Tunnel Thruster CP

PLC display
instruction manual
Commissioning Guide
DOEHLE CP
H. Michelsen
harald.michelsen@ser-schiffselektronik.de
Table of contents I
z
INTRODUCTION
z
z
System overview
Adjustment steps
1 SAIA DISPLAY OPERATION

z
z
z
z
1.1 Function buttons

1.2 Display access
1.3 Menu navigation
1.4 Parameter adjustment
2 HYDRAULIC AMPLIFIER ADJUSTMENT
3 FEEDBACK ADJUSTMENT
z
z
3.1 PLC adjustment

3.2 Feedback indicator adjustment
SER Schiffselektronik Rostock GmbH
Table of contents II
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4 LEVER ADJUSTMENT
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5 SETTINGS
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5.1 Store settings
6 MISCELLANEOUS PARAMETERS
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z
4.1 BRIDGE lever
6.1 Pitch controller parameters

6.2 Load controller parameters
7 ERROR DIAGNOSTICS
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7.1 Alarm buffer

7.2 Clearing the alarm buffer
INTRODUCTION
System overview
Hydraulic System
BRIDGE PANEL
HAWE
SWITCHBOARD
SET-POINT
COMMAND
ACTUATOR VALUE
CONTROL CHANNEL
ENI
Potentiometers
INDICATOR CHANNEL
INTRODUCTION
Adjustment steps
1.
Adjust Hydraulic Amplifier
2.
Adjust Feedback
Use the display hdr. ampli. adjustment menu to give a

static voltage of +0.3V or -0.3V to the hydraulic amplifier.
According to this voltages, the Qmin screws must be
adjusted so that the pitch begin to move slowly
If you skipped this procedure, the pitch response could
be to slow or to fast (oscillating), it is required to finish
this procedure before adjusting the digital parameters.
z
z
3.
Use the display feedback adjustment menu to calibrate

the 100% PORT/STBD and the ZERO of the control.
Use the ENI to adjust the indicators according the PLC
settings
Adjust Bridge-Lever
z
Use the display lever adjustment menu to recalibrate the

bridge lever to the full port/stbd and zero position.
1 SAIA Display Operation

1.1 Function buttons
push button
function
push button used to switch to the

following menu page (submenu)
or to activate a parameter for
changes
** Doehle **
date:
17.10.06
time:
12:33:56
Code:
1196
push button used to switch to the

previous menu page or to release
a parameter
push button used to scroll in the
menu upwards or to increase
the value of a parameter
push button used to scroll in the
menu downwards or to decrease
the value of a parameter
push button combination used to

accept the value of the active
parameter.

1.2 Display access
z
** Doehle **
date:
30.10.06
time:
12:33:56
Code:
PASSWORD is: 1196
The SAIA configuration terminal is

password protected.
The password is only required for
commissioning and adjustment.
All error diagnostic options and the
system status are available without
any password.
Password-free access is performed
by pressing the
key in the login
screen
The default password for the
adjustment part is 1196.

1.2 Display access
z
The input of the password is performed

with the help of the following function push
buttons
,
and
.
The buttons
(increase),
(decrease)
are used to set the value (0-9) of the digit.
The button
is used to change over to
the next digit.
After completing the input of the password

press the
push button. The display
changes automatically to the root menu
** Doehle **
date:
30.10.06
time:
12:33:56
Code:
1196
PASSWORD is: 1196

1.3 Menu navigation
values
Calibration
alarm buffer
alarm delays
Auto
Cal. Values
values
Calibration
alarm buffer
alarm delays
The buttons
(scroll up) and
(scroll down) are used for the menu
navigation.
The button
Press the push button

previous menu page.
is used to enter a submenu.

