Professional Documents
Culture Documents
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PREFACE ............................................................................................................................. 8
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1 SYSTEM ........................................................................................................................ 9
2 OPERATION................................................................................................................ 13
PREFACE
The monitoring and control system is developed in co-operation with our customers. We have
through many years had the opportunity to derive advantage from the immeasurable experience of
some of the world’s most influential operators. The system is designed to give the crew precise and
reliable information about the system status, as well as offering automatic functions that will enhance
the usability of the winch system.
Please Note:
Some of the screenshots and described functions may not apply on current installation.
The control system is in constant development.
This manual may cover functions not installed or applicable on current installation.
Software upgrades and additional functionality are available upon request.
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1 SYSTEM
1.1 System layout
The System is configured and operated from a Computer system, which hereafter is referred
to as a workstation .The workstation consists of a rugged display unit for displaying the
operating condition and data for the winch system, and a Marine Grade Computer. The
Display also functions as an input device enabling the operator to change system parameters
and operating modes. The actual presentation and contents of the display may differ from one
application to another, depending on which information is relevant to the specific application.
Mounted in
winch Chair
Canbus Canbus
WW1
Ethernet
Eth-switch
MSI
Monitor Features:
System Redundant • Built in features for error detection.
Interface Fiber optic • The system is easy to install.
ethernet • The system reduces the need for cabling to the Bridge.
• The systems functionality is expandable.
• Built in NMEA 0183 interface.
• Optional workstations may be installed.
• Optional VGA slave colour monitor may be installed.
Eth-switch
4 x Canbus
WA1 WIO1
1.2 Workstation
The workstation is basically a marine grade monitor, computer and pointing device. The
monitor is of high-resolution type and may be equipped with a user interface realized by a
touch screen or a trackball if preferred. A combination of touch screen and a trackball may
also be used. A Workstation may have several slave monitors connected to the same
computer and they all will display the same picture.
A system may also have several workstations, which is operated totally independent of each
other in respect to screen layout and input devices.
VGA Touch
Trackball
Ethernet Canbus
• LCD Monitor
Power 230VAC
VGA Video Input
RS232 Touch screen (option)
• Trackball
USB cable attached to trackball
• Controller
Size: 220x160x80 (WxHxD) mm
Power supply: 24VDC / dual
Interface: 2x USB, 2x LAN, 2xRS232, 4xCAN, 2xRS422/485, 3 relay outputs,PWM,
2xVGA, DVI.
Processor: NS Geode GX1 300 MHz, PC/104 based mainboard
Memory: 32-512MB (144 pin SO-DIMM SDRAM)
Storage: Compact Flash Type1 slot
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Speed Control
Tension Control
1.5 IO Interface
All connections to the winch system is done either via CAN Bus directly or via an Rolls-
Royce IO module. The IO Modules consists of a high-speed processing unit and terminals for
external connections.
I/O
Terminals
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2 OPERATION
This section describes the sub-systems to prepare, prior to actual operation of the winch. It
also contains general guidelines and precautions.
Please read this manual thorough. This gives You the best chance to be successful in winch
operations.
2.1.1 Precautions
Before starting any main pumps, one should always make sure that servo is running, brakes
are engaged, and that there are no open valves, filters etc due to maintenance work or other,
and that all personnel are alarmed against the danger of getting injured in chains, wires etc.
because of winches is now being used.
Before starting any pump or servo unit, make sure that no work is being carried out on winch
motors, pipes, valves or other part of the hydraulic systems!
All hydraulic pumps and servo units may be started and stopped by switches on starter
cabinets, but normal operation is remote controlled from bridge, by use of Touch Screen on
monitor for the TowCon RT control system or Winch operator chair.
Remember that the winch potentially could harm people if used wrongly, or out of
specification. Typically could a overload of the winch be dangerous. Please do not overload
or overspeed the winch motors. Overspeed could damage motors.
Please do not hesitate to contact the Rolls-Royce Service department if You are uncertain
regarding technical issues or need more information.
Contact Information:
Fax : +47 70 20 87 00
E-Mail: aftersales.brattvag@rolls-royce.com
HomePage: www.rolls-royce.com
Do also strive to follow Your company policy regarding safety on deck, safety for personnel,
and safety for ship and equipment.
On Setup canvas there is a section called Cable Lifter Type (see section below)
The winch will stop hauling when the allowed max pull is
reached.
Yet to be detailed.
All servo assisted remote controls need a servo pump/unit in service to operate continuously.
Servo units are found in the PUMPS canvas. (See section below)
2.1.4.2 Select Drum - Input Devices on Winch Chair and Bridge Panel
Drum selection is performed by cycling through drums, until wanted drum is shown in
display.
Winch motors are driven by low pressure pumps. Some pumps are directly connected to a
winch, while others is routed via change over valves or el non return valves, with
bidirectional or unidirectional flow. Flow of oil, is automated by a feature that is new on the
RT platform. (Last generation control system) This feature is called “Speed Step”
In short : Operator select the speed step to operate in. Blue bar indicates
how much of the total capacity that is wanted and Green bar indicates
how much of the total capacity that is actually feeding. “Speed Step” is
controlling the amount of pumps that are routed to a winch in a given
situation. Thus operator select desired speed range to adapt to
operational needs.
It is also possible to start and stop pumps in the “Pumps” tab. See screenshot above.
Starting a pump in “Pumps” tab will only start the pump, and does NOT control any
change over valves (Direction of oil flow from a pump).
The big difference in “wanting” a pump with “Speed Step” is the control of valves.
2.1.5.2 Valves
All remote operated valves are automatic controlled by the control system. Some pumps
could be dedicated to certain winches, thus the valves could be “locked” in a certain state.
See picture in section 2.1.5 above.
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2.1.6 Monitor pictures for operations
During winch operations there are tree monitor pictures available that’ll give the operator
read-out of what is happening on the winch. The first one “WINCH VIEW” gives you an
overview of the main winch, with active graphical elements to indicate the position of brake
and couplings.
Ex. If ‘TOW DRUM’ is coupled to ‘PORT MOTORSET’ the drum will adapt the colour of
the motor, which in this case is green. And if the band brake goes on it will be coloured red.
The couplings and brakes will move/change color according to their feedback sensor.
In addition to the winch layout the picture shows the drums tension end paid out length, both as bars
and digital readout. The bars change colors according to its state, red if its value is outside the set
maximum limit. The wire speed and motor RPM are shown only as digital readouts. Each motor-set
have indicators showing the number of active motor cells.
Screenshot above is for a 3-drum main winch with double drive capabilities.
Screenshot on next page is for a 2 drum main winch, with tension reading on the shark jaws
delivered from RRM.
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The ‘MAIN VIEW’ is the picture giving the user most information and possibilities for adjustment of
both manual and automatic operations on one main winch drum.
It gives the operator clear and concise information either in form of bars, as length and tension, but
also digital readout of secondary information such as wire speed, motor rpm and motor pressure. In
addition there are readout of oil temperature.
The drum selector enables the operator to easily switch the view between different drums, all data on
the screen will then of cause relate to the selected drum.
The full functionality will be described in detail later in the chapter concerning preparation for
operation.
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The ‘DUAL VIEW’ picture gives the operator a simultaneous view of two drums, as in the ‘MAIN
VIEW’ these pictures are selected by the operator. It contains the most important information about
the operation status and is intended for manual operations. If an automatic operation is desired the
‘MAIN VIEW’ gives the operator the ability to change critical parameters such as towing pressure
and operational mode.
This view normally covers all winches that has a feature that is controlled from screen.
E.g: A tugger have pressure indication on screen. Tugger is then selectable as a drum in either left or
right screen section.
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The ‘COMMAND’ screen gives the operator the ability to change command stations between bridge
and deck.
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The ‘PUMPS’ screen gives the operator overview over all remote controlled pumps and valves.
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The ‘SETUP’ screen contains all parameters that are operator adjustable.
This view will differ according to drum numbers and features installed.
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NOTE ! The operation of couplings are interlocked to brake. If brake is not ON, it is not
possible to move the coupling remotely.
Remote controlled couplings can be operated from device for speed or tension.
Operate by double-click on button for operation of coupling. The Input device must be “In
Command”
When the coupling position selector is operated, one of the adjacent control lamps will start
blinking.
It may be necessary to rotate motor to engage/disengage coupling.
The operator may choose to use more than one motor unit on the same drum, giving the drum
(double) more hoisting power. The coupling is operated from TowCon screen – Main View.
Normally, in double drive, 2 identical motorsets are connected. Therefore the name double
drive.
