Sperry Marine Rudder Angle Indicator System Operation, Installaion And Service Manual

Operation, Installation and Service Manual

RUDDER

X

RUDDER

Rudder Angle Indicator System

05014-0128-01; 056357/B; 05 Oct 2017

Northrop Grumman Sperry Marine B.V. (Representative Office)

Woltmanstr. 19 • D-20097 • Hamburg, Germany

Tel.: +49-40-299 00-0 • Fax: +49-40-299 00-146 • E-mail: [email protected]

056357/B RAIS

© 2017 Northrop Grumman Sperry Marine B.V. This document and the information herein is and remains the intellectual property of Northrop Grumman Sperry Marine B.V. [NGSM BV] and its associate companies and may not be copied, reproduced or translated without the express permission of NGSM BV. A limited license is granted for the user to reproduce this documentation for his own internal use, but not for distribution to third parties. Reproduction of this document for resale or commercial gain is expressly prohibited.

Specifications were correct at time of press but may be varied in accordance with NGSM BV’s policy of continuous product development. Any technical content should be verified with NGSM BV.

Sperry Marine, with major engineering and support offices in New Malden, England, and Hamburg, Germany, is part of the Northrop Grumman Navigation & Maritime Systems Division N&MSD.

Revision Record

Rev. Date Remarks

B 05 Oct 2017 updated release, RAIS system definition implemented, safety notes for

serial output and RS-422 output usage added

A 15 Jun 2009 initial release

RAIS 056357/B

Safety Instructions

Safety Notice Conventions

The following safety notice conventions are followed throughout this manual:

A Danger notice contains an operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, will

result in injury or death of personnel.

A Warning notice contains an operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed,

could result in injury or death of personnel.

A Caution notice contains an operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could

result in damage to, or destruction of equipment.

A Note contains an essential operating or maintenance procedure, condition or statement, which is considered important enough to be highlighted.

Special safety symbols may be used in this manual to indicate:

Danger: Risk of electrical shock. Used in conjunction with a Danger or Warning notice.

Caution: Components are sensitive to electrostatic discharge. Used in conjunction with a Caution notice.

v

056357/B RAIS

CAUTION

Note

General Safety Information for the Operator

Risk of misusage The ALR sentence as serial output of the RAC is not MED complaint and therefore NOT allowed as system setting for a ship under wheelmark certification. Always make sure that the ALR sentence setting is INACTIVATED when the RAC is used on a ship under wheelmark certification.

Risk of misusage The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. Always make sure that another baud rate setting (4880 or 9600 baud) must be selected as RS-422 output 1 and RS-422 output, when the RAC is used on a ship under wheelmark certification

Regularly check the indication of the RAIs against the actual position of the rudder angle shaft to make sure that calibration is applied properly and the specified accuracy is maintained.

A given alarm system may employ reverse output logic (closed on alarm). In this case, powering off the Rudder Angle Calibrator will not raise an alarm.

For recording all parameter settings see “Setup and Configuration Tables” in the appendix of this manual.

All content of the appended third party documentation is on behalf of the owners of the documentation. Sperry Marine is not responsible and not liable for any content of third party documentation. In case of doubt, verify the content of third party documentation with the owners of the documentation.

Sperry Marine Service:

In case of service refer to www.sperrymarine.com/offices for a list of all Sperry Marine Offices and Service Agents worldwide.

vi

RAIS 056357/B

DANGER

CAUTION

WAR NING

Note

WAR NING

General Safety Information for Service Personnel

Life danger through electrical shock Certain alarm devices may operate with hazardous voltages, switched by the alarm relay output contacts. NEVER connect live wires to the unit’s terminals, when wiring up the Rudder Angle Calibrator. ALWAYS make sure that any external device or power supply to be connected to the alarm relay outputs is de-energized and safeguarded against accidental switching-on.

Risk of damage of electrostatic-discharge-sensitive components Components on the Rudder Angle Calibrator PCB are sensitive to static discharge. While wiring up the Rudder Angle Calibrator, take the necessary precautions to prevent electrostatic discharges.

Risk of damage of electrostatic-discharge-sensitive components The

Rudder Angle Calibrator contains electrostatic sensitive components.

Electrostatic discharge may permanently damage components. When configuring the electrostatic discharge. Avoid touching any of the electronic circuitry.

Rudder Angle Calibrator, take precautions to prevent

Risk of personal injury To calibrate the feedback input, the rudder has to be moved over its entire range. Always make sure that the steering gear is operative and that the rudder may be actuated safely without any risk of personal injury or damage to equipment, especially when the vessel is drydocked and works are carried out by shipyard personnel. Always inform the shipboard or shipyard personnel in charge of your intention to actuate the rudder and obtain permission to operate the steering gear for calibration purposes, before moving the rudder.

The calibration procedures require that tasks are carried out at different locations on the vessel. If possible, use voice communication to instruct one or more helpers to report the actual rudder angle indications as read from the rudder stock scale and indicated at the RAIs respectively.

Risk of injury Connecting the RAC to a rudder angle feedback unit in parallel with the steering gear feedback loop bears the risk of malfunction of the steering gear in case of wire breaks or short-circuits resulting in possible injury and/or damage. Under no circumstances must the RAC be connected to a rudder angle feedback unit potentiometer in parallel with the steering gear feedback loop.

vii

056357/B RAIS

CAUTION

Note

Risk of damage As the feedback potentiometer supply voltage is provided by the Rudder Angle Calibrator, connecting the RAC to a feedback potentiometer in parallel to any device other than a second Rudder Angle Calibrator bears the

A

risk of damage in case of wire breaks or short-circuits. Never connect the RAC to a feedback potentiometer in parallel to any device other than a second RAC.

Risk of misusage The ALR sentence as serial output of the RAC is not MED complaint and therefore NOT allowed as system setting for a ship under wheelmark certification. Always make sure that the ALR sentence setting is INACTIVATED when the RAC is used on a ship under wheelmark certification.

Risk of misusage The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. Always make sure that another baud rate setting (4880 or 9600 baud) must be selected as RS-422 output 1 and RS-422 output, when the RAC is used on a ship under wheelmark certification

Generally, it cannot be guaranteed that the Rudder Angle Calibrator’s parameter settings are left intact during a firmware update. Before updating firmware, record all parameter settings to be able to reenter them manually, if required. Calibration settings will not be touched when updating the firmware.

For recording all parameter settings see “Setup and Configuration Tables” in the appendix of this manual.

viii

RAIS 056357/B

Chapter 1: Introduction

1.1 System Description

Intended Use

The Sperry Marine Rudder Angle Indicator System (RAIS) is a system for electric rudder angle indication on maritime vessels and must be operated only from appropriately trained and educated personnel familiar with all mandatory safety and operating procedures.

The Sperry Marine Rudder Angle Indicator System (RAIS) in total consists of the Rudder Angle Calibrator (RAC), a microprocessor-controlled signal conditioning device for electric rudder angle indicators, a series of Rudder Angle Indicators (RAI) and a series of Rudder Angle Feedback Units (RAFU) including limit switches and lever linkages.

Not Intended Use

The Sperry Marine Rudder Angle Indicator System (RAIS) is designed for marine purposes only and therefore not allowed to be used for the navigation of inland water vessels and river boats.

The ALR sentence as serial output setting of the RAIS is not MED compliant and must therefore permanently be inactivated for all ships under wheelmark certification.

The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. The 38400 Baud setting is therefore not allowed for all ships under wheelmark certification and another baud rate setting (4880 or 9600 baud) must be selected.

System Description 1-1

056357/B RAIS

Rudder Angle Calibrator

(RAC)

rudder angle indicators

analogue out (6)

feedback signal in

feedback supply

rudder angle

feedback unit

RUDDER

X

serial data out

alarm status

1.2 Design and Main Features

The Sperry Marine Rudder Angle Indicator System(RAIS) is a system for electric rudder angle indication on maritime vessels.

The Rudder Angle Indicator System has been type approved by DNV GL SE based on the

notification of the Federal Maritime and Hydrographic Agency of Germany in compliance with the requirements of Marine Equipment Directive (MED) 2014/90/EU of July 2014 as amended and is found to comply with the requirements in the following specified regulations / standards: Regulation (EU) 2017/306, item No. MED/4.20.SOLAS 74 as amended, Regulations V/18, V/19 & X/3 IMO Resolutions: A.694(17), MSC.36(63), MSC.97(73), MSC.191(79), MSC.302(87) and applicable to tests according: (IEC 60945(2002) incl. corrigendum 1 (2008), IEC 61162series, ISO 20673(2007) and IEC 62288(2014)

Figure 1-1:

RAIS

Basic

with 1 RAC for

single-rudder system

and has been assigned certificate no. 47252-12 HH / 47253-12 HH.

For further details see “Declaration of Conformity” on page 1-9.

The RAC is used to attain ISO_20673 compliant overall calibration accuracy in RAI systems with conventional moving-coil indicators. It reads the analogue signal from a rudder angle feedback unit and provides six individually calibratable analogue signal outputs, and illumination supply terminals for the connected RAIs. To increase the number of available outputs, two RACs may be connected in parallel to one feedback potentiometer. The RAC also provides two calibrated rudder angle outputs in serial format using the $--RSA sentence according to IEC 61162 (NMEA 0183).

To alert the operator of power failure and other alarm conditions, the RAC provides two status relay signal outputs and also transmits alarm status data via the $--ALR sentence according to IEC 61162 (NMEA 0183).

1-2 Design and Main Features

RAIS 056357/B

PORT

X X

STB

PORT

X X

STB

port side RAC stbd. side RAC

VDR

port + stbd.

rudder angles

Rudder Angle Calibrator (RAC)

data formatting

output calibration

input calibration

A/D conversion

D/A conversion

A

D

xy

D

A

xy

$...

RUDDER

X

In dual-rudder systems, RACs for the port and starboard rudder are used in a paired configuration. Each unit reads the feedback signal and drives the analogue outputs for its own side. Through a crosslink, it also reads the other unit’s digital output and produces a $--RSA sentence including port and starboard rudder angles according to IEC 61162 (NMEA 0183).

Figure 1-2:

RAIS with 2 RACs for

d

ual-rudder system

1.3 Principle of Operation

Figure 1-3:

RAIS:

principle of operation

To attain an ISO 20673 compliant calibration accuracy for all RAIs connected, the RAC applies calibration as part of the A/D conversion of the analogue feedback signal as well as of the D/A conversion for each analogue output.

An input calibration table maps the feedback input voltage to the corresponding rudder angle for a number of significant rudder positions. The actual feedback voltage is thus converted to a digital rudder angle value and automatically corrected according to the stored calibration table. This compensates for possible misalignment of the feedback unit and non-linearity of the feedback potentiometer. The corrected digital value forms the reference for both the serial data output and the subsequent conversion to the six separate analogue output voltages.

An output calibration table maps the digital rudder angle values to corresponding sets of analogue output voltages. This individually compensates for the non-linearity, range variation and zero-offset of the connected RAIs.

Principle of Operation 1-3

056357/B RAIS

03030

RUDDER

1.4 RAIS Overview

The Sperry Marine Rudder Angle Indicator System (RAIS) in total consists of the Rudder Angle Calibrator (RAC), a microprocessor-controlled signal conditioning device for electric rudder angle indicators, a series of different Rudder Angle Indicators RAI) types and a series of Rudder Angle Feedback Units (RAFU) including limit switches and lever linkages.