to return to the

1.4 Parameter adjustment - numeric
param1
param2
param3
param4
1.0<
2.0<
3.0<
4.0<
1.
Select parameter with the push buttons

and
.
param1
param2
Param3
param4
1.0<
2.0<
3.0<
4.0<
2.
Activate the selected parameter for

changes with
param1
param2
Param3
param4
1.0<
2.0<
3.0*
4.0<
4.
Increase or decrease the value of the

parameter with
and
.
param1
param2
Param3
param4
1.0<
2.0<
6.1<
4.0<
5.
Accept the parameter with the push

button combination
+
(hold shift-key then press E)
10

1.4 Parameter adjustment - binary
param1
param2
param3
param4
off<
off<
off<
off<
1.
Select parameter with the push buttons

and
.
param1
param2
Param3
param4
off<
off<
off*
off<
2.
Activate the selected parameter for

changes with
param1
param2
Param3
param4
off<
off<
on*
off<
4.
Set the value of the parameter to on

with
and
.
param1
param2
Param3
param4
off<
off<
on<
off<
5.
Accept the parameter with the push

button combination
+
(hold shift-key then press E)
11
2 Hydraulic amplifier adjustment

PREPERATION: 1.
adj ip current
reset buffer
Store/Restore
Test PV
TestMode
+0.3V
+10.0V
-0.3V
off*
off<
off<
off<
Switch to LOCAL/REMOTE SWITCH

to REMOTE MODE
3.
Start from Root-Menu

(after password login)
4.
Use the push buttons

,
to select
the menu Test PV and enter with
the push button .
5.
Use the push button

to activate the
menu item TestMode.
12

TestMode
+0.3V
+10.0V
-0.3V
on*
off<
off<
off<
TestMode
+0.3V
+10.0V
-0.3V
on<
off<
off<
off<
TestMode
+0.3V
+10.0V
-0.3V
on<
off*
off<
off<
TestMode
+0.3V
+10.0V
-0.3V
on<
on*
off<
off<
6.
7.

,
to set the
menu item TestMode to on and store with
the push button combination
.
+
The hydraulic pump now starts automatically
,
to select the
menu item +0.3V and activate with the
push button .
,
to set the
menu item +0.3V to on.
Now the PLC give a output of +0.3V to the
hydraulic amplifier, use the Qmin screw on
the Ampl. to increase or decrease the
current on the valve so that the pitch
(needle on the indicator) moves slowly.
13

You can see on the LED A or B
which screw you have to adjust: For
LED-A adjust the QminA and for LED
B adjust QminB.
z
If the pitch does not move while the

LED-A or LED-B is on adjust Qmin
clockwise to increase the minimum
current for that valve.
If the pitch does moves to fast
while the LED-A or LED-B is on
adjust Qmin counter-clockwise to
decrease the current on that valve.
14

TestMode
+0.3V
+10.0V
-0.3V
on<
off<
off<
off<
TestMode
+0.3V
+10.0V
-0.3V
on<
off<
off<
off*
TestMode
+0.3V
+10.0V
-0.3V
on<
off<
off<
on*
TestMode
+0.3V
+10.0V
-0.3V
on<
off<
off<
off<
8.

,
to set the
menu item +0.3V to off to stop the PLC
output and deselect the menu item with
.
9.
Now set the menu item -0.3V to on.

Proceed the same procedure like before in
the other direction.
Normally you do not need to adjust the
+10,0V and the -10,0V (QmaxA/B screws).
But you can test both option, if you switch
them to on the pitch should drive very
fast.
10. After you have finished, all menu items

must be turned off! The hydraulic pump
will stop.
15
3 Feedback adjustment
PREPERATION: 1.
2.
values
Calibration
alarm buffer
alarm delays
3.

(after password login)
4.

,
to select the
menu Calibration and enter with the
push button .
5.

,
to select the
submenu Auto and enter with the push
button .
6.

,
to select the
submenu Feedback and enter with the
push button .
Auto
Cal. Values
Set Port
Set Bridge
Feedback
Current
Switch to LOCAL/REMOTE SWITCH to

LOCAL MODE
Start the Hydraulic Pump
16
3 Feedback adjustment
In Value 2457
min
off<
zero
off<
max
off<
In Value
min
zero
max
7.
2457
off<
off<
off<
In Value
2457
min
off<
zero
off*
max
off<
(Example:
selection for
zero adjustment)
8.

the correct procedure:
to select
min
= full port-side adjustment
Proceed with page 20.
zero
= zero thrust adjustment
Proceed with the following page.
max
= full stbd-side adjustment
Proceed with page 22.
and activate with the push button
17
3 Feedback PLC adjustment