Operate coupling by pressing button on screen. When button is pressed, one of the adjacent
control lamps will start blinking. When the coupling is in right position, the control lamp will
be lit continuously. It may be necessary to rotate motor to engage/disengage coupling. If of
any reason one of the couplings should move from its decided position, the control lamp will
start blinking to alarm the operator.
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Select Drum or Cable Lifter:
REMEMBER!
This is a function that comprises manual cell control, display of tension order in %, display of
pressure on motor and automatic cell control as demanded by the control system.
The dotted lines in the Tension bar and in the Torque step bar
indicates actual tension order. Examples shows a drum with
400t max pull, given a system pressure at 60bars.
See section for torque step for more details about interaction between
Input device for tension and torque step function.
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Depending on the operation at hand there will be need for more or less speed,
the operator selects the desired speed by pressing either the up or down button
and the graph shows your desired speed (blue bar) and what you actually is
getting (green bar).
This function will automatically start/stop the necessary pumps and set the
changeover valves to their correct position. If you do not get the desired amount
of oil, it could be because the motor/manouver limits the amount of oil in the
current situation.
The dotted line in the green bar indicates position of manouver lever on motor. It is the actual
feedback from the motor. It is scaled as 0-100% of calibrated movement on lever, where 100%
equals dotted line in top of bar.
The bandbrakes is controlled from the device base. The parking brake symbol
shows where the button is located. See picture of base below.
Section of Device.
Example of button and lamps for operating brake on a
drum.
Drum selected is shown in display.
Observe:
Flashing Lamp = order not fulfilled!
Red light = Brake confirmed ON.
Green light = Brake confirmed OFF.
The drums equipped with remote controlled band brake can be operated from the Devices.
Please study instructions for emergency use of brakes on the name plate on Emergency Brake
Pump on winch. In case of leakage in servo pipes on Main winches, brakes will be engaged,
driven by an accumulator on the Emergency Brake Unit. Securing a minimum of brake force.
Other winches, not designed for emergency release functionality, will normally have spring
brake on, pressure off.
CAUTION!
DO NOT release brake when drum is not connected to motor unit!
Always evaluate load on winch before releasing brake!
2.2.1.6 Hoist
To haul in, pull lever firmly against you. Avoid too quick movements on control levers to
minimize stress on generators, pipes, pumps and other hydraulic equipment.
Releasing the lever will make the winch stop, as the lever automatically returns to stop
position.
OBSERVE:
Tension control set point is working in stop and hoist position of motor.
Please notice that it is necessary to have the Main Servo in service to operate as described
above.
2.2.1.7 Lower
To lower on winch, push lever firmly from you. Avoid too quick movements on control
levers to minimize stress on generators, pipes, pumps and other hydraulic equipment.
Releasing the lever will make the winch stop, as the lever automatically returns to stop
position.
OBSERVE:
When in lower MAX tension order is set to motor, regardless of tension set point from
operator.
Please notice that it is necessary to have the Main Servo in service to operate as described
above.
2.2.1.8 Rendering
The dotted lines in the Tension bar and in the Torque step bar
indicates actual tension order. Examples shows a drum with
400t max pull, given a system pressure at 60bars.
See section for torque step for more details about interaction between Input device for tension and torque step function.
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Rendering (continued) --- “Wire Length Limit”
Before starting to pay out wire or chain, operations as described in section 2.1 must be carried
out. Shooting may be done in two different ways; either lowering by use of the speed control,
or by reducing motors stalling force by the tension control until winch is rendering.
Please study users instructions for the remote control to get more information about this.
Often when paying out wire it is decided on beforehand what the wire-length is to be when
payout is completed. Of course the operator may look after this by constantly watching the
length bar graph and digital display on the monitor, but there is also a more pleasant way to
do this. By giving TOWCON the right information, the operator may get a warning when a
special wire length is reached, and thus do not have to pay too much attention to the monitor
screen during this operation.
EXAMPLE:
Wire length is to be 4800 metres when payout is completed, and towing
operation is to be carried out at that length.
Operator is preparing to pay out wire by use of the tension control. (Or
speed control) Because he’ll not be constantly watching the monitor
during payout of almost 3300 metres of wire, he is now adjusting the wire
length alarm limit to 4800 m.
Then he’ll adjust the tension control until winch starts to render, and when
the length limit is reached he’ll get an audible alarm from TOWCON in
time to concentrate merely on the winch before the determined towing
length is exceeded.
The length bar will now become red, when the alarm limit is
exceeded.
When towing length is reached, he’ll once again adjust the length alarm
limit to get a warning if the winch pays out too much during towing
operation. Normally just a few meters should suffice.
Hint: Length
Want to stop exactly at the metre?
Don’t bother the length bar graph,
but rather concentrate on the
Digital Length Display
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2.3 Automatic Towing Functions
This section will explain briefly what to be done before winch operations are executed.
Before starting any pumps, one should always make sure that brakes are engaged,
and that there are no open valves, filters etc due to maintenance work or other, and that all
personnel are alarmed against the danger of getting injured in chains, wires etc. because of
winches is now being used. Further information is to be found in Users Instructions for
Remote Control. Take special notice of all procedures concerning safety of crew and craft.
Be aware that there are certain restrictions attended with accessibility to automatic operations.
Detailed explanations about this are to be found in document section
describing the topical operation.
Do also pay attention to the limits for wire lengths possibly needed to be adjusted.
Select monitor picture PARAMETER to get access to these settings.
These parameters should always be checked before starting any automatic function.
Hint : “Auto/Manual-limit”
“Brake limit”
“Tow/Hoist limit”
In this part of manual adjustments of the pressure limits is essential. Please find more
information about use of the limits in the following examples. Illustration beneath indicates
adjustment of Pmax.
Click the “Down-arrow”-button decrease Pmax One click will decrease the value by one
bar. To increase the limit value just click on the “DOWN-arrow”-button.
In the opposite way clicking on the “UP-arrow” for Pmin will increase the Pmin limit.
Adjusting Ptow (Towing Pressure) is done simply by clicking the UP/Down buttons.
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“Shoot” is introduced to take off the winch operator’s hands the unpleasant job of lowering
maybe several hundred metres of wire. This might of course be done in the traditional,
manual way but why not let TowCon take care of it?
Remember that to get access to this function, wire must on beforehand be paid out to a length
at least equal to what’s set as Auto / Manual Limit for the current drum.
Please study both the example below and the “frequently asked questions” on next page.
Example:
Vessel is to pay out 700m of wire.
Auto/Manual limit is set to 140m.
Example:
Vessel is towing with fixed wire length at 800m and brake engaged. Tension in wire is not
allowed to exceed 180 tonnes, and must not be less than 120 tonnes. Wire length is to be
increased to 1000m.
Notice that the Tension Controller Indicator will move up and down on the Tension Bar Scale according to
more than one factor : Calculated maximum rendering force is dependent on wire-length, motor-pressure and
maybe even of how many motors being connected to the topic drum at the time
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FREQUENTLY ASKED QUESTIONS : AUTOMATIC “SHOOT”
Why isn’t TOWCON able to stop at the length, and winch continues to pay out?
You may have adjusted Towing Pressure too low, and if also maximum allowed pressure
Pmax is too low, winch doesn’t have enough power to pull in.
Check/adjust Towing Pressure and Pmax.
Brake Limit:
To be adjusted on monitor picture SETUP, to be adjusted by use of pop-up keypad,
used as braking-length in final sequence of automatic “SHOOT”
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In section 2.3.3 is described the advantages of dynamic towing compared to towing with
brake engaged. However, the winch operator doesn’t have to look after the towing length
himself as he has TOWCON. By giving TOWCON the right instructions it’ll do the job for
him.
On a set limit the system itself will start hoisting until wire length once more is at the
requested value. Like as for the automatic function “SHOOT” the automatic “TOWING”-
function is not either accessible unless wire length is at minimum equal to the Manual / Auto
Limit. As already mentioned in previous section, TOWCON may have swapped to automatic
“TOWING” because automatic payout has just been completed. However it is also possible to
select “TOWING” if system is in “MANUAL”-mode, the only condition is that wire length
must not exceed last adjusted Towing Length plus last adjusted Tow/Hoist Limit.
Please study both the example below and the “frequently asked questions” on next page.
Why isn’t TOWCON able to keep the length, and winch continues to pay out?
You may have adjusted Towing Pressure too low, and if also maximum allowed pressure
Pmax is too low, winch doesn’t have enough power to pull in.
