).

5.2.2 Setting panel computer address for the back-up panel computer

The procedure is carried out by the five circular push-buttons numbered 16 to 20 just below the graphic display. Once
entered the mode for changing panel address, description of the push-buttons are given in the display.

The procedure for setting the address for the back-up panel computer is described below:
1. Press and hold down push-button no. 20 until a menu is shown in the graphic display.
2. Select menu choice 'SYSTEM'
3. Select menu choice 'PANEL ID panel_id', where panel_id is the selected id (giving the address).
4. Select the address to be set by cycling through the available with the right arrow (push-button no. 19).
5. Leave the menu by pressing push-button no. 20 (OK).
6. Leave the menu by pressing push-button no. 20 (EXIT).
7. Remove and apply power.

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 1

4
System Drawings
5 System tegninger

10
 DRAWING LIST Page 1 of 1
Customer / Cust. plant no. Yard / Yard plant no. Ship's name Other
Scana Volda as Ebin S/A
1664-1665 EB-004
Mar-El Propulsion Thruster Rudder Joystick Other
Type no. Neptune
CPP 23/C23
Plant no. 2440/2441
Text Drawing number Information

CPU Cabinet,
002 Neptune CPP 002-6624 1-5/5
Main panel bridge,
003 propulsion 003-5623
Slave panel bridge,
004 propulsion 004-5624
ECR,
005 propulsion 005-5625
Alarm plant
011 Connections 011-6625
Cableplan,
016 propulsion 016-6626
Start / Stop Principle diagram
035 Servopump 035-4489
Layout rack front / cabinet, Neptune CPP cabinet
043 adjustments etc. 043-6627
Panel layout(s) Main panel
045 (general) 045-6628
Panel layout(s) Slave panel(s)
045 (general) 045-6629
Panel layout(s) ECR panel
045 (general) 045-6630
Mechanical drawings Cabinet Neptune CPU
058 058-6267
Terminal box, gear
076 076-6631

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5
Miscellaneous
6 Diverse

10