System Components

Table 1-1:

RAIS system

components

System Component Name Stock No.

Rudder Angle Calibra-

074849-0000-000

tor (RAC), type 5014

RAI, third party, three face panorama type, (example)

060396-0000-000 (range ± 45°) 060397-0000-000 (range ± 70°)

RAI, standard type, third party, (example)

060327-0000-000 060328-0000-000 060334-0000-000 060335-0000-000 060338-0000-000 060339-0000-000 060352-0000-000 060353-0000-000 060357-0000-000 060359-0000-000

RAI, third party, Panama type, (example)

060325-0000-000 060326-0000-000 060331-0000-000 060337-0000-000 060332-0000-000 060362-0000-000 060340-0000-000 060341-0000-000 060354-0000-000 060355-0000-000

Rudder Angle Feedback Unit (RAFU); type 4968-

074720-0000-000 074721-0000-000 074722-0000-000 074724-0000-000 074725-0000-000 074784-0000-000 074785-0000-000 074788-0000-000 074791-0000-000 074795-0000-000 074796-0000-000

1-4 RAIS Overview

RAIS 056357/B

Note

System Component Name Stock No.

- Limit Switches (inside

074723-0000-000 RAFU housing, not shown)

Lever Linkage 020508-0000-000

022501-0000-000

For all details regarding the Rudder Angle Indicators, refer to the third party documentation from the supplier Faiveley Mors Smitt, as listed in the appendix of this manual.

RAIS Overview 1-5

056357/B RAIS

1.5 RAIS Technical Data

Environmental Requirements

ambient temperature, operation -15 °C – +55 °C

ambient temperature, storage -25 °C – +70 °C

protection grade IP 23 to DIN EN 60529

environmental conditions / EMC in accordance with IEC 60945,

equipment category “protected from the weather”

Power Supply

RAC supply voltage 24 VDC

RAC max. ripple content - 10 – + 20% Vpp

RAC power consumption 3 W max.

Rudder Angle Indicator System power consumption

RAC Magnetic Clearance

to standard magnetic compass 0.30 m

to steering magnetic compass 0.30 m

reduced, to standard magnetic compass 0.30 m

reduced, to steering magnetic compass 0.30 m

RAC Dimensions and Weight

width 230 mm

height 145 mm

depth 65 mm

weight 3.0 kg

RAFU Dimensions and Weight

15 W max. in total, for rudder angle indicator illumination via RAC:

width 293 mm

height 200 mm

depth 192 mm

weight 7.5 kg

1-6 RAIS Technical Data

RAIS 056357/B

CAUTION

RAC Signal and Data Inputs

rudder angle feedback input Wiper signal from rudder angle

feedback potentiometer; ±15 VDC supply voltage provided by RAC.

RS-422 input NMEA 0183 / IEC 61162;

other side’s rudder angle in dual rudder systems ($--RSA)

RAC Signal, Data and Status Outputs

analogue rudder angle outputs (6x)

six independently calibratable voltage outputs to moving-coil rudder angle indicators, ±15 VDC max. into 10 k

RS-422 output 1 IEC 61162 (NMEA 0183),

4800 9600 or 38400 Baud* rudder sensor angle ($--RSA)

RS-422 output 2 IEC 61162 (NMEA 0183);

4800 9600 or 38400 Baud* rudder sensor angle ($--RSA), set alarm state ($--ALR)

Risk of misusage The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. Always make sure that another baud rate setting (4880 or 9600 baud) must be selected as RS-422 output 1 and RS-422 output, when the RAC is used on a ship under wheelmark certification

“Power Fail. / Gen. Alarm” output opto-isolated solid state relay;

peak off-state voltage 100 V AC/DC, on-state current 100mA, on-state resistance < 25, isolation voltage 1500 Vrms; configurable as NO or NC contact, open if power off

“Spare” relay output (for future use)

opto-isolated solid state relay; peak off-state voltage 100 V AC/DC, on-state current 100mA, on-state resistance < 25, isolation voltage 1500 Vrms; configurable as NO or NC contact, open if power off

RAIS Technical Data 1-7

056357/B RAIS

RAC Service I/O Port

USB service port Connects to a Windows host PC

through a vendor-specific USB communications device class driver. The Rudder Angle Calibrator is accessed via the “SUSI” application, using a proprietary data protocol.

1-8 RAIS Technical Data

RAIS 056357/B

Note

1.6 Declaration of Conformity

Marine Equipment Directive EC Declaration of Conformity:

Northrop Grumman Sperry Marine B.V. Woltmanstrasse 19 D-20097 Hamburg, Germany.

as manufacturer hereby declares that the following specified equipment:

„Sperry Marine Rudder Angle Indicator System“

complies with the Marine Equipment Directive (MED) 2014/90/EU of July 2014 as amended, as

„Rudder Angle Indicator“ (RAI)

This equipment has been tested to verify compliance with the Regulations and Testing Standards according to implementing regulation (EU) 2017/306 as per EC - Type Examination Certificate (Module B) and QS - Certificate of Assessment -EC (Module D):

Notified Body No. 0098 DNV GL SE based on the notification of the Federal Maritime and Hydrographic Agency of Germany.

The current issue of the detailed Marine Equipment Directive EC Declaration of Conformity of Northrop Grumman Sperry Marine B.V. Hamburg is part of the client CD stock no. 56 800. For further details please contact: Northrop Grumman Sperry Marine B.V. Hamburg Regulatory Support Group

Declaration of Conformity 1-9

056357/B RAIS

1-10 Declaration of Conformity

RAIS 056357/B

Note

Chapter 2: Operation

The RAC possesses no user-accessible controls. Once installed and properly configured, it will take up operation unattended, as soon as power is applied to the RAIS.

Likewise, no special procedures need to be followed to power off the system. The RAC may be safely switched off at any time and will reboot into normal operational mode as soon as it is switched on again.

2.1 Normal Operational Mode

When power is applied, the RAC boots up and enters the normal operational mode within a few seconds.

The unit applies in- and output calibration according to the stored calibration tables at all times. If no errors are present, the only noticeable effect of the RAC being included in the RAIS, will be an increased accuracy in comparison to conventional systems.

Regularly check the indication of the RAIs against the actual position of the rudder angle shaft to make sure that calibration is applied properly and the specified accuracy is maintained.

To alert the operator when the RAC is powered off or an alarm condition is present, in most installations, the “Power Fail. / Gen. Alarm” relay will be connected to an alarm indicator or central alarm panel.

A given alarm system may employ reverse output logic (closed on alarm). In this case, powering off the RAC will not raise an alarm.

Normal Operational Mode 2-1

056357/B RAIS

2-2 Normal Operational Mode

RAIS 056357/B

CAUTION

Note

Chapter 3: Alarms System

Risk of misusage The ALR sentence as serial output of the RAC is not MED complaint and therefore NOT allowed as system setting for a ship under wheelmark certification. Always make sure that the ALR sentence setting is INACTIVATED when the RAC is used on a ship under wheelmark certification.

3.1 Alarm Indication

The RAC does not contain built-in audible or visible alarm indicators. To indicate the presence of an alarm, the alarm status output must be connected to an external device, such as an alarm buzzer or a central alarm unit, or the RAC must be configured to transmit the alarm state to an IEC 61162 (NMEA 0183) compliant serial data alarm handling facility.

Alarm Status Output

The “Power Fail. / Gen. Alarm” relay output signals the current alarm state via a potential-free relay contact pair

In case the RAC raises an alarm, the output changes from the “no alarm” to the “active alarm” state. The output’s logic behaviour may be independently configured as NO (normally open, closed on alarm) or NC (normally closed, open on alarm). If the RAC is powered off, the output contacts are open.

The operator cannot actively reset the outputs from the “active alarm” to the “no alarm” state. The outputs will only return to the “no alarm” state when no alarm condition is present any more.

1

.

Serial Data Alarm Output

The RS-422 output 2 may be configured to transmit alarm status information using the $--ALR sentence according to IEC 61162 (NMEA 0183).

When the RAC raises an alarm, an $--ALR sentence is transmitted, containing the corresponding alarm number and description text. The alarm will be marked as “active” and “not acknowledged”. When a given alarm condition is no longer present, the RAC transmits the respective $--ALR sentence once, with the status set to ”acknowledged”. The unit then stops transmitting the sentence in question. When no active alarms are present, the RAC cyclically transmits a “no alarms” message as recommended in IEC 80/520/INF. This is an $--ALR sentence with null fields for the alarm code and description.

1. A second relay output is provided for future use (“Spare” output), which currently behaves identical to the “Power Fail. / Gen. Alarm” output. However, this output may be assigned a different functionality in future software releases.

Alarm Indication 3-1

056357/B RAIS

Note

The RAC does not support remote alarm acknowledgement via the $--ACK sentence. Alarms will be transmitted as being “not acknowledged”, even if acknowledged locally at the receiving end.

3-2 Alarm Indication

RAIS 056357/B

Note

3.2 Alarm Numbers

If the RAC is configured to transmit the $--ALR sentence according to IEC 61162 (NMEA 0183), the type of an active alarm may be determined in more detail from the alarm number and description text contained in the sentences transmitted.

Currently, $--ALR sentences are only generated in case of data I/O errors. If the RAC exhibits malfunction without generating a corresponding $--ALR sentence, contact Sperry Marine Service (Net) for troubleshooting assistance.

Table 3-1:

RAC alarm numbers

Error IDError Text Cause Corrective Action

none

group 400: data I/O errors (NMEA crosslink between starboard and port RACs in dual rudder system)

401 "wrong checksum

none $--ALR sentences

with null fields for the code and description are “no alarm” messages. These are sent cyclically when no active alarm is present.

faulty checksum in

(RxD1)"

NMEA sentence received at the RS-422 input.

none

If error occurs only occasionally, no action required. If error occurs frequently, check proper function of other side’s RAC; check connection between RACs.

405 "data error (RxD1)" faulty data in

NMEA sentence received at the RS-422 input.

410 "overrun error

(RxD1)"

415 "com port error

(RxD1)"

Alarm Numbers 3-3

RS-422 input receive buffer overrun

internal error accessing RS-422 input port

Check proper function of other side’s RAC; check connection between RACs.

Check function and configuration of other side’s RAC (baud rate, selected sentences); check connection between RACs.

Cycle power to restart RAC. If error persists, contact Sperry Marine Service (Net) for assistance.

056357/B RAIS

Error IDError Text Cause Corrective Action

430 "no nmea message

received (RxD1)"

435 "wrong sentence id

received (RxD1)"

440 "wrong talker id re-

ceived (RxD1)"

expected NMEA sentences not received

wrong NMEA sentence type received at the RS-422 input

wrong NMEA talker ID received at the RS-422 input

If RAC is not used in dual rudder system, disable the RS-422 input. In dual rudder system, check configuration of other side’s RAC (baud rate, selected sentences); check connection between RACs.

Check the type of data source at the RS-422 input. Only other side’s RAC in dual rudder system may be connected to the input.

Check the type of data source at the RS-422 input. Only the other side’s RAC in a dual rudder system may be connected to input.

445 "error in received

NMEA message"

480 "no RSA message

received"

481 "no starboard rud-

der received"

482 "no port rudder re-

ceived"

malformed NMEA sentence received at the RS-422 input

no NMEA $--RSA sentence received at the RS-422 input

received $--RSA sentence does not contain starboard rudder

received $--RSA sentence does not contain port rudder

Check function of other side’s RAC; check connection between RACs.