3.1 Zero thrust adjustment
9. Start the thruster motor
10. Locate the zero thrust according
vessel movement or blade position.
Use the Amp-meter as helper, the
zero thrust position is in the area of
the minimum current.
In Value
2457
min
off<
zero
on*
max
off<
In Value
2457
min
off<
zero
off*
max
off<
11. Use the push buttons ,

to switch
the menu item zero to on.
Wait 1 second
to switch
the menu item zero back to off
18

In Value
2457
min
off<
zero
off<
max
off<
13. Use the push button

menu item zero.
to release the
The PLC zero thrust adjustment is now completed.
19

3.2 Full PORT thrust adjustment
In Value
min
zero
max
1023
off*
off<
off<
In Value
min
zero
max
1023
on*
off<
off<
In Value
min
zero
max
1023
off*
off<
off<
1.
2.
3.
Select the min procedure and

activate it with push button .
Start the thruster motor (if not running)
Use the push button to drive to portside until the needle reached nominal
current (red mark) at the amp meter
It is possible that the pitch runs slowly

away to portside, try to hold the needle
below the red mark with the stbd button)
to switch
the menu item min to on.
Wait 1 second
to switch
the menu item min back to off
20

3.2 Full PORT thrust adjustment
In Value
min
zero
max
1023
off<
off<
off<

menu item min.
to release the
The PLC full portside adjustment is now completed.
21

3.3 Full STBD thrust adjustment
In Value
min
zero
max
3890
off<
off<
off*
In Value
min
zero
max
3890
off<
off<
on*
In Value
min
zero
max
3890
off<
off<
off*
1.
2.
3.
Select the max procedure and

activate it with push button .
Start the thruster motor (if not running)
Use the push button to drive to stbdside until the needle reached nominal
current (red mark) at the amp meter
It is possible that the pitch runs slowly

away to stbd-side, try to hold the needle
below the red mark with the port button)
to switch
the menu item max to on.
Wait 1 second
to switch
the menu item max back to off
22

In Value
min
zero
max
3890
off<
off<
off<

menu item max.
to release the
The PLC full stbd-side adjustment is now completed.
23
3 Feedback indicator adjustment

z
z
z
z
The ENI is used to calibrate the

indicators according the PLC
settings.
This adjustment has no effect
on the pitch settings!
It is only used to adjust the
indicators!
The ENI has 4 adjustment
screws:
z
z
z
z
M-Screw:
12-Screw:
4-Screw:
20-Screw:
adjust the ENI

adjust zero
adjust full port
adjust full stbd
24

values
Calibration
alarm buffer
alarm delays
set-pitch
act-pitch
Current
0<
0<
0<
1.
Switch on the hydraulic pump, NOT the

thruster motor
2.
Drive with the push buttons PORT and

STBD in zero position so that
act-value equals 0
25

z
counter clockwise
clockwise
WARNING, if you skipped this

procedure, the full STBD-side and
the full PORT-side adjustment would
be to inaccurate.
z
OK
z
Use the marked M-Screw to

adjust the electrical zero of the ENI.
If right LED is on, adjust clockwise

if left LED is on, adjust counter
clockwise until both LEDs are on or
off
The M-Screw adjustment is now
completed.
26

z
12. Use the zero adjustment

screw to set the zero pitch on
the indicators.
Adjust the 12-Screw clockwise

for port
Adjust the 12-Screw counter

clockwise for stbd
The zero thrust adjustment is

now completed.
12-Screw
12-Screw
27

3.2 Full port thrust adjustment
set-pitch
act-pitch
Current
0<
-100<
0<
2.

STBD in full port position so that
act-value equals -100
28

3.2 Full port thrust adjustment
NOTE: This adjustment has no
effekt on the pitch settings only
on the indicators.
z Use the marked 4 screw to
set the full portside pitch on the
indicators.
clockwise

for stbd

clockwise for port
The full portside indicator

adjustment is now completed.
counter clockwise
29

set-pitch
act-pitch
Current
0<
100<
0<
2.