Check/adjust Towing Pressure and Pmax.
Towing Pressure :
to be adjusted on pressure meter, Hint :
displayed as a black dot on the scale, Want to get a warning before winch
digital value visible when adjusting, starts to pull in ?
used when holding load during auto “TOWING”
Use the Wire Length Alarm to give
Pmax = maximum allowed pressure: you a caution. Adjust the alarm
to be adjusted on pressure meter, quite a little below the sum of
displayed as the left end of red area on scale, wanted Towing Length plus
digital value visible when adjusting, Towing Limit.
used when pulling in during auto “TOWING”
(also used in automatic “HOIST” )
Towing Length:
to be adjusted on Wire Length bar graph,
displayed as a horizontal, dotted black line on scale,
digital value visible when adjusting,
used as reference-length during auto “TOWING”
EXAMPLE:
Wire length is to be 2800 metres when shoot is completed, and towing operation is to be
carried out at that length.
First step should be to adjust the tension control until winch just starts to render to find the
minimum necessary pressure. Then, to secure that the winch is capable of holding the load
without rendering, the tension adjustment should be increased a little.
How much extra power to be calculated must be decided by the winch operator as a result of
his experience and know-how, regarding to the present towing conditions. As a default
setting may be used the measured pressure plus 15%.
In our example let’s say that the winch renders at about 25 Bar, and that pressure variation is
between 20 and 30 Bar. Operator estimates 32 Bar to be passable. The maximum pressure in
our example system is 48 Bar. So, roughly calculated the adjustment on tension knob, which
has a scale 0 – 100, should be somewhere between 60 and 70 is set to a little above 60.
When this is done, an alarm limit for motor pressure may be adjusted to get a warning each
time this limit is exceeded.
Click the “Down-arrow”-button decrease Pmax One click will decrease the value by one
bar. To increase the limit value just click on the “DOWN-arrow”-button.
In the opposite way clicking on the “UP-arrow” for Pmin will increase the Pmin limit.
Adjusting Ptow (Towing Pressure) is done simply by clicking the UP/Down buttons.
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2.3.3 Towing Static
During towing operation with engaged brake, the winch has no other strain restriction than
what is in the brake itself. Adjusting towing force must than be done by operation of the
vessel. The TOWCON system offers however the possibility of setting an alarm limit at a
certain load. An alarm will be given also if load exceeds this limit when brake is disengaged.
Example:
Vessel is supposed to be towing with fixed wire length.
Tension in wire is not allowed to exceed 280 tonnes.
Winch operator has adjusted wire length to agreed value and engaged the
brake. He wants TOWCON to give him a warning if wire tension
approaches the allowed maximum limit of 280 tonnes. To have some safety
margin he decides to set the alarm limit at 265 tonnes.
This is done by placing the cursor on the scale line between green and red
on the Tension Bar; and then drags the limit to the new alarm value.
This narrow part of the tension bar is also referred to as the “tension limit
bar” in this manual.
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2.3.4 Hoist
In other sections of this manual are described the great advantages TOWCON can offer
during towing and anchor-handling operations. Not mentioned in any other section is the
possibility of getting help when wire is to be pulled in. In fact, TOWCON can take care of the
hoisting operation on its own. Just tell the system what the new length should be, click the
“HOIST”-button and consider the job as done. Notice that there’s still a certain limitation:
you are not allowed to let the system hoist automatically unless there’s more than 100 metres
of wire remaining to be pulled in. System will stop hoisting when the Auto/Manual Limit is
reached;
and it’s not possible to adjust this limit to values lower than 100 m. In fact the automatic hoist
operation will always be stopped at the Auto/Manual Limit, so you may stop at any length you
wish, just by adjusting this limit.
Please study section 2.3.1 to learn more about limits- and parameter-settings.
Example :
Vessel has paid out a lot of wire during a towing operation, and all
this wire must now be spooled back on drum.
The present wire length is almost 2400 metres. Brake is not
engaged, and pressure in hydraulic motors is about 28 Bar.
Knowing that the winch will need more pressure to pull in the
same load as the drum is filled with wire, he adjusts the maximum
allowed pressure Pmax high enough to compensate for this. He
estimates that 35 Bars should do.
Why does TOWCON swap to “MANUAL” when there’s still much to pull in?
You may accidentally have adjusted Auto / Manual Limit to a high value.
Check/adjust Auto / Manual Limit.
Brake Limit:
This parameter decides how firmly the winch will stop when wire is paid out to a certain
length automatically by the “SHOOT” function. Value is to be entered in metres.
A long braking length will give a very firm stop, but it’ll take some more time. Too short
braking length may however give a rather brutal stop, especially if shoot speed is high.
TOWCON will use the braking length to increase pressure from being the shoot pressure
Pmin to being the on beforehand-adjusted Towing Pressure. Adjustment of this value must be
based on experience and skills of the crew.
Example:
Vessel is supposed to be towing with fixed wire length.
Tension in wire is not allowed to exceed 280 tonnes.
Winch operator has adjusted wire length to agreed value and engaged the
brake. He wants TOWCON to give him a warning if wire tension
approaches the allowed maximum limit of 280 tonnes. To have some
safety margin he decides to set the alarm limit at 265 tonnes.
This is done by placing the cursor on the scale line between green and red
on the Tension Bar; and then drags the limit to the new alarm value.
This narrow part of the tension bar is also referred to as the “tension limit
bar” in this manual.
Example:
Vessel is to set an anchor,
and will have to lower about 1800m.
Winch operator has adjusted tension and the winch is rendering at acceptable speed. As wire
is paid out the necessary load to make the winch render will increase.
To compensate this tension control will have to be continuous adjusted during the shoot. At
the same time load on wire caused by the vessels propulsion may vary, and will also influence
on the necessary rendering force on winch. As a result of this, the tension control may
accidentally be adjusted to low, and the rendering speed may exceed the maximum limit.
If the over speed protection system is activated it’s not a special pleasant event, because it
may cause a rather severe yank in the towing line. It should therefore be avoided as far as
possible by keeping a watchful eye on the tension settings.
2.4.3 Length
Manual pay-out --- “Wire Length Limit”
Before starting to pay out wire or chain, operations as described in section 2.1.2 must be
carried out. Shooting may be done in two different ways; either lowering by use of the speed
control, or by reducing motors stalling force by the tension control until winch is rendering.
Please study users instructions for the remote control to get more information about this.
Often when paying out wire it is decided on beforehand what the wire-length is to be when
payout is completed. Of course the operator may look after this by constantly watching the
length bar graph and digital display on the monitor, but there is also a more pleasant way to
do this. By giving TOWCON the right information, the operator may get a warning when a
special wire length is reached, and thus do not have to pay too much attention to the monitor
screen during this operation.
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EXAMPLE:
Wire length is to be 4800 metres when payout is completed, and towing
operation is to be carried out at that length.
Operator is preparing to pay out wire by use of the tension control. (Or
speed control) Because he’ll not be constantly watching the monitor
during payout of almost 3300 metres of wire, he is now adjusting the wire
length alarm limit to 4800 m.
Then he’ll adjust the tension control until winch starts to render, and when
the length limit is reached he’ll get an audible alarm from TOWCON in
time to concentrate merely on the winch before the determined towing
length is exceeded.
The length bar will now become red, when the alarm limit is
exceeded.
When towing length is reached, he’ll once again adjust the length alarm
limit to get a warning if the winch pays out too much during towing
operation. Normally just a few meters should suffice.
Hint: Length
Want to stop exactly at the metre?
Don’t bother the length bar graph,
but rather concentrate on the
Digital Length Display
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Measuring wire length (Length continued)
All calculations TOWCON executes are dependent on the few basic parameters concerning
wire data. These parameters may be individual for wire on each drum, and they are available
by selecting monitor picture PARAMETERS.
It’s of coarse no problem to adjust all parameters needed to calculate wire length correct when
they are known. But what is to be done when you don’t know the wire length? Entering a
faulty value as wire length will most likely have influence also on tension calculations.
Following example will give some hints of how to deal with such problems.
Example :
Vessel has to take onboard an unknown length of wire, which later on is to be paid out again
when placing a buoy. All that’s known about wire is that diameter is 76mm, and that length
can’t possibly be more than 2400 metres. Most likely length is something between 2000 and
2300 metres. First part of wire is already spooled up on Stb Common-Handling Drum. About
5 turns on first layer is now on drum.
Actual length=3000-978=2022m
When wire now later on is paid out, length will be displayed correctly
as contents on drum shrinks. Digital display and Length Bar will
indicate length of wire paid out.