Check configuration of other side’s RAC ($--RSA transmission must be enabled).

Check that both RACs are assigned correctly to sides; check function of transmitting RAC.

3-4 Alarm Numbers

RAIS 056357/B

3.3 Viewing RAC Errors through SUSI

When connected to the RAC, the Sperry Universal Service Instrument application (SUSI) provides an “Errors” page which displays current state and counts the occurrence of the alarms listed in table

Figure 3-1:

SUSI’s Error Page

for the RAC

3-1 above:

For more information on the SUSI application, refer to chapter 6 (System Configuration) and to the SUSI Installation Guide included in the appendix of this manual.

Viewing RAC Errors through SUSI 3-5

056357/B RAIS

3-6 Viewing RAC Errors through SUSI

RAIS 056357/B

Note

Chapter 4: Scheduled Maintenance

4.1 Maintenance by Shipboard Personnel

The RAC is a solid-state electronic device and contains no consumable parts. Therefore, no set maintenance schedule to be carried out by shipboard personnel or service personnel is required.

The housing should be kept clean and a regular visual inspection of cables and connectors should be carried out to detect any signs of damage or deterioration.

Should the RAC fail to attain the required calibration accuracy, thoroughly check the cables for mechanical damage. Check the connectors at the RAC, the rudder angle feedback unit and the RAIs for signs of corrosion, loose contacts etc. Inspect the feedback unit and the feedback linkage in particular for any signs of mechanical damage or wear. In case the RAC does still fail to attain the required calibration accuracy, maintenance by authorized service personnel is required.

4.2 Maintenance by Service Personnel

If re-calibration of the RAC is required, field service attendance must be requested from Sperry Marine directly or through an authorized Sperry Marine service representative.

The RAC is re-calibrated using the Sperry Universal Service Instrument (SUSI). This tool is provided to authorized service personnel only and is generally not available to end-customers.

Maintenance by Shipboard Personnel 4-1

056357/B RAIS

4-2 Maintenance by Service Personnel

RAC 056357/B

DANGER

CAUTION

Chapter 5: Installation

5.1 Mechanical Installation

The RAC is to be installed at a protected location. In most cases, it will be placed inside a bridge console or bulkhead mounted in the vicinity of the connected RAIs.

Attach the RAC to a level surface with four M6 screws (or nuts and bolts). For the dimensions of the housing, refer to dimension drawing 5014-0112-01.

When not installed in a bridge console, the RAC is to be mounted vertically (bulkhead mounting), with the cable inlets facing down. Inside a bridge console, the RAC may be installed vertically, horizontally or inclined.

5.2 Electrical Installation

Rudder Angle Calibrator

Wire up the system according to the connection diagrams and other relevant documents provided.

Life danger through electrical shock Certain alarm devices may operate with hazardous voltages, switched by the alarm relay output contacts. NEVER connect live wires to the unit’s terminals, when wiring up the Rudder Angle Calibrator. ALWAYS make sure that any external device or power supply to be connected to the alarm relay outputs is de-energized and safeguarded against accidental switching-on.

Risk of damage of electrostatic-discharge-sensitive components Components on the Rudder Angle Calibrator PCB are sensitive to static discharge. While wiring up the RAC, take the necessary precautions to prevent electrostatic discharges.

Mechanical Installation 5-1

056357/B RAC

WAR NING

CAUTION

Rudder Angle Feedback Unit Potentiometer

Risk of injury Connecting the Rudder Angle Calibrator to a rudder angle feedback unit in parallel with the steering gear feedback loop bears the risk of malfunction of the steering gear in case of wire breaks or short-circuits resulting in possible injury and/or damage. Under no circumstances must the RAC be connected to a rudder angle feedback unit potentiometer in parallel with the steering gear feedback loop.

Risk of damage As the feedback potentiometer supply voltage is provided by the Rudder Angle Calibrator, connecting the RAC to a feedback potentiometer in par-

A

allel to any device other than a second RAC bears the risk of damage in case of wire breaks or short-circuits. Never connect the RAC to a feedback potentiometer in parallel to any device other than a second RAC.

Generally, a dedicated rudder angle feedback unit will be installed for the RAC. Alternatively, one or more RACs may use a separate potentiometer in a feedback unit which also contains potentiometers for, e. g., other RAI systems or the VDR.

5-2 Electrical Installation

RAIS 056357/B

DANGER

WAR NING

Note

CAUTION

Note

Chapter 6: System Configuration

Life danger through electrical shock Certain alarm devices may operate with hazardous voltages, switched by the alarm relay output contacts. During configuration, the Rudder Angle Calibrator must be operated with the housing open. Make sure that any external device or power supply connected to the alarm relay outputs is de-energized and safeguarded against accidental switching-on.

Risk of personal injury To calibrate the feedback input, the rudder has to be moved over its entire range. Always make sure that the steering gear is operative and that the rudder may be actuated safely without any risk of personal injury or damage to equipment, especially when the vessel is drydocked and works are carried out by shipyard personnel. Always inform the shipboard or shipyard personnel in charge of your intention to actuate the rudder and obtain permission to operate the steering gear for calibration purposes, before moving the rudder.

The calibration procedures require that tasks are carried out at different locations on the vessel. If possible, use voice communication to instruct one or more helpers to report the actual rudder angle indications as read from the rudder stock scale and indicated at the RAIs respectively.

Risk of damage of electrostatic-discharge-sensitive components The

Rudder Angle Calibrator contains electrostatic sensitive components.

Electrostatic discharge may permanently damage components. When configuring the

Rudder Angle Calibrator, take precautions to prevent

electrostatic discharge. Avoid touching any of the electronic circuitry.

This chapter is intended for authorized service personnel configuring or servicing the Rudder Angle Calibrator. These tasks require a PC running the Sperry Universal Service Instrument (SUSI) application. SUSI is provided to authorized service personnel only and is generally not available to end-customers.

The RAC must be configured and calibrated before it can be put into operation. This is done from a PC (field engineer’s laptop or notebook computer) connected to the RACs USB service port, running the Sperry Universal Service Instrument application (SUSI).

The present chapter assumes that you have successfully installed SUSI and the Rudder Angle Calibrator USB device driver on your PC. If you have not yet installed the SUSI and/or the device driver, refer to the separate SUSI Installation Guide for Field Service Personnel, doc no 056358.

The procedures described below are performed using the RAC application controls inside SUSI’s application tab. More advanced configuration features, accessible through SUSI’s terminal and parameter tabs, are beyond the scope of this manual.

6-1

056357/B RAIS

6.1 Initial system configuration

Configuring the RAC with SUSI

1. If the RAC is currently powered up, switch off the power first.

2. Open the RAC housing and locate the USB service port receptacle, J3, on the PCB. Make sure that the port is freely accessible for plugging and unplugging the USB cable. Do not plug in the cable yet.

3. Power up the RAC.

4. At the PC, start up the SUSI application.

A login dialogue pops up:

5. Enter the PIN “20097”. This will start up SUSI in the service mode.

Click at the enter key to continue.

6. SUSI’s main window now opens, with the “Application” tab displaying a list of supported devices:

7. The “Online” button at the top left of SUSI’s main window will be greyed out, as SUSI has not yet detected a device to connect to. The top status line at the top center of the window will read “Waiting for Connection...”.

6-2 Initial system configuration

RAIS 056357/B

8. Plug in the USB cable at the PC and at the RAC’s service port. The “Online” button should now become clickable (not greyed-out), indicating that SUSI has found a device to connect to:

The LED icon next to the button will remain grey, as no connection has been made yet.

9. Click to connect to the RAC. The LED icon should now change to green and the status line should read “Connected with RAC”.

Upon connection, SUSI populates the Application tab with the RAC application controls and displays the application’s “Main Page”:

10. If the service PC has not previously been used to service a RAC, a warning message will pop up, indicating that the parameter list for the device is empty:

Click . to read the current configuration from the RAC and to set the Main page parameter controls accordingly, or

click . if you intend to set all parameters manually in SUSI first and write them to the RAC later.

Initial system configuration 6-3

056357/B RAIS

Note

11. If you clicked in the previous step, a dialogue box will pop up, asking whether the parameters should be saved as default settings for this device:

Click . to save the parameters as default settings or

click to cancel.

12. If you clicked in the previous step, the default settings are now written to a file named “RACdefault.xml“ in the sub-directory “Parameter Files” in SUSI’s installation directory.

If a default parameter file for the Rudder Angle Calibrator already exists, e. g. if the service PC previously been used to service another RAC, the warning message described above will not appear. In this case, do not write back settings to the RAC before all system parameters have been set as required for the installation at hand.

13. Using the Main page controls, set all system parameters as required. An overview and detailed descriptions of the system parameters are given below (see “System Parameters” on page 6-6).

14. When all parameters are set as required, click to transfer the settings to the RAC.

15. Carry out the initial calibration procedure (see “Initial Calibration” on page 6-16). If the steering gear is operative and permission is given to actuate the rudder, start with the input calibration. If the rudder cannot be actuated now, an input calibration may be carried out using dummy input signals (see “Input Calibration using Dummy Values” on page 6-24). Continue with the output calibration, calibrating at least one of the analogue outputs. If no RAI is connected to the RAC yet, dummy values may be supplied for the output calibration.

The setting of the system parameters and the input and output calibration may be carried out at different points in time. However, the Rudder Angle Calibrator’s initial configuration is complete only if all three of these tasks have been completed successfully and it has been checked that the required calibration accuracy is attained with all components of the RAI system being connected and operational.

16. When the in- and output calibration procedures have been fully completed and all components of the RAI system are operational, carry out a brief function-check.

6-4 Initial system configuration

RAIS 056357/B

Note

17. Determine the calibration accuracy attained through the initial calibration. For this purpose, compare the actual angle at the rudder stock with the angles displayed at the RAIs. In conformance with the requirements of ISO 20673, the angles should be recorded every 5° for a ±45° steering gear and every 10° for a ±70° steering gear.

18. Should the difference between the angles at the rudder stock and the values shown at the RAIs exceed 1.5% of the full scale angle (performance requirement according to ISO 20673), determine the angles where the largest errors occur. Then, set additional input and/or output calibration points for these angles and determine the calibration accuracy again. If necessary, repeat this step until the required calibration accuracy is attained.

19. The RAC configuration as such is now complete and the unit is ready to be taken into operation.

20. To finish off the configuration, click in the SUSI application to read all configuration and calibration settings from the RAC back into SUSI’s runtime memory. A dialog box will pop up, asking whether these parameters should be saved as default settings for this device:

21. Click to save the parameters. The file containing the configuration parameters is named “RACdefault.xml“ and is located in the sub-directory “Parameter Files” in SUSI’s installation directory. To be able to retrieve and restore the configuration at a later point in time, this file should be copied and saved to an appropriate location.

Saving the Rudder Angle Calibrator settings will overwrite a previously saved settings file in SUSI’s “Parameter Files” sub-directory without further warning. To be able to retrieve and restore the configuration at a later point in time, rename the file “RACdefault.xml“ and/or copy it from the “Parameter Files” sub-directory to a different location.

22. Fill out the RAC setup table to retain an easily retrievable written record of the RAC configuration.

23. Unplug the USB cable from the RAC and the service PC.

24. Power down the RAC and put the cover back on the housing.

25. If the RAC is to be taken into operation now, power up the unit again. Re-check for proper operation.

Initial system configuration 6-5

056357/B RAIS

Feedback Type

port rudder

starboard rudder

single rudder

Serial I/O

RS-422 In

Baudrate

38400

9600

4800

Messages

RSA

RS-422 Out 1

Baudrate

38400

9600

4800

Messages

RSA

RS-422 Out 2

Baudrate

38400

9600

4800

Messages

RSA ALR

Update Rate

1 Hz

10 Hz

Update Rate

1 Hz

10 Hz

Relay Setup

General Alarm

closed on alarm

closed on no alarm

closed on alarm

closed on no alarm

Spare

2

3

4

1

Read-Only Controls:

RAC Serial No., Software Version, Act. Feedback Angle

System Parameter Controls:

1

2

3

4

6.2 System Parameters

The Rudder Angle Calibrator application Main page contains a number of settable interface controls. These are used to configure the RAC’s basic system parameters as required for the installation at hand. The settable system parameters fall into three groups, the Feedback Type setting, the Serial I/O settings and the Relay Setup.

Figure 6-1:

Controls on the RAC

application Main page

6-6 System Parameters

RAIS 056357/B

Feedback Type

Selects the type of the input feedback signal.

Setting: single rudder

The input signal is read from the feedback unit of a single rudder steering gear. The RAC’s serial data outputs transmit the own rudder angle as the “starboard (or single) rudder sensor angle” in the $-RSA sentence. The “port rudder sensor angle” will be transmitted as a null field.

starboard rudder

The input signal is read from the starboard feedback unit of a dual rudder steering gear. The RAC’s serial data outputs transmit the own rudder angle as the “starboard (or single) rudder sensor angle” in the $-RSA sentence. If a valid port rudder angle is read from a second Rudder Angle Calibrator at the serial input, it will be transmitted as the “port rudder sensor angle” in the $--RSA sentence.

port rudder

The input signal is read from the port feedback unit of a dual rudder steering gear. The RAC’s serial data output transmits the own rudder angle as the “port rudder sensor angle” in the $--RSA sentence. If a valid starboard rudder angle is read from a second RAC at the serial input, it will be transmitted as the “starboard (or single) rudder sensor angle” in the $--RSA sentence.

System Parameters 6-7

056357/B RAIS

Serial I/O

These settings configure the RAC’s serial data ports.

RS-422 In

Configures the RS- 422 serial data input.

Baudrate

Selects the receive baudrate.

Settings: 4800 Baud

Data is received at 4800 Baud (standard according to NMEA / IEC 61162-1).

9600 Baud

Data is received at 9600 Baud (non-standard).

38400 Baud

Data is received at 38400 Baud (high-speed, not compliant to IEC 61162-2)

Messages

Selects the NMEA sentences to receive.

Settings RSA

In a dual rudder system, evaluate the $--RSA sentence received from another RAC. If a stb. Rudder Angle Calibrator receives a valid port angle or if a port RAC receives a valid stb. angle, the unit transmits a $--RSA sentence containing both of these angles. Select (check) this option in a dual rudder system where the stb. and port RACs are connected via a serial data crosslink. De-select (uncheck) this option in all other cases.

6-8 System Parameters

RAIS 056357/B

CAUTION

RS-422 Out 1

Configures the RS- 422 serial data output 1 (rudder angle output).

Baudrate

Selects the transmit baudrate.

Settings: 4800 Baud

Data is transmitted at 4800 Baud (standard according to NMEA / IEC 61162-1).

9600 Baud

Data is transmitted at 9600 Baud (non-standard).

38400 Baud*

Data is transmitted at 38400 Baud (high-speed, not compliant to IEC 61162-2).

Risk of misusage The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. Always make sure that another baud rate setting (4880 or 9600 baud) must be selected as RS-422 output 1 and RS-422 output, when the RAC is used on a ship under wheelmark certification

Update Rate

Selects the rate at which output sentences are transmitted.

Settings: 10 Hz

Sentences are transmitted at a rate of 10 Hz. This option should be selected only if a rate of 1 Hz would be too slow, e. g. when the serial rudder angle data is used to feed a live display.

1 Hz

Sentences are transmitted at a rate of 1 Hz. This rate should suffice in most cases and should be selected unless a higher rate is absolutely required.

Messages

Selects the NMEA sentences to transmit.

Settings: RSA

Transmit the rudder angle(s) using the $--RSA sentence. Select (check) this option to activate transmission of the $-RSA sentence at the RS-422 serial output 1. De-select (uncheck) this option to disable transmission of the $--RSA sentence at the RS-422 serial output 1. This will disable the output completely.

System Parameters 6-9

056357/B RAIS

CAUTION

RS-422 Out 2

Configures the RS- 422 serial data output 2 (VDR output).

Baudrate

Selects the transmit baudrate.

Settings: 4800 Baud

Data is transmitted at 4800 Baud (standard according to NMEA / IEC 61162-1).

9600 Baud

Data is transmitted at 9600 Baud (non-standard).

38400 Baud*

Data is transmitted at 38400 Baud (high-speed, not compliant to IEC 61162-2)

Risk of misusage The RS-422 output 1 and RS-422 output 2 of the RAC is not MED compliant in case 38400 baud are selected as interface setting. Always make sure that another baud rate setting (4880 or 9600 baud) must be selected as RS-422 output 1 and RS-422 output, when the RAC is used on a ship under wheelmark certification

Update Rate

Selects the rate at which output sentences are transmitted.

Settings: 10 Hz

Sentences are transmitted at a rate of 10 Hz. This option should be selected only if a rate of 1 Hz would be too slow, e. g. when the serial rudder angle data is used to feed a live display. Note that $--ALR sentences are always transmitted at 1 Hz, regardless of the update rate setting.

1 Hz

Sentences are transmitted at a rate of 1 Hz. This rate should suffice in most cases and should be selected unless a higher rate is absolutely required.

Messages

Selects the NMEA sentences to receive.

Risk of misusage The ALR sentence as serial output of the RAC is not MED complaint and therefore NOT allowed as system setting for a ship under wheelmark certification. Always make sure that the ALR sentence setting is INACTIVATED when the RAC is used on a ship under wheelmark certification.

6-10 System Parameters

RAIS 056357/B

Settings: RSA

Transmit the rudder angle(s) using the $--RSA sentence. Select (check) this option to activate transmission of the $-RSA sentence at the RS-422 serial output 2. De-select (uncheck) this option to disable transmission of the $--RSA sentence at the RS-422 serial output 1.

Settings: ALR

Transmit the RAC’s set alarm state using the $--ALR sentence. Select (check) this option to activate transmission of the $-ALR sentence at the RS-422 serial output 2. De-select (uncheck) this option to disable transmission of the $--RSA sentence at the RS-422 serial output 2.

When the output is connected to a VDR, it is recommended to limit the message update rate to 1 Hz and to disable transmission of data which is already fed to the VDR from another source. Disabling both options will disable the output completely.

Relay Setup

Configures the status relay outputs.

General Alarm

Configures the “Power Fail. / Gen. Alarm” relay output

Settings: Closed on no alarm

The relay contact is closed in the “no alarm” state. On alarm, the contact opens.

Closed on alarm

The relay contact is open in the “no alarm” state. On alarm, the contact closes.

Spare

Configures the “Spare” relay output

Settings: Closed on no alarm

The relay contact is closed in the “no alarm” state. On alarm, the contact opens.

Closed on alarm

The relay contact is open in the “no alarm” state. On alarm, the contact closes.

System Parameters 6-11

056357/B RAIS

WAR NING

Note

6.3 In- and Output Calibration

Risk of personal injury To calibrate the feedback input, the rudder has to be moved over its entire range. Always make sure that the steering gear is operative and that the rudder may be actuated safely without any risk of personal injury or damage to equipment, especially when the vessel is drydocked and works are carried out by shipyard personnel. Always inform the shipboard or shipyard personnel in charge of your intention to actuate the rudder and obtain permission to operate the steering gear for calibration purposes, before moving the rudder.

The calibration procedures require that tasks are carried out at different locations on the vessel. If possible, use voice communication to instruct one or more helpers to report the actual rudder angle indications as read from the rudder stock scale and indicated at the RAIs respectively.

To attain the calibration accuracy required to comply with ISO 20673 for all RAIs connected, the RAC applies calibration to the input signal as well as to all analogue outputs separately.

Before the system may be taken into operation, the feedback input and all used outputs are to be calibrated. The RAC application’s calibration page provides the required controls for these tasks:

6-12 In- and Output Calibration

RAIS 056357/B

Note

Figure 6-2:

Controls on the RAC

calibration page

1

Input Calibration Controls:

Rudder Angle dial and spin box Calibration Point spin box Delete and Save buttons

2

Output Calibration Controls:

1

2

Rudder Angle Indicator dial and spin box Calibration Point spin box Delete and Save buttons Output Digit sliders and spin boxes

Accessing the calibration page puts the Rudder Angle Calibrator into a special calibration mode. In this mode, the analogue output voltages do not correspond to the actual rudder angle but are determined directly by the settings of the output calibration controls. Serial output of the rudder angle is disabled in the calibration mode.

In- and Output Calibration 6-13

056357/B RAIS

Input Calibration Table

To compensate for possible misalignment of the feedback unit and nonlinearity of the feedback potentiometer, the RAC permanently applies correction to the input value, according to a stored calibration table.

The input calibration table contains a number of calibration points, each of which maps a feedback input value to the corresponding true rudder angle, as read from the rudder stock scale. Values in-between the set calibration points are linearly interpolated.

As a minimum, three calibration points must be set. Normally, an initial input calibration is carried out where calibration points are set at every 5° for a ±45° steering gear and every 10° for a ±70° steering gear. This makes sure that the optimum calibration is achieved at the rudder angles where the calibration accuracy is to be checked later, according to ISO 20673. Additional calibration points may be added later, up to a total of 73.

Output Calibration Table

To compensate for the existing non-linearities and zero-point offsets of the connected RAIs, the RAC permanently applies correction to the analogue output signals, according to a stored output calibration table.

The output calibration table contains a number of calibration points, each of which maps an actual rudder angle value to a set of six corresponding output voltage values. Values in-between the set calibration points are linearly interpolated.

As a minimum, three calibration points must be set. Normally, an initial output calibration is carried out, to set calibration points for the hardover port, the midships and the hardover starboard rudder indications. Additional calibration points may be added later, up to a total of 73.

6-14 In- and Output Calibration

RAIS 056357/B

General Remarks on Calibration

With regard to the RAC in- and output calibration using SUSI, observe the following points:

• Port rudder angles are displayed as negative numbers in SUSI. Accordingly, port angles must also be entered as negative numbers, prefixed with a minus sign. Starboard angles carry no sign. Thus, “-45.0°” denotes an angle of 45 degrees to port, “45.0°” denotes an angle of 45 degrees to starboard.

• Calibration settings are written back to the RAC when the calibration page is quit by clicking “Finish”. However, SUSI refuses to write back the calibration settings to the RAC before the minimum number of three input and three output calibration points has been set. Clicking “Cancel” quits the calibration page and discards all changes, leaving the RAC settings untouched.

• Consequently, when deleting existing calibration points, at least three input and three output points must remain set. Otherwise, an error message will be displayed when attempting to quit the page by clicking “Finish” and it will not be possible to save any of the changes made since the page was entered.

• Once an in- or output calibration point has been set, the rudder angle value stored for this point cannot be altered directly. Instead, the settings of an existing calibration point will be overwritten if a new point is added for exactly the same rudder angle value. The analogue in- or output values associated with a given calibration point, however, may be freely edited after the point has been set.