Please observe:
TOWCON doesn’t know anything about the outer
diameter of the drums. This means that the estimated
wire length may be adjusted much longer than what
As the Stb CH –picture shows up on the drum actually can take.
the monitor screen he can see that So you don’t have to estimate length very carefully,
wire length display indicates 0 just decide on a length that you are sure is too long.
metres. This is correct because all
wire now is spooled up on the drum
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2.4.4 Temperature
2.4.5 Trend
Notice that alarm limits (red area of the narrow Bar Graph to the left of Trend Display) may
be adjusted both on Trend Displays and on other Bar Graphs or Meters. Adjusting limit on
one of these devices will cause the limit to be corrected also on all the others.
Example :
Vessel has been towing for a period with brake engaged to keep the wire length fixed.
Now the winch operator is told to concentrate on avoiding heavy jerks in wire.
It is however not necessary to keep the length fixed any longer.
During towing operation with disengaged brake one will derive advantage from the low-
pressure hydraulics’ special quality of being a strain restrictive braking device.
If pressure in hydraulic motors exceeds a certain limit the winch will render,
and in this way it’s possible to control how powerful the winch should be.
Winch operator may then look at the trend display showing how the tension has varied the
last minutes to get an idea of the holding power the winch motors will have to cope with.
He’ll then be able to adjust tension according to this before releasing the brake.
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2.4.6 Coupling
See screen example below. The “picture” is taken from the Winches tab in TowCon.
It shows the status for couplings and brakes for the main winch. The motors and shaft turns
green when the motor is fed by a pump. WRK PRT is shown engaged, with motor ready for
operation and with brake engaged. The coupling at top of WRK PRT is the double drive
coupling. The double drive coupling is shown in passive state.
It shows the status for drum 0 – A.H. (Anchor Handling Drum). The coupling is engaged and
the brake is on.
The status for couplings and brakes are also shown on the input devices.
2.4.7 Brake
Example :
Vessel is to keep a specified distance to the object it’s towing, and the winch operator has engaged
the brake.
Suddenly a hose on the brake cylinder blows, servo oil is flushed out on deck; and level in oil
reservoir on servo unit decreases in a short time to a minimum.
Because the hose blew, servo pump couldn’t maintain pressure in servo system. TOWCON detected
this and activated the audible alarm. Winch operator changed to the picture
“ALARMS” to see what was wrong, and pressed Alarm Reset –button. He found the message LOW
BRAKE PRESSURE, but didn’t stop servo pump unit. Then he got a new alarm, LOW OIL LEVEL
- MAIN SERVO. He’d had to press the Alarm Reset button once more to get rid off the audible
alarm given because of the oil level. Before so is done, the explaining text will be red. On the
monitor picture in our example we can see that there also was an alarm earlier the same day, because
someone activated Emergency Stop. That situation has obviously been clarified, because the text has
turned to grey.
By pressing the ALARM tab at top of the screen the picture changes to the alarm folder where
alarms are shown, both currenent and past. The alarms have 3 different statuses differentiated
by color.
Red alarms are new alarms not yet acknowledged.
Yellow alarms are acknowledged by user but the situation is not resolved.
Gray alarms are acknowledged by the user and is no longer valid.
All alarms recorded and kept on the screen until they disappear at the bottom of the alarm
window.
In addition to the alarms mentioned in the following chapters a Towcon system may have
several customer specific alarms.
Alarm lamp
The alarm lamp turns Red as soon as an alarm situation has occurred. And switches to Green
as soon as the operator have pressed the reset alarm button. This is basically to inform the
operator that there is a new alarm situation that needs his attention.
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Maxvalue logging
The system is also equipped with an internal logging system that keeps track of the maximum
pressures, speeds and temperatures of the systems winches.
2.4.8.3 Overspeed
There is three different overspeed limits. Prewarning which is the adjusted hi limit on the rpm
dial. Hi and HiHi limits is factory preset depending on type of motor is used. The three
different alarms produce individual texts in the alarm picture so they can easily be separated.
The Hi and HiHi alarms may also on some systems activate rpm slowdown or system
shutdown functions.
Insert a USB stick into any of the USB ports on the workstation controller on the bridge. After 1-2
seconds the following dialog box is displayed on the main screen. It shows the number of available
log files and how much disk space they require. Press the OK button to transfer the log files to the
USB stick, or the Cancel button to abort the operation.
If the OK button is pressed the log files will be transferred to the USB stick. The progress of each file
is displayed on the screen.
The following message is displayed when the log files have been transferred to the USB stick. Press
the OK button to close it.
The log files are now removed from the workstation controller and stored on the USB stick in a
folder called yyyy.mm.dd_hh.mm_Logs, where yyyy.mm.dd and hh.mm is the current date and time.
For example 2006.08.30_15.30_Logs.
If there is no log files available the following message is displayed. Press the Cancel button to close
it. Then remove the USB stick.
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If there is not enough free space on the USB stick to hold the log files the following message is
displayed. In this case none of the log files are transferred to the USB stick. Remove files from the
USB stick to make room for the log files. Then reinsert the USB stick in the workstation controller to
retry the operation.
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Then just one click on the left Red Hand is needed to get you online!
In the SETUP picture contains also the monitors day / night adjustments, these are presented
as % where 0% is almost black and 100% is full intensity. 100% gives the best contrast and
readability during daytime and approximately 25% gives a suitable intensity for nighttime.
In addition the disabling of the touch screen is located here, this mode gives the operator the
ability to clean the LCD screen without unintentionally activating system functions. This is a
time limited operation and times out in 30 sec. The count is clearly visible on the screen.
The light intensity on all input devices ( Joystick and Tension controllers) connected to the
workstation are controlled from this picture. The alphanumeric display and the indication
led’s have separate adjustments, as for the mains LCD, are the intensity levels given in % , 0
being the lowest and 100 the highest intensity.
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Example 1 :
Vessel is to pull in a 100 mm rig chain. It’s essential to know how much chain that’s being
pulled in. Cable Lifter is already mounted on Stb Common-handling drum and the first few Select
links has been pulled in. Cable lifter
Before starting to pull in and meassure the rig chain operator’ll have to choose the rigth pitch
diameter and enter this in the parameter settings for the topical winch.
First of all the winch operator selects the monitor picture for Stb CH –Drum and clicks on
the ”CAB”-button. Then he selects the monitor picture PARAMETERS to adjust the pitch
diameter. He finds the pitch diameter in the table on the ”Rig Chain Data”-panel, and enters
this into the ”Cable lifter diam”-box belonging to the Stb CH Winch. Next step is to enter 0
(zero) in the”Wire Length Out” –box. Then ”RESET LENGTH” must be clicked to tell TOWCON to start using
the new values. ( ”Wire diameter” and “Wire length” will now not be used, so what’s ever displayed in this box
doesn’t matter )
more about this example on next page …..
NOTE ! Always remember to enter correct length and press RESET LENGTH, when changing
between drum and cable lifter. The button is found in the Setup-tab. There is one button for
each drum/cable lifter.
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Remember to click
”Reset Length”
each time Length Out
has been corrected.
Winch operator now selects the monitor picture for Stb CH Drum, and starts the pull-in operation When pull-in
of chain stops, the digital display shows 345m.
Operator swaps to PARAMETER picture and re-adjusts the ”Wire length out” value. To enter the correct length
operator now has to add the first part of chain ( 15m ) that were pulled in before measuring started. Measuring is
now completed, and length indicated on monitor screen will show how much chain is pulled in.
Chain :
Pulled in before Reset :
about 15 m.
Meassured : 345 m
Winch operator is aware of the limitation on this special winch to be just 370
Tonnes when operating with this chain dimension.
To be on the safe side he wants an alarm if tension of any reason should approach
to even levels far beneath this. In fact he don’t expect tension to exceed 250
tonnes, so he decides to adjust the tension alarm to just 230 tonnes.
If this limit is exceeded he’ll get an audible alarm as well as the Tension Bar
being red on his monitor picture.
All calculations TOWCON executes are dependent on the few basic parameters concerning
wire data. These parameters may be individual for wire on each drum, and they are available
by selecting monitor picture SETUP.
Before starting any pumps, one should always make sure that brakes are engaged, and that there are
no open valves, filters etc due to maintenance work or other, and that all personnel are alarmed
against the danger of getting injured in chains, wires etc. because of winches is now being used.
“Chapter 3” of the manual gives a step-by-step briefing on how to operate the main parts of the
winch installation. It does not cover maintenance or service work.