• When adding an output calibration point, all analogue outputs are set to provide a nominal 0 V signal at the respective rudder angle. Therefore, the indicated rudder angle must be read at all connected RAIs and the output values adjusted whenever an output calibration point is added.

• The largest port and starboard rudder angles for which input calibration points exist are taken as range limits for the RAC’s internal rudder scale. The angles transmitted at the analogue and the serial data outputs cannot exceed these limits. Therefore, input calibration points must be set at the hardover starboard and hardover port positions. It is recommended to use NFU control to position the rudder to the absolute mechanical limit when setting the hardover calibration points.

• The input polarity may be reversed by applying positive input voltages for port angles and negative voltages for starboard angles. Likewise, an output’s polarity may be reversed by generating positive output voltages for port angles and negative voltages for starboard angles. However, the in- and output voltages must ascend or descend steadily along the rudder angle range. In particular, the input signal curve may not exhibit peaks or troughs, as this would imply that the same input voltage could occur at different rudder angles.

In- and Output Calibration 6-15

056357/B RAIS

WAR NING

Note

Initial Calibration

As delivered from the factory, the RAC is not yet able to take up normal operation. At least three input and three output calibration points must be set to make the outputs become functional.

Sperry Marine recommends to carry out an initial calibration directly after the basic configuration parameters have been set. During this initial calibration, input calibration points are to be set at the hardover and midships rudder positions. Output calibration points are then to be set for the hardover and rudder midships indications. After this initial calibration, it is always possible to set further calibration points or to edit existing ones. Providing that the feedback unit has been carefully adjusted mechanically and that the RAIs do not exhibit severe non-linearities, the initial calibration should already result in sufficient calibration accuracy in many cases.

During a performance check according to ISO_20673, the angles shown by the RAIs will be recorded at every 5° for a ±45° steering gear and every 10° for a ±70° steering gear. To meet the required accuracy, the difference between the angles of the transmitter shaft (rudder stock) and the corresponding value shown at the RAIs is to be less than 1.5% of the indicators’ full scale value.

Should this accuracy not be attained after the initial calibration, additional calibration points need to be set. Errors affecting all outputs, including the serial data outputs, are corrected by setting additional input calibration points. Errors affecting individual analogue outputs only are corrected by setting additional output calibration points Such additional points may be set systematically at every 5° for a ±45° steering gear and every 10° for a ±70° steering gear. This ensures optimum calibration for the angles at which the accuracy is tested according to ISO_20673. Alternatively, it is also possible to determine the rudder angles where the largest errors occur and to set calibration points at exactly these angles. By repeating this procedure until the required accuracy is met, good results are achieved with as few calibration points as possible.

Risk of personal injury To calibrate the feedback input, the rudder has to be moved over its entire range. Always make sure that the steering gear is operative and that the rudder may be actuated safely without any risk of personal injury or damage to equipment, especially when the vessel is drydocked and works are carried out by shipyard personnel. Always inform the shipboard or shipyard personnel in charge of your intention to actuate the rudder and obtain permission to operate the steering gear for calibration purposes, before moving the rudder.

The calibration procedures require that tasks are carried out at different locations on the vessel. If possible, use voice communication to instruct one or more helpers to report the actual rudder angle indications as read from the rudder stock scale and indicated at the RAIs respectively.

6-16 In- and Output Calibration

RAIS 056357/B

To carry out the initial calibration:

1. If not already connected, connect to the RAC with SUSI now, as described in “Configuring the RAC with SUSI”, steps 1 through 12, starting on page 6-2.

2. Click on the “Calibration” tab of the Rudder Angle Calibrator application to enter the calibration page.

3. As the first part of the initial calibration, the feedback input is to be calibrated now.

In case the steering gear cannot be operated at this point in time, use the potentiometer supply and center tap potentials as dummy input signals (see “Input Calibration using Dummy Values” on page 6-24).

4. Put the rudder to the hardover port position.

5. Read the exact rudder angle from the rudder stock scale and enter it in the input calibration rudder angle control. You may edit the displayed angle directly or use the dial and spin controls to set it to the required value:

enter exact angle read

from rudder stock scale

Port angles must be entered as negative numbers, i. e. prefixed with a minus sign.

6. Click to set a new calibration point. The rudder angle and the corresponding internal A/D conversion value are now saved to runtime memory.

The calibration point index is incremented automatically. Upon saving a calibration point, all points are re-indexed. The point for the largest port angle is assigned index “1”, while the point for the largest starboard angle is assigned the index matching the total number of existing points.

7. Put the rudder to the midships position.

In- and Output Calibration 6-17

056357/B RAIS

8. Read the exact rudder angle from the rudder stock scale and enter it in the input calibration rudder angle control:

enter exact angle read

from rudder stock scale

9. Click to set a new calibration point.

10. Put the rudder to the hardover starboard position.

11. Read the exact rudder angle from the rudder stock scale and enter it in the input calibration rudder angle control:

enter exact angle read

from rudder stock scale

12. Click to set a new calibration point.

13. Check that all input calibration points have been stored correctly:

The calibration point index should now read “4”.

Scroll down the list of calibration points with the spin control and verify that:

– For points 1 to 3, the rudder angles displayed are those you

entered for the hardover and midships positions. The input controls will be greyed-out for the saved points.

– For each point, the number shown below the “Delete” and

“Save” button lies between 0 and 4095 and is largest for the hardover port and smallest for the hardover starboard value:

feedback signal

A/D conversion value

This number represents the 12-bit A/D conversion value of the input voltage, at the moment when the respective calibration point was saved.

6-18 In- and Output Calibration

RAIS 056357/B

Note

enter full scale port angle of connected RAIs

45 45

30

1515

0

RAI

adjust output for exact full-scale port indication

14. At least three output calibration points must be set now before the calibration page can be quit and the calibration settings are written to the RAC.

If no RAIs are connected to the RAC at this point in time, zero output values may be entered as a temporary measure, to be able to finish the initial calibration and transfer the calibration settings to the RAC. The RAC may not be taken into regular operation before all used outputs have been calibrated with the respective RAIs being installed at their proper locations.

15. Enter the RAI’s full scale port angle in the output calibration rudder angle control. In most cases, this will be the nominal hardover port angle, e. g. -45 or -70 degrees. You may edit the displayed angle directly or use the dial and spin controls to set it to the required value. Port angles must be entered as negative numbers, i. e. prefixed with a minus sign.

16. At the RAIs to calibrate, read the actual rudder angle indication. Adjust the output sliders in SUSI to bring the RAI’s indication to the exact full scale port value:

The numbers shown in the analogue output spin boxes are the 12-bit digital values fed to the D/A converters, to be converted into the analogue output voltages. Hereby, the number 0 represents the maximum possible positive output voltage (+15 V nominal) and 4095 represents the maximum possible negative output voltage (-15 V nominal). In case no RAIs are connected to the RAC at this point in time, leave all output settings at the default value of 2048.

17. Click to set a new calibration point. The rudder angle and the corresponding set of output values are now saved to runtime memory.

The calibration point index is incremented automatically. Upon saving a calibration point, all points are re-indexed. The point for the largest port angle is assigned index “1”, while the point for the largest starboard angle is assigned the index matching the total number of existing points.

18. Enter 0.0 in the output calibration rudder angle control.

19. At the RAIs to calibrate, read the actual rudder angle indication. Adjust the output sliders in SUSI to bring each RAI’s indication to rudder midships exactly:

In- and Output Calibration 6-19

056357/B RAIS

enter zero

(rudder midships)

45 45

30

1515

0

RAI

adjust output for exact rudder midships indication

45 45

30

1515

0

RAI

adjust output for exact full-scale stb. indication

enter full scale stb. angle of connected RAIs

In case no RAIs are connected to the RAC at this point in time, leave all output settings at the default value of 2048.

20. Click to set a new calibration point.

21. Enter the RAI’s full scale starboard angle in the output calibration rudder angle control.

22. Adjust the output sliders in SUSI to bring the RAI’s indication to the exact full scale starboard value:

In case no RAIs are connected to the RAC at this point in time, leave all output settings at the default value of 2048.

23. Click to set a new calibration point.

24. Check that all output calibration points have been stored correctly:

The calibration point index should now read “4”.

Scroll down the list of calibration points with the spin control and verify that:

– For points 1 to 3, the rudder angles displayed are those you

entered for the full scale and midships indications. The input controls will be greyed-out for the saved points.

– For each point, the calibrated RAIs indicate the respective rudder

angle exactly.

25. Click to quit the calibration page and write the calibration settings to the RAC.

If the above steps have been carried out with all components of the RAI system being operational, the initial calibration is now complete.

6-20 In- and Output Calibration

RAIS 056357/B

Note

In case dummy signals or zero values have been supplied during the inor output calibration, the RAC may not be taken into operation yet. The configuration of the unit is not complete before the input has been calibrated using the actual input signal from the feedback potentiometer and the outputs have been calibrated for the individual RAIs installed.

26. Carry out a first performance check now, to determine whether additional input and/or output calibration points need to be set. In particular, check the accuracy of the input calibration by comparing the angle read at the rudder stock scale with the angle indicated on the dial on the RAC application main page in SUSI.

27. If required, set additional input calibration points, applying one of the following strategies:

– Either, set points at every 5° for a ±45° steering gear and every

10° for a ±70° steering gear. This ensures optimum calibration for the angles at which the accuracy is tested according to ISO_20673.

– Or, determine the rudder angles where the largest errors occur

and set calibration points at exactly these angles. Repeat this procedure until the required accuracy is met. This ensures good calibration with as few calibration points as possible.

28. If required, set additional output calibration points to correct the errors in indication of the RAIs. While it is possible to set points systematically every 5° or 10°, this requires to adjust the output for every RAI at every point set. It will mostly suffice to set calibration points selectively at those indications where individual RAIs exhibit the largest error.

In- and Output Calibration 6-21

056357/B RAIS

Note

Adding, Editing and Deleting Calibration Points

After the initial calibration procedures, a performance check of the RAI system may reveal that the required calibration accuracy is not yet attained over the entire rudder angle range. This may happen especially if the feedback lever linkage is poorly aligned or the feedback unit’s shaft runs not exactly parallel to the rudder stock. It will then be required to set additional input calibration points or to alter the existing ones.

Once a calibration point has been set, the rudder angle stored for this point cannot be edited. Instead, an existing calibration point can be overwritten by adding a new point at exactly the same rudder angle. However, it is recommended to always delete an existing point first, before adding a new point at the same or nearly the same rudder angle.

To add input calibration points:

1. If not already connected, connect to the RAC with SUSI and enter the RAC application’s calibration page.

2. Put the rudder to the required angle.

3. Read the exact rudder angle from the rudder stock scale and enter it in the input calibration rudder angle control.

4. Click to add the new calibration point.

5. Repeat steps 2 to 4 above to set further additional calibration points, if necessary. In total, up to 73 points may be entered.

6. Click to write back the calibration settings to the RAC and quit the calibration page.

To add output calibration points:

1. If not already connected, connect to the RAC with SUSI and enter the RAC application’s calibration page.

2. Enter the desired true rudder angle in the output calibration rudder angle control.

3. At each RAI, read the actual rudder angle indication and adjust the corresponding output slider in SUSI to bring the RAI’s indication to the exact value entered in the output rudder angle control.

4. Click to add the new calibration point.

5. Repeat steps 2 to 4 above to set further additional calibration points, if required. In total, up to 73 points may be entered.