Please read carefully the complete manual to gain as much confidence with the equipment as
possible. Please do practice winch operation before actually applying load on the winch.
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Before starting any pump or servo unit, make sure that no work is being carried out on winch motors,
pipes, valves or other part of the hydraulic systems!
All hydraulic pumps and servo units may be started and stopped by switches on starter cabinets, but
normal operation is remote controlled from bridge, by use of Touch Screen on monitor for the
TowCon RT control system or Winch operator chair.
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On most vessels were TOWCON is the winch monitoring system, remote start of Servo Units
and Hydraulic Pump Units is only executed by this system. Of course operating switches on
the starter cabinets still may start all pumps, and the Emergency Stop system will always be in
function.
Example: Picture for monitoring and manual operation of the hydraulic pumps.
Pump number.
Start button with RUN indication.
Stop button.
Disable button.
Pump Number:
The number refers to the pump number on the hydraulic Piping Diagram.
To start the pump, just click on the button. (See User control section 3.1/3.2)
This will start the pump. When the pump are running, the background on the button will be
green. Note that this is a manual operation, so the valves will not be operated automatically.
So the pump will be directed according to current position of the valves.
We recommend to use the Speed Step function to start the pumps.
Stop button:
To stop the pump, just click on the button. (See User control section 3.1/3.2)
The background of the “Start button” will be grey when the pump are not running.
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Disable button:
To disable the pump, just click on the button. (See User control section 3.1/3.2)
The background of the button will turn to red. The stop signal to the starter will be activated
continuously, and the automatic functions such as Speed Step will ignore the actual pump as
long as it is disabled.
This table shows what winches each pump can be directed to.
Eksample:
Pump 23 can be directed to Main winch and Secondary Port.
AUTO:
When this button is pressed/lit, the servo will start automatically when one or more devices in the
control system requires servo oil to operate. Typical if operator wants to operate the spooling devices,
the servo will start automatically when a LP pump for a spooling device is started. When pressing
AUTO, the “Long Time Towing” will be reset. A given time after last request for servo oil is
removed, the servo unit will stop.
START:
When pushing the “Start”-button servo unit will start necessary pumps to maintain a minimum servo
pressure. Pressing “Start” will force “Auto” and “Long Time Towing” to be reset.
STOP:
When pushing the “Stop”-button all servo pumps on unit will stop. “Auto” and “Long Time Towing”
will be reset.
P1/P2 RUN:
Running feedback from each pump on a servo unit. A typical main servo for an anchor handling
winch is always equipped with two pumps, 1 normally operating in standby.
P1/P2 TRIP:
If the motor protection on a servo pump motor is activated, a red lamp will indicate the “fault”.
Depending on safety scheme on vessel, operational demands etc, it may be necessary to have the
possibility to control a winch from other locations than the control devices on bridge.
Command Allocation is monitored and controlled by a special picture on the TOWCON Monitor.
An example of this is shown below. On the screen it is possible to select operation of a winch either
from bridge or from deck. In addition to this it may also be more than one control device for a
particular winch both on the bridge and on deck. As an example it may be possible to control a winch
both by a joystick on the Bridge Control Panel and by a joystick on the Winch Control Chair; and in
addition to this it may also be possible to control this by use of a Portable Controller. By use of
touch screen on monitor it is possible to allocate command to Deck, but personnel on Bridge can at
any time take over.
Be aware of :
A winch may be operated from several locations, but it may be that all functions can’t be controlled
from all control stands. What functions that may be operated by each control stand is shown on the
monitor picture COMMAND. A yellow indicator shows that a function can be operated by use of a
Deck Controller ( normally a portable control unit ) Blue indicators show that a function can be
controlled by equipment on bridge. Be aware that even if command has been allocated to deck, there
may be functions on a winch that still must be controlled from bridge.
Please study example below :
Example shows :
Command is allocated to Deck System, but
control devices for use on deck can only
operate hoist/lower functions. Tension and
Speed Steps on Tugger Winches must still be
controlled by use of devices placed on bridge.
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After a longer standstill there might be need for lubrication of gears. The Force
Lubrication button activates an automatic lubrication cycle.
(See section for Forced Lubrication for more details.)
Depending on the operation at hand there will be need for more or less speed,
the operator selects the desired speed by pressing either the up or down button
and the graph shows your desired speed (blue bar) and what you actually is
getting (green bar).
(See section for speed step for more details.)
This function controls the number of active hydraulic chambers in the motor.
To decrease torque step, the tension setpoint has to be >95%.
Normally a motor operates with all three chambers activated, this gives
maximum torque on the shaft. The Increase/Decrease buttons are used to change
the number of active chambers.
(See section for torque step for more details.)
On the winch chair the speed levers controls what drum to monitor and control on screen. The
difference is easily spotted. The screen selectors are removed, compared to TowCon screen.
Drum selection is performed by “cycling drums”, until wanted drum is shown in display.
“Cycling” is done simply by pressing the + or ÷ buttons. Selectable drums will then be shown on the
display, but this is not possible unless controlled device is “Stand By”. When control device is
“Stand By” there is a yellow light on the “Activate”-button, and functions normally controlled by the
device will not be affected by buttons being pressed or joystick movement. Do not try to “cycle
drums” when there is a blue light on the “Activate”-button! When device is activated the + and ÷
buttons is used to control torque step on winch motors.
“Command”-button
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The drums equipped with band brake can be remote operated from the Devices. These brakes may
also be manually operated at the winch, but that opportunity is normally not used under ordinary
circumstances. Please study instructions for emergency use of brakes on the name plate on
Emergency Brake Pump on winch. In case of leakage in servo pipes on Main winches, brakes will be
engaged by a accumulator on the Emergency Brake Unit, securing a minimum of brake force. Other
winches, not designed for emergency release functionality, will normally have spring brake on,
pressure off.
Please spend some time to study how the emergency systems works before releasing brakes by use of
remote control. Before releasing any brake, be sure about the precautions mentioned in chapter 1.1
concerning security of crew is carried out.
Section of Device.
Observe:
Flashing Lamp = order not fulfilled!
Red light = Brake confirmed ON.
Green light = Brake confirmed OFF.
Brake is operated by a button with integrated control lamps on the left side of the Input device.
Operate brake from ON to OFF: (Red light is lit, green in dark.)
Operate brake by double-clicking the button.
The green lamp will now start blinking, and after a few seconds it will light continuously, indicating
that brake now is completely released. The red light will be dark.
Operate brake from OFF to ON:
Operate brake by double-clicking the button.
The red lamp will now start blinking, and after a few seconds it will light continuously,
indicating fully engaged brake. Green light will be dark.
CAUTION!
It is inadvisable to release brake when drum is not connected to motor unit!
Always evaluate load on winch before releasing brake!
Remote controlled couplings can be operated from device for speed or tension.
Operate by double-click on button for operation of coupling. The Input device must be “In
Command”
When the coupling position selector is operated, one of the adjacent control lamps will start blinking.
It may be necessary to rotate motor to engage/disengage coupling.
When the coupling is in right position, the control lamp will light continuously.
Section of Device showing coupling confirmed engaged. Green light in lower section of
button is lit with a green colour.
Indication glowing continuous indicates actual state. Blinking indication indicates wanted
state. Red light indicates coupling out, or in progress to go out.
NOTE ! The operation of couplings are interlocked to brake. If brake is not ON, it is not
possible to move the coupling remotely.
Coupling, engaged.
Operate coupling by pressing button on screen. When button is pressed, one of the adjacent control
lamps will start blinking. When the coupling is in right position, the control lamp will be lit
continuously. It may be necessary to rotate motor to engage/disengage coupling. If of any reason one
of the couplings should move from its decided position, the control lamp will start blinking to alarm
the operator.
Section of Control Panel. (OLDER SYSTEMS)
Illustration only!
Please observe
It is not possible to disengage the drum coupling for any of the drums if the brake is released.
If interlock is active the request of operation will be ignored.
If for any reason one of the couplings should move from its decided position, the topical control lamp
will start blinking to alarm the operator.
Operating more than one drum in double drive will generate an alarm in the system
It may be necessary to rotate motor to engage/disengage coupling.
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On newer systems the double drive couplings is named Shaft Couplings. It results in the same , but is
named by function on shaft, rather than function on system.
The environment where the couplings are operated is intuitive and easily operated. When operator
has the “whole” picture, it is more likely to operate the shaft couplings correctly.
CAUTION!
Disengage drum coupling when towing with brake on!
Take precautions not to exceed specified max-load on cable lifters!
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Depending on the operation at hand there will be need for more or less speed,
the operator selects the desired speed by pressing either the up or down button
and the graph shows your desired speed (blue bar) and what you actually is
getting (green bar).
This function will automatically start/stop the necessary pumps and set the
changeover valves to their correct position. If you do not get the desired amount
of oil, it could be because the motor/manouver limits the amount of oil in the
current situation.
The dotted line in the green bar indicates position of manouver lever on motor. It is the actual
feedback from the motor. It is scaled as 0-100% of calibrated movement on lever, where 100%
equals dotted line in top of bar.
Example of situation where the motor/manouver valve is limiting the amount of oil:
The operator wants full speed on the winch, and clicks on the up button until the blue bar are
completely blue. At this point the manouver valve are in stop position, and the manouver valve can
only handle half of the desired oil rate in this situation. Then the green bar will be green half way up,
and the rest of the oil are directed away from the motor.
The operator start hoisting and the manouver valve comes into fully hoist position, in this situation
the manouver valve can handle all the desired oil. The rest of the oil will then be automatically
directed to the motor, and the green bar will be completely green.
The pressure in the motor have to be less than 66% to be able to decrease number of active chambers,
this is to prevent the drum to pay out caused by reduced torque on the shaft. The black arrows the
buttons/green light in base, indicates that it is possible to decrease/increase.
Here are some figures on how the number of active chambers affects the motor:
3 active chambers gives: nominal speed nominal torque
2 active chamber gives approx.: 1,5 x nominal speed 0,67 x nominal torque
1 active chamber gives approx.: 3 x nominal speed 0,33 x nominal torque
The system is constantly monitoring the cells and denies any requests that might strain the motors
above its specification.
The dotted lines in the Tension bar and in the Torque step bar
indicates actual tension order. Examples shows a drum with
400t max pull, given a system pressure at 60bars.
See section for torque step for more details about interaction between Input device for tension and torque step function.
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Motors equipped with remote controlled capabilities can be can be remote operated from an Device
for speed or by radio/cable control.
It is always possible to operate a motor by opening the bypass-throttle on the motor, and moving the
lever manually. On big winches this can be very heavy.
To pay out, push lever firmly ahead. To haul in, pull lever firmly against you. Avoid too quick
movements on control levers to minimize stress on generators, pipes, pumps and other hydraulic
equipment, and to make winch operations as little “noisy” as possible.
Releasing the lever will make the winch stop, as the lever automatically returns to stop position.
Please notice that it is necessary to have the Main Servo in service to operate as described above.
Before rotating any winch, be sure about the precautions mentioned in chapter concerning security of
crew is carried out.
The spooling devices are operated by moving joystick left/right, and by use of two push buttons on aft
top section of joystick. This makes it possible to operate both Hoist/Lower and spooling at the same
time by using only one hand. Necessary pumps are automatically started when operating a device.
A given time after last spool operation the pumps will be stopped automatically. This time is set to 15
min as of today.
Select which drum to operate by cycling through the drum by pressing (+) or (-) on Input device base.
When correct drum name is shown in display, double-click on “Command”. When blue light “in
command” is lit, joystick is ready for spooling operation.
Joystick
Select
spooling roll
(+) INC-button
(-) DEC-button
Command button
Selected drum
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Even though this system is automatic it is necessary to check the amount of grease on the wheels
before every winch operation. This must be done by manual inspection because the system has no
sensors that can verify that grease is in fact applied to the wheels and is not squeezed out through a
damaged pipe, or that something else has made the system failing. There are inspection lids on all
gear covers.
If inspection unveils lack of grease, extra lubrication must be supplied by manual override of the
automatic function. Push the “Force Lubrication” –button on the TowCon or Winch chair monitor.
Grease will now be supplied continuously until drum has rotated one turn. The “Force Lub.”- button
will glow when grease lubrication system actually injects grease.. The “Force Lubrication” period
cannot be interrupted from the remote control, but the function will be aborted if drum is stopped.
The control lamp on panel will be shut off immediately if the period is ended or the function of any
reason is aborted.
The lamp on the “Force Lubrication”-button will be lit when grease is applied to one of the wheels.
Please observe this control lamp during winch operation to be sure that system is in order. If one of
the drums is rotating for longer periods without this lamp being lit there is reason to suspect that
there is a malfunction in the lubrication system, and tooth wheels must immediately be inspected.
Alarm ”Grease lubrication System xxx – winch xxx – Grease supply failing” will be set off on
TowCon screen if grease level in reservoir gets low. Action must immediately be taken to refill the
tank or unveil any fault in the system.
On the Lubrication Cabinet on winch is to be found the same control lamps that are described above,
and there is also a “Force Lubrication”-switch inside the cabinet. Be aware that pushing this button
will not give continuously greasing for more than one turn of the rotating wheel.
CAUTION!
The automatic lubrication system can fail. For this reason always check the gear transmission
visually to verify that the teeth are covered with grease.
The winch must never run without grease on gearwheels. If this is done, you will get
breakdown and excessive wear on the gearwheels.
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If something unexpected or dangerous should occur, demanding the winches to release the load,
there is an Emergency Release Switch on the Control Panel on bridge. There is also one switch
placed on deck. Please make sure that the crew is informed about where they are placed before any
winch operations are started. One should however be ware of the rather serious consequences using
these switches may cause to ship, crew and equipment; and because of this the switches are also
protected against being pushed down by accidents. Pushing down one of these switches will cause
brakes being only smoothly engaged, with a rather weak force, just enough to prevent uncontrolled
rotation on drum resulting wire injury.
Section of Control Panel.
Illustration only!
NOTICE!
Observe that pulling up again the activated switch
will make the brake be engaged (if it was engaged
before the Emergency Release was activated). If so
is done while there is load in wire this may cause
serious damages to winch equipment, towing wire,
ship, and even expose crew members to great
danger.
If the Remote Control system detects rotation speed on a motor above allowed limit, the hydraulic
pressure in the winch motors will automatically be increased to maximum to reduce motor RPM. At
the same time the Speed Control will adjust manoeuvre valves on the topical motor units to Stop-
Position. A Brake On order will be given simultaneously to reduce the RPM under the preset limit.
If this happens one should increase the motor pressure a little next time when similar operations is to
be carried out, to prevent damages on winch motors caused by too high revolution speed.
By reducing the RPM limit on the Towcon Monitoring System, over speed protection can easily be
tested. Lowest possible limit is 15RPM.
The maximum value allowed in the display equals max. allowed rpm on motor.
If the Remote Control system detects rotation speed on a motor above allowed limit, the power to the
proportional valve, controlling the motor tension, is cut. This causes the motor to give max tension
according to shock valves on motor.
If the Remote Control system detects rotation speed on a motor above allowed limit, the bandbrake
on drum connected to motor is engaged.
Active stop is the common name for forcing speed control order to zero (stop position), the speed
order from the operator is then superseded
It is used to protect the winch installation in various situations, such as:
Some features on screen are password protected. This is to protect them from unintended
change.
Password for these features is : 9173 – Looking at the keypad it is the corner numbers entered
in a “diagonally” order.
Under is a screenshot from the SETUP-canvas
Wire Strength Lim is a Class Society
demand. The value entered is the actual
breaking force of the wire. An alarm will
be generated at 0.5x this value.
3.15.1 SlowDrive
3.15.2 LengthGuard
3.15.3 ReReel Hoist Limitation - To be selected for use
3.15.4 CableLifter Hoist Protection – Uses data from cable-lifter table. Not user selectable.
3.15.5 Shark Jaw tension reading – Calibration / Reset
3.15.6 Length Reading Stern Roller
3.15.7 Auto Mode Chain Pull winches
3.15.8 Max Speed Range – Adjustable max order from speed lever / Rescaling.
PLEASE NOTE:
The following describes what functions that are currently available in addition to “standard” winch
control package.
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Will force only one pump, and three chambers on motor. Used in
conjunction with ALG, a very controlled movement is ensured.
It is not possible to start more than one pump for a given motor. In double
drive each motor will have one pump each.
Screenshot below shows ALG (Length Guard) turned on at the same time as ASD.
Drum is stopping to hoist when limit given in ReReel SWL limit is reached.
Bar graph in top shows how many % of SWL winch actually is paying in
with. (SWL = Safe Work Load.) The hoisting force in Cable lifter mode is
also limited to max allowed hoisting force, for the selected cable lifter.
See screenshot below showing max allowed hoisting force for cable lifter.
Picture below shows AHL function activated. Approx 66% of the SWL set in Setup tab is utilized.