6. Click to write back the calibration settings to the RAC and quit the calibration page.

6-22 In- and Output Calibration

RAIS 056357/B

Note

To edit in- or output calibration points:

1. If not already connected, connect to the RAC with SUSI and enter the RAC application’s calibration page.

2. With the spin control, scroll down the list of existing calibration points to the point you wish to edit.

3. In case of an input calibration point:

– If the rudder can be positioned exactly to the angle where the

point has been set, position the rudder to this angle.

Click to save the edited point.

– If the rudder cannot be positioned exactly to the angle where the

point has been set, delete the existing point.

Position the rudder to an angle close to the previous one, then read the exact rudder angle from the rudder stock scale and enter it in the input calibration rudder angle control.

Click to save the newly set point.

In case of an output calibration point:

For all of the outputs you wish to edit, adjust the output slider to bring the respective RAI’s indication to the exact value where the calibration point has been set.

Click to save the edited point.

4. Repeat steps 2 to 3 above to edit further calibration points, if required.

5. Click to write back the calibration settings to the RAC and quit the calibration page.

To delete in- or output calibration points:

1. If not already connected, connect to the RAC with SUSI and enter the RAC application’s calibration page.

2. With the spin control, scroll down the list of existing calibration points to the point you wish to delete.

3. Click to delete the point.

4. Repeat steps 2 to 3 above to delete further calibration points, if required.

5. Click to write back the calibration settings to the RAC and quit the calibration page.

Make sure not to delete the calibration points for the hardover and midships rudder angles, unless you intend to directly add new points in their place. At least three points must remain set, otherwise it will not be possible to leave the calibration page by clicking “Finish”.

In- and Output Calibration 6-23

056357/B RAIS

Input Calibration using Dummy Values

In some installations, it may be required to carry out the output calibration before the input calibration. E. g., if the RAI system is installed and wired up, but the rudder cannot be actuated because the steering gear is not operational. As a temporary measure in such cases, the input may be calibrated using the feedback potentiometer supply and center tap potentials as input signals, instead of the actual feedback signal.

To calibrate the input using dummy values:

1. Disconnect the feedback unit from the RAC, TB 1.3 through 1.6 (refer to circuit diagram 5014-0115-01).

2. Proceed as if carrying out the initial input calibration (see “Initial Calibration” on page 6-16). However, instead of putting the rudder to the hardover and midships positions,

– shorten TB 1.4 to 1.5 to connect the negative feedback supply

potential to the input. Then, enter the nominal hardover port angle (e. g. -45 or -70 degrees) in the rudder angle control and

click to set the hardover port calibration point;

– shorten TB 1.4 to 1.6 to connect the feedback center tap potential

to the input. Then, enter a value of 0.0 degrees in the rudder

angle control and click to set the midships calibration point;

– shorten TB 1.4 to 1.3 to connect the positive feedback supply

potential to the input. Then, enter the nominal hardover starboard angle (e. g. 45 or 70 degrees) in the rudder angle control

and click to set the hardover starboard calibration point.

3. Re-connect the feedback unit to the RAC, TB 1.3 through 1.6.

6-24 In- and Output Calibration

RAIS 056357/B

DANGER

CAUTION

Chapter 7: Troubleshooting

Life danger through electrical shock Certain alarm devices may operate with hazardous voltages, switched by the alarm relay output contacts. NEVER connect live wires to the unit’s terminals, when wiring up the Rudder Angle Calibrator. ALWAYS make sure that any external device or power supply to be connected to the alarm relay outputs is de-energized and safeguarded against accidental switching-on.

Risk of damage of electrostatic-discharge-sensitive components The

Rudder Angle Calibrator contains electrostatic sensitive components.

Electrostatic discharge may permanently damage components. When configuring the electrostatic discharge. Avoid touching any of the electronic circuitry.

Rudder Angle Calibrator, take precautions to prevent

7.1 General Troubleshooting Instructions

The RAC is a complex electronic device. In case of malfunction, it would neither be practical nor economical to carry out troubleshooting and servicing in the field down to the level of individual circuit components. Defective units must be sent back to Sperry Marine for repair.

Field service personnel should limit troubleshooting to the basic checks given below.

• Visual inspection of mechanical components, the PCB and wiring.

• Continuity checks of wiring connections.

• Checks for short circuit or overload conditions or reversed polarity of the external supply powers.

• Checks of the on-board supply voltages and I/O signals and data. The presence of voltages, signals and data is indicated by diagnostic LEDs on the PCB. Exact voltage levels must be checked with a voltmeter. The data content on serial I/O lines must be checked with the aid of suitable analyzing tools, such as PC-based protocol interpreters or terminal programs.

• Software-aided troubleshooting using Sperry Marine’s SUSI application, if instructed accordingly by Sperry Marine.

General Troubleshooting Instructions 7-1

056357/B RAIS

TB 1 TB 2

CR 34 CR 20 CR 17 J 3 CR 4

CR 33 CR 29 CR 23 CR 16

CR 13

CR 12 CR 9CR 28

K 2

K 1

Location of Parts on the Rudder Angle Calibrator PCB

Figure 7-1 below shows the locations of connectors and diagnostic LED indicators on the RAC.

Figure 7-1:

Location of parts

on the RAC PCB

Terminal Boards and Connectors

Table 7-1:

Terminal boards

and connectors

TB 1 24 VDC supply power in, feedback unit supply out, feedback

TB 2 RAI signal and illumination outputs, RS-422 in, RS-422 out 1

J 3 USB service interface connector

Function

signal in, “Pwr. Fail. / Gen. Alarm” status relay out

and 2, “Spare” status relay out

Exchangeable Components

Table 7-2:

Exchangeable

components

Part Function

K 1 photocoupler/photo relay;

“Spare” status output contact closure

K 2 photocoupler/photo relay;

“Pwr. Fail / Gen. Alarm” status output contact closure

7-2 General Troubleshooting Instructions

RAIS 056357/B

Diagnostic LEDs

As an aid in troubleshooting, a number of diagnostic LED indicators are provided on the PCB. These indicate the presence of supply voltages, activities on the serial data I/O lines and the current states of the status output ports.

Table 7-3:

Diagnostic LEDs

LED Colour Indication

CR 4 green relay status output “Spare”; on = relay attracted

CR 9 green activity on RS-422 input

CR 12 green system mode/status indication:

CR 13 green

CR 16 green activity on RS-422 output 1

CR 17 green activity on RS-422 output 2

CR 20 green relay status output “Power Fail. / Gen. Alarm”;

CR 23 green on-board +5 VDC power present

CR 28 green on-board +15 VDC power present

CR 29 green on-board –15 VDC power present

CR 33 red reversed polarity 24 VDC supply power

CR 34 green 24 VDC supply power present

both flashing: power-up in progress both off: normal operation mode both on: error reading setup data

on = relay attracted

General Troubleshooting Instructions 7-3

056357/B RAIS

7-4 General Troubleshooting Instructions

RAIS 056357/B

DANGER

CAUTION

Note

Chapter 8: Corrective Maintenance

Life danger through electrical shock Certain alarm devices may operate with hazardous voltages, switched by the alarm relay output contacts. NEVER connect live wires to the unit’s terminals, when wiring up the Rudder Angle Calibrator. ALWAYS make sure that any external device or power supply to be connected to the alarm relay outputs is de-energized and safeguarded against accidental switching-on.

Risk of damage of electrostatic-discharge-sensitive components The

Rudder Angle Calibrator contains electrostatic sensitive components.

Electrostatic discharge may permanently damage components. When configuring the electrostatic discharge. Avoid touching any of the electronic circuitry.

The Rudder Angle Calibrator is generally not field-serviceable on the component level. Defective devices must be sent back to Sperry Marine for repair.

Rudder Angle Calibrator, take precautions to prevent

Maintenance by field service personnel is limited to the software-based configuration and update procedures supported by the Sperry Universal Software Instrument application (SUSI).

8.1 Updating the RAC Firmware with SUSI

Generally, it cannot be guaranteed that the Rudder Angle Calibrator’s parameter settings are left intact during a firmware update. Before updating firmware, record all parameter settings to be able to reenter them manually, if required. Calibration settings will not be touched when updating the firmware.

For recording all parameter settings see “Setup and Configuration Tables” in the appendix of this manual.

The RAC’s firmware may be updated in the field using SUSI. Being a newer device, the RAC supports the uploading of firmware files. This allows to selectively update either the actual RAC system software (“MCU-Application”) or the RAC’s bootloader (“MCU-Bootloader”).

Compared to overwriting (“flashing”) the memory, as necessary with older devices, the file upload is a much safer method to update a device’s firmware, as SUSI is able to validate the provided files before the upload. In case an upload should fail for any reason, the RAC will remain fully functional, continuing to run the previous firmware.

In case a new firmware is released for the RAC, authorized field service personnel will be provided with the required files upon request.

Updating the RAC Firmware with SUSI 8-1

056357/B RAIS

Firmware files issued by Sperry Marine will usually be named such that the filename identifies the device type and the firmware revision. The file extension used for firmware files is “.upd”.

To update the Rudder Angle Calibrator firmware:

1. If the RAC is currently powered up, switch off the power first.

2. Open the RAC housing and locate the USB service port receptacle, J3, on the PCB. Make sure that the port is freely accessible for plugging and unplugging the USB cable.

3. At the PC, start up the SUSI application.

A login dialog pops up:

4. You may either:

– Enter the PIN “20097”.

This will start up SUSI in the service mode.

Or:

– Leave the PIN empty.

This will start up SUSI in the “unknown login” mode. In this mode, you may update the RAC firmware, but will not be able to access the RAC’s configuration parameters without quitting and restarting SUSI in the service mode.

Click to continue.

5. SUSI’s main window now opens, with the “Application” tab displaying a list of supported devices:

6. Plug in the USB cable at the PC and at the RAC’s service port.

8-2 Updating the RAC Firmware with SUSI

RAIS 056357/B

7. Power up the RAC. The “Online” button should now become clickable (not greyed-out), indicating that SUSI has found a device to connect to:

The LED icon next to the button will remain grey, as no connection has been made yet.

8. Click to connect to the RAC. The LED icon should now change to orange and the status line should read “Connected with RAC Bootloader”.

Upon connecting, SUSI opens the update tab:

The update tab provides file browsers to select firmware update files for the Rudder Angle Calibrator’s system software (“MCU-Application”) and the RAC’s bootloader (“MCU-Bootloader”). The option to update program code for an FPGA (“FPGA-Application“) is greyed out, as the RAC does not contain an FPGA.

9. Depending on whether you intend to update the RAC’s MCU bootloader or its MCU application, click the respective button to call up the file open dialog. Then, navigate to the firmware update

file, select it in the dialog and click .

Updating the RAC Firmware with SUSI 8-3

056357/B RAIS

Note

The file open dialogue searches for files with the extension ”.upd” only. In case the update file has been given another extension for any reason, the filename, including the complete access path, must be entered manually in the respective text box of the update tab.

10. Click or respectively to initiate the actual file upload. The bargraph at the bottom of the screen indicates the progress of the update:

11. When the update is complete, unplug the USB cable at the PC and at the RAC’s service port.

12. The RAC now reboots with the new firmware.

8-4 Updating the RAC Firmware with SUSI

RAIS 056357/B

8.2 Replacing Alarm Output Relays

The alarm output relays, K1 and K2, are socketed solid state relays in a 6-pin DIL package. In case of failure, these components can easily be replaced against a new ones.