PLEASE NOTE !
The continuous allowed load on the Re reel sheave is 30t. The sheave has to be sprayed constantly
with water, to ensure sufficient cooling.
ALG function used in conjunction with ASD will give the best
condition to operate the winch in a very slow and controlled manner.
Accurate display of movement since
function activated. Relative value.
When the limit set in Setup tab is reached, active stop is activated and the bandbrake is
turned on. See screenshot below. Limit is in current picture set to 65cm.
NOTE !
It is not possible to turn off the brake when ALG limit is reached. The button has to be
pressed, thus function disabled/reset, to allow brake to be turned off, once turned on by
ALG.
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By reducing the RPM limit on the Towcon Monitoring System, over speed protection can
easily be tested. Lowest possible limit is 15RPM.
The maximum value allowed in the display equals max. allowed rpm on motor.
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3.15.5 Shark Jaw tension reading
NOTE!
There is one TARA button for each
Sharkjaw.
The easiest way to calibrate Sharkjaw is to use the bandbrake on the main winch as reference.
• Run the Sharkjaw to calibrate 90% to the top. Use a crowbar or similar to rotate the
Sharkjaw 180° clockwise.
• Run the Sharkjaw completely to the top. Insert the socket of wire/chain to the
Sharkjaw. Remember to secure the connection so it does not damage anything if it
slips.
• Adjust loadcell so the RAW VALUE is displaying ~100. Press “SET MIN” on
Sharkjaw – in calibrating mode.
• Tension up the Sharkjaw with the winch. Hold the speed lever in hoist while engaging
the brake. Wait for some seconds after the brake FB on is received.
• Read value on reference loadreading system (TowCon screen). Enter the value in
MAX VAL window. Press “SET MAX”. The ACTUAL SCALED” display should
now be reading the same number as entered in the “MAX VAL” window.
• The calibration is now completed. Press “CAL MODE” button to leave cal mode.
• Run Sharkjaw down to 90%, and use a crowbar or similar to rotate the Sharkjaw 180°
anti-clockwise.
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• The load cell should be tensioned as much as possible. If “MAX VAL” is a very low
value, the calibration may be of poor quality.
• The “SET INIT” value and button is for initial setup only. If no calibration is done the
“INIT” values will be entered into the calculation. Only to be used for “getting
started”.
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3.15.6 Length Reading Stern Roller
On stern rollers equipped with rpm detectors the control system can keep track of movement
of the stern roller.
This application is typically used when winch operator wants to spool chain directly to a
drum. Length counting on drum will be suspended when length counting on stern roller is
activated.
Select the correct cable lifter size compared to what chain is going to
be spooled on to drum.
If actual chain dimension is not to be found in the table, select the
closest match.
Reset:
When pressing reset, the number in “start length” will be entered into the sternroller counter.
Thus length on sternroller will be set to “start length”.
Please note:
The length is ”stored” on the sternroller. If same sternroller is used for different chain spooled on
different drum, operator manually has to keep track of actual length spooled on to a drum.
When resuming operation on a drum, after the sternroller has been used for other purposes or a
different drum, please be sure to set the correct start length on sternroller.
Screen dump below shows the location of this information.
Initially the start length on a sternroller is set to zero.
Chain Pull Winches (CPW) are often mounted on top of chain locker. This makes it possible
to have the chain lockers in some distance from the winch.
Screenshot above shows a configuration where both chain pull winches are using same main
pump, thus there is only one SpeedStep function element. Current picture shows STB CPW is
in auto mode and pulling with 68% tension, and Port CPW is ready and waiting for operator.
No screen elements in the CPW function will be blinking for more than 15 seconds.
Elements will be blinking when operator attention is wanted, but is lit or turned off, if no
operator action within 15 seconds.
Not possible to select AUTO mode when ready lamp not lit.
When AUTO is selected the CPW start to hoist, with given tension order.
Pulling: (Lamp)
Gray: Not active.
Blinking: CPW is pulling in hoist direction with given tension setpoint. Under 15 sec
since function was activated.
Steady: CPW pulling – active for more than 15 sec.
Colour: Yellow / Gray
Speed Step
Used for requesting oil to given winches. On some plants it will be dedicated pumps, on other
the pumps are shared with other winches.
4 USER CONTROLS
Spooling Device
Move Stb / Port by tilting
the joystick sideways.
Decrement Increment
Move the Spooling device to Stb Move the Spooling device to Port
Command button:
To activate the command on the selected drum double click at the button, and the light in the
button will change from yellow to blue. If the light still are yellow, the drum may be operated
from an another Input Device.
To deactivate the command just double click again, and the light in the button will change
from blue to yellow.
When the input device is not in command the “select drum” is the only function active.
Select Drum:
This function is only available when the Input Device is not in command. To select a drum,
just press the Increment or Decrement buttons to cycle through the drums until wanted drum
is displayed.
Torque Step:
The function is only available when the Input Device is in command, the brake is off and the
coupling engaged.
Brake ON/OFF:
The function is only available when the Input Device is in command.
To alter the Brake between On/Off, just double click on the button.
The red light indicates that the brake is ON. If the red light flashes, the brake is not fully
engaged yet.
The green light indicates that the brake is OFF. If the green light flashes, the brake is not
released yet.
Coupling IN/OUT:
The function is only available when the Input Device is in command and the brake is ON.
To alter the coupling between IN/OUT, just double click on the button.
The red light indicates that the coupling is OUT. If the red light flashes, the coupling is not
fully released yet.
The green light indicates that the coupling is IN. If the green light flashes, the coupling is not fully
engaged yet.
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TOUCH SCREEN
POWER SWITCH
CONTRAST
POWER INDICATION LAMP
BRIGHTNESS
RESET BUTTON
CONTROL +
Like so many other systems that surround us today, the monitoring and control system is
based on computer technology. The operator will usually identify the control system with the
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Monitor and the Trackball, which he’ll use in his daily work. All communication between the
operator and the control system will almost without exception be confined to these two units.
This is what often is called the MMI; the Man Machine Interface. There are several possible
options to choose from when selecting the MMI units, hence the configuration described in
this manual may not be equal to the one of your system. The two units used for MMI are a
Trackball and/or a monitor with built-in Touch-screen facility. Your system may include
either options, or only a trackball and an ordinary monitor. If your system includes both
options, they will both be usable at the same time.
Ball
If you are familiar to using a PC you may most likely have used a trackball before,
or you’ll pretty soon find out by yourself how it works.
However, if you are new to using this type of equipment, here are some hints :
• Look at the picture on the monitor, and try to find the Cursor.
Move
Keep an eye on the cursor and at the same time rotate the ball on the Trackball.
Cursor
You should now see the cursor moving on your screen.
Try to move the cursor to and from definite places on the picture to get used to its
movements.
• Now move the cursor to the top of the screen and place it on one of the tabs.
Press the left key on the Trackball. The picture on your screen will now change according to
”Click” your selection. Try to change between the different pictures to get the ‘feel’ of how this
works. This is what is called a “click”
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• Move the cursor to the lower right corner and place it on the Clock-panel.
Press the left key on the trackball rapidly two times.
”Double- This is what is called “double-click”
Click” Your screen should now contain a panel with the heading “Adjust Time”.
Move the cursor to the “OK”-button and press the left key once more. The panel disappears.
Try this a number of times to get used to “click” and “double-click”
You have probably been using a touch-screen quite a lot of times without even thinking about
what is behind the surface. What is common for all types of touchscreens is that they all
display some kind of “buttons” on a monitor screen. The most familiar is maybe the type you
find on some ATM’s and Infosystems at various airports. In the way of use, they are all the
same: simply press your finger on the “button” on the screen.
However, if you are new to using this type of equipment, here are some hints :
• Look at the picture on the monitor, and try to find the Cursor.
Move Keep an eye on the cursor and tap your finger somewhere else on the screen. Not on a
Cursor “button” this time. Notice that when you withdraw your hand the cursor has now moved to
where you tapped your finger. Try to move the cursor to and from definite places on the
picture to get used to its movements. Be careful not to hit one of the “buttons”.
• Now press your finger on the cursor and move it upwards while keeping a light pressure on
the screen, then move down an around the screen. Be careful not to cross one of the
“buttons”. Notice that the cursor now follows your fingertip and when you withdraw your
hand it remains where you last touched the screen.
• Tap your finger on one of the tabs or labels at the top of the screen, the picture on your
screen will now immediately change according to your selection.
”Click” .Try to change between the different pictures to get the ‘feel’ of how this works. This is what
is called “click” when operating the touchscreen.