Both relays are photocoupler photo relays (TLP 598GA), available from Sperry Marine Hamburg upon request.

Replacing Alarm Output Relays 8-5

056357/B RAIS

8-6 Replacing Alarm Output Relays

RAIS 056357/B

Note

Abbreviations

The following list contains abbreviations and shortcuts used in this manual and in displayed text of CDU menus.

A

1x1 frame Standard frame 96x96 mm

6 step/° scale measure setting of servomotor

A/DO-160 Section A, DO-160E, Environmental Conditions and

Test Procedures for Airborne Equipment

ACK Acknowledge alarms

ADA Name of a Programming Language

AIS Automatic Identification System

ALR NMEA sentence for alarm status information

AMS Alarm Management System

ANSI American National Standards Institute

approx. Approximately

ARS Attitude Reference System

ASME American Society of Mechanical Engineers

AZ Azimuth

B

BD Baud

Bd. Baud

BIT Built In Test

BIU Bus interface unit

BSH German Federal Maritime and Hydrographic Agency

btl. Bottle

(BSH)

C

CCelsius

CA Correction Angles

CAB Compass Amplifier Board

CAU Compass Amplifier Unit

Abbreviations I

056357/B RAIS

CAL. Calibration

CAM Central Alert Management

cal. no. s. Calibration numbers

CCFL Cold Cathode Fluorescent Lamp

CCU Compass Controller Unit processor

CDU Control and Display Unit

CN CompassNet

CN Ringbus CompassNet Ethernet Bus

CNET CompassNet

COG Course over ground

COMP Compass

Comp. Mon. Compass monitor

CONST. Constant

contd. Continued

CORR. Correction

cos. Cosine

CR Carriage return

CSU Compass Sensor Unit processor

D

D00 D00 - D32 (D-Code, = Fault code)

DAC Digital analogue converter

DC Direct Current

D-Code Fault code (D00 - D32)

DDU Data Distribution Unit

DGPS Differential GPS (see also GPS)

dia. Diameter

diff. Difference

DIFF. Difference

DIM dimmer

DIN Deutsches Institut für Normung (German institute for

standardization)

Dnn D00 - D32 (D-Code, = Fault code)

II Abbreviations

RAIS 056357/B

DNV Det Norske Veritas

DNV Naut-AW Det Norske Veritas Class notation for enhanced nauti-

cal safety

DP Dynamic positioning

dwg. drawing

E

E. East

EC European Union Council

ECCN Export Control Classification Number

ECDIS Electronic Chart Display and Information System

EMC Environmental conditions

EM-Log Electromagnetic (speed) log

EN European Norm

ERR.STAT.BITS Validity check of fiber-optic sensor data status

ESD electrostatic discharge

ext. External

Ext. External

Ext. Sel. External selector switch

Ext Status In External status input port (TB 3.11)

F

FIU Fiber optic interface unit (synonym for IPSU)

FL Line filter

Flash Nonvolatile Memory

FMEA Failure mode effect analysis

FOG Fiber optic gyro

FPGA Field-programmable gate array

FRAM Ferro Electrical RAM (Non volatile RAM)

FU Follow up

Abbreviations III

056357/B RAIS

G

G1 Gyrocompass 1

G2 Gyrocompass 2

G/M headings Gyro /Magnetic headings

GAS Grounding avoidance system

Gen. General

GGA NMEA sentence which provides the GPS current fix

data.

GL Germanischer Lloyd

GLL Geographic position - latitude/longitude

GMDSS Global Maritime Distress and Safety System

Gnd Ground

GNSS Global Navigation Satellite System

GPS Global Positioning System

GPS/AIS Global Positioning System / Automatic Identification

System

GSR Gyrosphere service report

GT Gross tonnage

H

HCS Heading control system

HDG Heading, Magnetic

Hdg. Heading

hdg. Heading

Hdg. Diff Heading Difference Alarm

Hdg. Sel Heading selection; Selection of heading source device

Hdg. Sel. Heading selection

HDG/G Heading/Gyro

HDT Heading, True

HMS Heading management system

HSC High speed craft

HSC-2000 Class notation for high speed craft

HTC Heading track control command

IV Abbreviations

RAIS 056357/B

HTD Heading track control data

Hz Hertz

I

I/O Input/Output

IC Integrated circuit

ICD Interface Control Document

ID Identifier

IEC International Electro Technical Commission

IHO International hydrographic office.

IMO International Maritime Organization

IMU Inertial Measurement Unit

INS Integrated navigation system

INT HDG ONLY Internal heading only

INT/EXT HDG Internal or external heading

IP International Protection

IPD Illustrated Parts Data

IPL Illustrated Parts List

IPSU Interface and power supply unit

ISO International Organization for Standardization

J

J Jack (connector)

K

KF Kalman Filter

Kt. Knot

kt. Knot

L

LAT Latitude

Lat. Latitude

Abbreviations V

056357/B RAIS

lat. Latitude

LCD Liquid crystal display

LED Light Emitting Diode

LEHMK Lehmkuhl (transmission standard company Lehm-

kuhl)

LF Line feed

LFK Litef Faser Kreisel (Litef fiber optic gyroscope)

lon. Longitude

Lon. Longitude

LORAN Long Range Navigation

LORAN-C Long Range Navigation C

LSB Least significant Bit

M

Mag Magnetic

Mag Hdg. Inp. Magnetic heading input

MAGN. Magnet

Magn. Cal. Tab Magnetic compass calibration table

Magn. DEV Magnetic deviation

Magn. VAR Magnetic variation

MAN. Manually

MarED Marine Equipment Directive

max. Maximal

MED Marine Equipment Directive

MIN Minute

min Minute

min. Minimal

MMS Mechanical mode switch

Mod. Model

Mod. Modus

Mod. 10/2 Gyrocompass container model 10/2

Mod. 10/3 Gyrocompass container model 10/3

Mod. 7/2 Gyrocompass container model 7/2

VI Abbreviations

RAIS 056357/B

MSB Most significant Bit

MSC Maritime Safety Committee

MTBF Mean time between failure

N

N. North

NAUT-AW Class notation with augments requirements for bridge

congfiguration for ships largely operating largely in coastal and narrow waters

NAUT-HSC Class notation for high speed craft

NAUT-OC Class notation with fundamental requirements for

ships largely operating largely at high seas

NAUT-OSV Class notation with requirements for ships largely

operating as support vessels for various offshore operations.

Nav. Navigation

n.c. Normally closed

NC Normally closed

NFU None follow up

NG NAVIGAT

NG 100 NAVIGAT 100

NG 200 NAVIGAT 200

nm Nautic mile

NM Nautic mile

NMEA National Marine Electronics Association

NMEA NMEA format 4800 Bd

NMEA $--HDG NMEA $--HDG sentence

NMEA $--HDM NMEA $--HDM sentence

NMEA $--HDT NMEA $--HDT sentence

NMEA Sup.FAST SuperFAST serial data output

NMEA-GGA NMEA-GGA sentence

NMEA-GLL NMEA-GLL sentence

NMEA-HCHDG NMEA-HCHDG sentence

NMEA-HCHDM NMEA-HCHDM sentence

NMEA-HCHDT NMEA-HCHDT sentence

NMEA-HDG NMEA-HDG sentence

Abbreviations VII

056357/B RAIS

NMEA-HDM NMEA-HDM sentence

NMEA-RMA NMEA-RMA sentence

NMEA-RMC NMEA-RMC sentence

n.o. Normally open

NO Normally open

No. Number

NVR None Volatile RAM

O

Off Hdg Off heading alarm

OUTP Output

P

p. Pulse

P.Gnd Power ground

P/N Part number

PAL Pre-programmed IC

PCB Printed circuit board

PLATH Binary protocol of company C. Plath

PLCC Plastic leaded chip carrier

POS Position

POSITION N No position

PPE Personal protective equipment

PSU Power Supply Unit

PSR Product service report

Q

QUICC Quad Integrated Communications Controller

QUART Quad Universal Asynchronous Receiver and Transmit-

ter

VIII Abbreviations

RAIS 056357/B

R

RAC Rudder angle calibrator

RAFU Rudder angle feedback unit

RAI Rudder angle indicator

RAIs Rudder angle indicators

RAIS Rudder angle indicator system

RAM Random Access Memory

Ref. Voltage Reference voltage

RM Recommended minimum navigation information

RMA Recommended minimum navigation information

NMEA sentence A

RMB Recommended minimum navigation information

RMC Recommended minimum navigation information

RMS Root mean square

NMEA sentence B

NMEA sentence C

ROM Read Only Memory

ROR Rudder order status

ROT Rate of turn

ROTI Rate of turn indicator

rpm Revolutions per minute

RS-422 RS-422 serial data interface standard

RSA NMEA sentence for rudder set angle

RUD rudder angle graph

S

S. South

s Second

S/FAST M. Outp. Superfast / fast data output of magnetic heading

SAT-Log Satellite (speed) log

sc. Factor Scale factor

SCU Steering control unit

SEC Second

sec Second

SENS.D.M.OUTP. Output sentence format for magnetic heading at the

sensor data output

Abbreviations IX

056357/B RAIS

Sentence A self-contained line of data

SFA unit Steering failure alarm unit

sin. Sine

SMS Steering mode switch

SOG Speed over ground (actual measured speed of

advance of a vessel over the surface of the earth)

SOLAS Safety of life at sea

SoS Scope of supply

SOU Switch-over unit

SPEED N No speed

SRAM Static RAM

SRD Abbreviation for speed log

Stat. Status

stb. Starboard

STW Speed through water (ship's speed, as measured rela-

tive to the water).

SUSI Sperry universal service instrument

SVDR Simplified voyage data recorder

T

TB TB 3.11 (external input port)

TB Terminal block

THS True heading and status

THS Transmitting heading system

TMC Transmitting magnet compass

TMC function Transmitting magnet compass function

TSS1 TSS1 protocol; Heading, pitch, roll, and heave mes-

sage in the commonly used TSS1 message format

TTL Transistor-transistor-logic

TxD NMEA FAST Fast serial data output

U

UART Universal asynchronous receiver transmitter

UDR Universal digital repeater

X Abbreviations

RAIS 056357/B

UML Unified Modelling Language

USCG United states coast guard

V

VVolt

VAC Volt alternating current

VDC Volt direct current

VDR Voyage data recorder

VHW Water speed and heading

VMS Voyage management system

VMS/ECDIS Voyage management system / electronic chart display

and information system

VOSS Vessel optimization & safety system

Vpp. Voltage peak to peak

VTG Velocity through ground

VTS Vessel traffic service

W

WWatt

W. West

w. with

w/ with

W/DO-160 Section W, DO-160E, Environmental Conditions and

Test Procedures for Airborne Equipment

w/o without

X

X rate Roll rate

X/Y rates Roll and pitch rates

Y

Y rate Pitch rate

Abbreviations XI

056357/B RAIS

Z

Z/DO-160 Section Z, DO-160E, Environmental Conditions and

Test Procedures for Airborne Equipment

XII Abbreviations

RAIS 056357/B

Note

Appendix

The following documents and drawings are appended to this manual:

A Setup and Configuration Tables

Designation Drawing No.

RAC Setup table (blank form) 5014-0125-001

After installation of the Rudder Angle Calibrator, please return a filled-out copy of the Setup Table to Sperry Marine for inclusion in the ship’s file. When permanent changes are made to the system configuration, please return an updated copy of the Setup Table to Sperry Marine.