• Move the cursor to the lower right corner and place it on the Clock-panel by touching the
screen at that point. Tap on the panel rapidly two times. You may also tap two times on the
”Double- panel at once. This is what is called “double-click” when operating the touchscreen.
Click” Your screen should now contain a panel with the heading “Adjust Time”.
Tap with your finger on the “OK”-button. The panel disappears.
Try this a number of times to get used to “click” and “double-click”
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This section will explain briefly about the different elements you’ll find on the monitor
pictures. The monitor is not only used to display information; it is in fact more like a control
console. As described in earlier the monitor is the systems most important
MMI-element. Getting familiar with the MMI and the several picture elements is essential to
the comprehension of how to use the system. It is advisable to study this part of the manual
before proceeding to the more advanced functions.
Unlike many other systems this system has no pulldown menus. This means that you never
need to change from one picture to another just to get access to the one you really wanted.
Your monitor screen may be compared to a file cabinet with an open drawer. Just “click” on
one of the tabs at the top of the picture, and the folder you have selected will display its
contents on the screen. You may open any folder at any time just by one “click” on its tab.
Every monitor picture is made up of numerous elements. You’ll see that the picture is divided
into separate parts, called Panels. Each panel have its own special function; and some panels
are even “pop-ups” that presents itself to you only when it is needed..
The System Panel occupies a narrow section across the lower part of all pictures, and is
mainly intended to display the System’s condition..
At the left side of this panel, there is an text field showing the operational status of the
system, if the system is fully operational the window will be empty , otherwise the system is
showing either CONFIG or PARAM mode. This means they are in a maintainance mode,
which is only used by service engineers.
Next to the operation mode-indicators there is a small box with a text like “ 125/50 “. The
digit will vary according to the traffic on the bus, first digit shows the number of received
messages per second and the last sendt messages. A low value will indicate that the traffic at
the moment is moderate. That’ll be typical when winches are not used. The value may be very
low (50 /8) if no operations has been executed for a long time. When hoisting heavy loads in
rough weather, with wire tension constantly changing, the bus traffic pick up and he value in
the traffic indicator window will then be considerably higher. This indicator is only useful for
service engineers.
Next to the right is a box displaying a percentage of free memory left in the system.. The
value displayed will normally be changing, but variation should be insignificant. This
indicator is only useful for service engineers.
On the right part of the System Panel there is a box displaying time and date.
The clock may be adjusted at any time to synchronise with other systems.
As described earlier in this manual the monitor screen is the main part of the systems MMI . The
pictures on the screen are more like control panels rather than just illustrations.
Graphic techniques are used to make it look like the screen contains real push-buttons and indicator
lamps. To activate a Button you should “click” on it as described in section 3.1 and 3.2. Buttons may
have several different shapes, but they all have in common that you’ll see some kind of alternation
when you activate them. Some buttons will change appearance permanently as you activate or
deactivate them, while others will go back to their original look as soon as you release the left key on
the trackball. ( or moves your finger away from the touchscreen ). It may seem difficult to discern
between Lamps and Buttons. This doesn’t really matter, because nothing will happen if you “click”
on a lamp. Lamps are only used to display changes in some kind of operation, and have no influence
on the winch control.
Some pictures introduce important information in Digital Displays. This is boxes of different extent
displaying a digital value of some measured and calculated indicator signal. Typical use is
presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm
limit related to the topical measuring result, the display’s background colour will change if calculated
value is too high (or too low).
”Lamps”
”Buttons”
”Digital Display”
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4.5.5 Bargraphs
On other pictures, measuring results may be displayed as Bar Graphs. This is boxes of different
extent, containing a coloured bar with adjacent scale lines and dimension text. Typical use is
presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm
limit related to the topical measuring result, the bar’s colour will change if calculated value is too
high ( or too low ).
4.5.6 Meters
Some measuring results will even be displayed as Panel Meters. This is images having an appearance
more or less like those good, old-fashioned circular dial instruments that were used on control panels
some years ago. Typical use is presentation of oil temperature, motor pressure/RPM and wire length.
The dial plate may be divided in sectors with different colours,
indicating for instance “low”-values, normal operation and “high”-values.
4.5.7 Sliders
Both Bar Graphs, Trend Displays and Meters may have attached “Sliders”. A Slider is an image
that may be moved in certain directions along a specified path, typical along the outer circle of a
meter. How to “drag” sliders is explained in chapter 3.1 and 3.2 . As a slider is moved, the
appurtenant meter/bar’s appearance will change. As an example the size of the sectors on a meter
may be adjusted in this way. As long as the slider is moving, there’ll also be a digital value displayed
to show its position at the moment.
Hint :
If you think it’s difficult to ”get a
grip” of the slider you want to
move, try to place the cursor on the
”bar-area” and move it towards the
limit you want to change.
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To be able to adjust wire lengths, wire diameters, or maybe just correct the system clock,
a keypad is needed. The keypad is a “pop-up” that’ll be accessible by double-clicking on the right
elements on certain monitor pictures. What may be adjusted by use of the numeric keypad is
described in other sections of this manual. Notice that the pop-up menu for correcting the system
clock is made special for this purpose, and don’t look exactly like the numeric keypad.
Nevertheless, they are quite similar in the way they are used.
Keypad is only accessible on monitor pictures showing system parameters such as mentioned above.
These parameters are normally displayed on special pictures, and are most easily recognised as a text
followed by a small, black on white digital display, and behind that some unit of measure. These
picture images’s will in this manual be referred to as executing elements. When opening the keypad,
place the cursor on the executing element on screen and double-click on it. The keypad will then
open and be accessible until you click on the “enter”-button.
To get access to the keypad, double-click on one of the lines or its topical digital display.
On this clip you can see the text-cursor in the display box for Wire Length. This is the only
mark that for sure is indicating what digital value you are about to adjust.
Click on the ”Cancel”-button if you have opened the wrong digital display,
or if you after all decide not to change the value.
Keypad will then close, and the digital value’ll remain unchanged.
To adjust a value, click on the CLR-button until you have deleted what was wrong and then
write in the correct value by using the number-buttons. As you clear faulty digits or write in
the correct ones you’ll see the contents of the digital display change.
When you have changed the value and can see in the digital display box that it’s correct, just
click ”ENTER” and the keypad’ll close. The correct value is now stored in the system.
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A double-click on the canvas tab will display the user menu. This menu
gives the user the possibility to view some system information, adjust the
date and time, and calibrate the touchscreens.
This menu also gives the operator viewing access to the database, copying
log files and wash screen function.
General Info
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Peripheral Info :
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CANopen Info:
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Can Open continued
Use this dialog box to adjust the date and time on the system.
Double clicking on the date/time field on the status line will also
open this dialog.
Click on the number you want to change. The keypad will pop
up. Then type the new value and click the ENTER-button to
apply it to the system.
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The Calibrate Touch button in the User menu will let you calibrate all connected touch
screens.
Press and release point 1. It will turn yellow as long as you press it, and disappear when you
release it. Now the second calibration point (number 2 in the picture above) is displayed.
Repeat the procedure for this one. Finally, when you have pressed the third calibration point
(number 3 in the picture above), the result of the calibration is displayed. This is shown in the
next picture
A successful calibration will be reported like the following picture. It also gives some system
information about which Com-port it is connected to.
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5 OPTIONS
6 INDEX
A
Alarm 47, 52, 55, 56, 67
alarms 55, 56
Auto / Manual Limit 37
B
Bar 38, 53, 67
Brake 67
C
Cable 64, 67
Chain 64
Click 36, 42, 113
Control 35, 38
D
Data 64
G
Graph 53
H
hoist 44
Hoist 40, 41, 46
L
Length 34, 38, 39, 40, 41, 46, 48, 66
Limit 34, 37, 39, 40, 41, 44, 45, 48
Lock 62
M
Measuring 50, 66
O
Overspeed 39, 48, 57
P
Pmax 36, 39, 40, 41, 42, 45
Pmin 36, 39, 42, 46
Pressure 36, 39, 40, 41, 42, 46, 53
R
Reset 55, 56
RPM 57, 67
S
Security 62
Speed 38
T
Temperature 52
Tension 38, 47, 53, 57, 67
Touchscreen 10
Tow 40, 41, 46
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Towing 36, 39, 40, 41, 42, 46
Trackball 10
Trend 52, 53
W
wire 34, 35, 37, 38, 39, 40, 44, 45, 46, 47, 48, 50, 53, 55, 58, 64, 68