B Third party Documentation

Designation Drawing No.

Faiveley Mors Smitt Rudder Angle Indicators, Installation instructions

All content of the appended third party documentation is on behalf of the owners of the documentation. Sperry Marine is not responsible and not liable for any content of third party documentation. In case of doubt, verify the content of third party documentation with the owners of the documentation.

2017-07-03

056357/B RAIS

Note

CDrawings

Designation Drawing No.

RAC, Dimension Drawing 5014-0112-01

RAC, Circuit Diagram 5014-0115-01

Rudder Angle Feedback Unit, Dimension Drawing 4968-0112-01

Rudder Angle Feedback Unit, Option Linkage rod, Dimension Drawing

Rudder Angle Feedback Unit, Telemotor, Dimension Drawing

Rudder Angle Feedback Unit, Option Linkage Rod, Dimension Drawing

Rudder Angle Indicator System, Single Rudder, up to 6 indicators (Standard Connection Drawing)

Rudder Angle Indicator System, Single Rudder, more than 6 indicators (Standard Connection Drawing)

Rudder Angle Indicator System, Dual Rudder (Standard Connection Drawing)

All appended documents and drawings are revision-controlled separately at Sperry Marine. In case of doubt, verify the current revision status of the drawings with Sperry Marine. This manual’s revision status does not change when the revision of an appended document or drawing changes.

4968-0112-02

4968-0112-03

4968-0112-04

5014-0153-11

5014-0153-13

5014-0153-15

Rudder Angle Calibrator (RAC)

Setup Table

Vessel:

IMO No.:

Service Station / Installer: Date / Signature:

Hull No.:

Shipyard:

/

Installation Reference

RAC Serial Number:

Feedback Type

single rudder

Serial I/O

RS-422 In

Baudrate

4800 9600 38400

Location:

System Parameter Settings

starboard rudder

RS-422 Out 1

Baudrate

4800 9600 38400

Update Rate

Software Version:

port rudder

10 Hz 1 Hz

005014-0125-001/B; 26 Jun 2017; Page 1 of 4

Messages

RSA

CAUTION

Relay Setup

General Alarm

closed on no alarm closed on alarm

Messages

RSA

RS-422 Out 2

Baudrate

4800 9600 38400

Messages

RSA ALR

Risk of misusage The ALR sentence as serial output of the RAC is not therefore NOT allowed as system setting for a ship under wheelmark certiﬁcation Always make sure that the ALR sentence setting is INACTIVATED when the RAC is used on a ship under wheelmark certiﬁcation.

Spare

closed on no alarm closed on alarm

Update Rate

10 Hz 1 Hz

MED complaint and

Northrop Grumman Sperry Marine B.V. (Representative Office)

Woltmanstr. 19, 20097 Hamburg, Germany

Tel.: +49-40-29900-0, Fax: +49-40-29900-146, E-mail: [email protected]

Rudder Angle Calibrator (RAC)

Input Calibration Table

Setup Table

Rud. Angle

1

3 4

5 6

7 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

31 32

33 34

A/D Digits

Rud. Angle

2

A/D Digits

005014-0125-001/B; 26 Jun 2017; Page 2 of 4

35 36

37 38

39 40

41 42

43 44

45 46

47 48

49 50

51 52

53 54

55 56

57 58

59 60

61 62

63 64

65 66

67 68

69 70

71 72

73

Northrop Grumman Sperry Marine B.V. (Representative Office)

Woltmanstr. 19, 20097 Hamburg, Germany

Tel.: +49-40-29900-0, Fax: +49-40-29900-146, E-mail: [email protected]

Rudder Angle Calibrator (RAC)

Output Calibration Table

Setup Table

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

1

2

3

4

5

6

7

8

9

Rudder

Angle

Digits

Out 1

Digits Out 2

Digits

Out 3

Digits

Out 4

Digits

Out 5

Digits Out 6

005014-0125-001/B; 26 Jun 2017; Page 3 of 4

Northrop Grumman Sperry Marine B.V. (Representative Office)

Woltmanstr. 19, 20097 Hamburg, Germany

Tel.: +49-40-29900-0, Fax: +49-40-29900-146, E-mail: [email protected]

Rudder Angle Calibrator (RAC)

Setup Table

Output Calibration Table (continued)

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

Rudder

Angle

Digits

Out 1

Digits Out 2

Digits

Out 3

Digits

Out 4

Digits

Out 5

Digits Out 6

005014-0125-001/B; 26 Jun 2017; Page 4 of 4

Northrop Grumman Sperry Marine B.V. (Representative Office)

Woltmanstr. 19, 20097 Hamburg, Germany

Tel.: +49-40-29900-0, Fax: +49-40-29900-146, E-mail: [email protected]

Installation instructions

Rudder Angle Indication Systems

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 1

Console mounting:

Frontsize: 96x96:

060334-0000-000 Range ±45° 060335-0000-000 Range ±70°

Frontsize: 144x144:

060338-0000-000 Range ±45° 060339-0000-000 Range ±70°

Frontsize: 192x192:

060352-0000-000 Range ±45° 060353-0000-000 Range ±70°



060331-0000-000 Range ±45 060337-0000-000 Range ±70°

060340-0000-000 Range ±45° 060341-0000-000 Range ±70°

060354-0000-000 Range ±45° 060355-0000-000 Range ±70°



PANAMATYPE

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 2

Panel-cutout:

Frontsize: Dimensions (mm) “A” 96x96 92 144x144 138 192x192 186

+0.8

+1 +1

Mounting withe fastening clamp:

Mounting withe angleclamp:



Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 3

Zero adjustment:

At the back of the indicator is a small “screw”. Turn gently with a well-fitting screwdriver to left or right (max +/-30°) to adjust the pointer to zero on the scale.

Span adjustment: At the back of the meter is a small blue potentiometer.

This is intended for the adjustment of the span of the meter. Apply the signal and turn this pot to set the pointer on the desired position.

Terminals:

The instrument has four terminals for input 1 = + signal

2 = - signal 11 = illumination 12 = illumination.

The illumination has no preferred polarity. The min/max wires sizes are 0,14-2.5 mm

2

(26-14 AWG).

For solid or flexible wire.

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 4

Housing with bracket, built-in dimmer:

Scale 144x144mm:

060327-0000-000 Range ±45° 060328-0000-000 Range ±70°

Scale 192mmx192mm:

060357-0000-000 Range ±45° 060359-0000-000 Range ±70°

Drilling scheme:

Scale: Dimensions (mm) “A” “B” “C” “D” “E” “F” 144x144 235 60 125 117,5 62,5 11 192x192 284 60 174 142 87 11



060325-0000-000 Range ±45° 060326-0000-000 Range ±70°

060332-0000-000 Range ±45° 060362-0000-000 Range ±70°



PANAMATYPE



Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 5

Zero adjustment:

At the back of the indicator is a small “screw”. Turn gently with a well-fitting screwdriver to left or right (max +/-30°) to adjust the pointer to zero on the scale.

Span adjustment: At the back of the meter is a small blue potentiometer.

This is intended for the adjustment of the span of the meter. Apply the signal and turn this pot to set the pointer on the desired position.

Terminals:

The instrument has six terminals for input 1 = + signal

2 = - signal 11 = illumination 12 = illumination. 2 terminals for earth of the housing

The illumination has no preferred polarity. The min/max wires sizes are 0,14-2.5 mm For solid or flexible wire.

2

(26-14 AWG).

Cable glands:

The housing has two Cable glands Pg11 for cable diameter: 5-10mm



Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 6

Instructions for the exchange of the measuring instrument:

Tools you need: inbus 6mm, socket wrench 5,5mm, small screwdriver

Open the case (4x mm inbus bolt (hex key or Allen key))

BCI without cover

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Page 7

Erstellt: 06/17

Disconnect cable (blue -> 2; red -> 1; black -> 11, gray -> 12)

Instrument with disconnected cable

Disconnect the 8x screw which fixing the instrument (8x M3 screw and key)

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 8

Remove the instrument from the housing

Check the new instrument ( is the rubber seal present)

Put the new instrument in the housing

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Page 9

Erstellt: 06/17

8x screw which fixing the instrument (8x M3 screw and key 5,5mm)

connect cable (blue -> 2; red -> 1; black -> 11, gray -> 12)

close the case (4x mm inbus bolt (hex key or Allen key))

Finished!

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 10

Three-face panorama rudder angle indicator:

Scale 144x144mm:

060396-0000-000 Range ±45° 060397-0000-000 Range ±70°

Drilling scheme:

Ø6,5

0

4

Ø

8

37

Ø

°

0

2

1

Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 11

Zero adjustment:

Remove the plate with the dimmer potentiometer Turn gently with a well-fitting screwdriver the potentiometer “ZERO” to left or right to adjust the pointer to zero on the scale.

The instrument must be supplied with 24V! And the input to be set to zero

Span adjustment: Remove the plate with the dimmer potentiometer

Turn gently with a well-fitting screwdriver the potentiometer “SPAN1” (for PORT side) or “SPAN2” (for STBD side) to left or right to adjust the pointer to zero on the scale.

The instrument must be supplied with 24V! For span adjust PORT side apply full scale input as on label (e.g. -12V) For span adjust STBD side apply full scale input as on label (e.g. +12V)

Terminals:

The instrument has six terminals for input 1 = + signal

2 = - signal 11 = illumination 12 = illumination. 21 = + supply 24V 22 = - supply 24V.

The illumination has no preferred polarity. The min/max wires sizes are 0,14-2.5 mm For solid or flexible wire.

2

(26-14 AWG).

Cable glands:

The housing has two Cable glands Pg11 for cable diameter: 5-10mm Additional 1 place for a third Pg11



Index:

2017-07-03 installation instructions rudder angle indication systems.docx

Erstellt: 06/17

Page 12

Sperry Marine Rudder Angle Indicator System Operation, Installaion And Service Manual

Contents

Safety Instructions

Chapter 1: Introduction

1.1 System Description

Intended Use

Not Intended Use

1.2 Design and Main Features

1.3 Principle of Operation

1.4 RAIS Overview

System Components

1.5 RAIS Technical Data

1.6 Declaration of Conformity

Chapter 2: Operation

2.1 Normal Operational Mode

Chapter 3: Alarms System

3.1 Alarm Indication

Alarm Status Output

Serial Data Alarm Output

3.2 Alarm Numbers

3.3 Viewing RAC Errors through SUSI

Chapter 4: Scheduled Maintenance

4.1 Maintenance by Shipboard Personnel

4.2 Maintenance by Service Personnel

Chapter 5: Installation

5.1 Mechanical Installation

5.2 Electrical Installation

Rudder Angle Calibrator

Rudder Angle Feedback Unit Potentiometer

Chapter 6: System Configuration

6.1 Initial system configuration

Configuring the RAC with SUSI

6.2 System Parameters

Feedback Type

Serial I/O

Relay Setup

6.3 In- and Output Calibration

Input Calibration Table

Output Calibration Table

General Remarks on Calibration

Initial Calibration

Adding, Editing and Deleting Calibration Points

Input Calibration using Dummy Values

Chapter 7: Troubleshooting

7.1 General Troubleshooting Instructions

Location of Parts on the Rudder Angle Calibrator PCB

Terminal Boards and Connectors

Exchangeable Components

Diagnostic LEDs

Chapter 8: Corrective Maintenance

8.1 Updating the RAC Firmware with SUSI

8.2 Replacing Alarm Output Relays

Abbreviations

Appendix