STBD in full stbd position so that
act-value equals 100
30

NOTE: This adjustment has no
effekt on the pitch settings only
on the indicators.
z Use the marked 20 screw to
set the full stbd pitch on the
indicators.
clockwise

for stbd

clockwise for port
The full stbd thrust indicator

adjustment is now completed.
counter clockwise
31
4 LEVER adjustment
4.1 BRIDGE LEVER adjustment
1.
values
Calibration
alarm buffer
alarm delays
2.
Use the push buttons , to select

the menu Calibration and enter with
the push button .
Auto
Cal. Values
3.

the submenu Auto and enter with
the push button .
4.

the submenu Set Bridge and enter
with the push button .
Set Stbd
Set Port
Set Bridge
Feedback
32
4 LEVER adjustment
Analog In 2040
min
off<
zero
off<
max
off<
Bridge LEVER IN ZERO POSITION

(Analog In ~ 2047)
Analog In 2040
min
off<
zero
off<
max
off<
5.

menu point zero.
Analog In 2040
min
off<
zero
off*
max
off<
6.
Activate the menu item zero with
7.

,
menu item zero to on.
Analog In 2040
min
off<
zero
on*
max
off<
to select the
to set the
33
4 LEVER adjustment
Analog In 2040
min
off<
zero
on*
max
off<
Analog In 2040
min
off<
zero
off<
max
off<
8.
Use the push buttons ,

to switch the
menu point back to the off state.
9.
Use the push button

menu item zero.
to release the
The zero lever recalibration is now completed.
34
4 LEVER adjustment
Analog In 409
min
off<
zero
off<
max
off<
Analog In
409
min
off<
zero
off<
max
off<
BRIDGE LEVER IN FULL PORT POSITION

(Analog In ~ 410)
5. Use the push buttons , to select the
menu point min.
6.
Activate the menu item min with
7.

,
menu item min to on.
Analog In
409
min
off*
zero
off<
max
off<
Analog In 409
min
on*
zero
off<
max
off<
to set the
35
4 LEVER adjustment
Analog In
409
min
off*
zero
off<
max
off<
Analog In
409
min
off<
zero
off<
max
off<
8.

to switch the
menu point min back to the off state.
9.
Use the push button

menu item min.
to release the
The full PORT position lever recalibration is now completed.
36
4 LEVER adjustment
Analog In 3680
min
off<
zero
off<
max
off<
Analog In
min
zero
max
3680
off<
off<
off<
Analog In
min
zero
max
3680
off<
off<
off*
Analog In
3680
min
off<
zero
off<
max
on*
BRIDGE LEVER IN FULL STBD POSITION

(Analog In ~ 3700)
5. Use the push buttons , to select the
menu point max.
6.
Activate the menu item max with
7.

,
menu item max to on.
to set the
37
4 LEVER adjustment
Analog In
3680
min
off<
zero
off<
max
off*
Analog In
min
zero
max
3680
off<
off<
off<
8.

to switch the
menu point max back to the off state.
9.
Use the push button

menu item max.
to release the
The full STBD position lever recalibration is now completed.

Now proceed with the same procedure with the PORT and STBD
LEVER, use the menu Set Port and Set Stbd for the adjustment.
38
5 Settings
5.1 Store settings
The PCD supports the permanent storage of all process parameters.
Without the storage procedure, all modified parameters will be lost after a
power fail restart.
The store-settings procedure is used to make changes permanent after every was
checked and OK!
1. Use the push buttons
,
to select the submenu Store/Restore.
to enter the menu Store/Restore.
,
to select Store and activate it with .
,
to set the menu item to on and then back to off.
5. Use the push button to release the menu item.
Store
Restore
Factory
off<
off<
off<
Store
Restore
Factory
on*
off<
off<
Store
Restore
Factory
off*
off<
off<
Store
Restore
Factory
off<
off<
off<
39
6 Miscellaneous parameters
6.1 Pitch Controller parameters
alarm buffer
alarm delays
pitch reg
Drive prog
1.
deathzone 1.0<
gain
1.3<
steeredg+
0.3<
Steeredg- -0.3<
2.

the menu pitch reg and enter with
the push button .
Adjust these parameters with the help of the parameter adjustment

procedure (chapter 1.4). The following table explains the function of the
parameters. (see next page for detailed description)
40
6.1 Pitch Controller parameters
process value
description
default value
deathzone
Deadband between set-point and feedback

Increase this value to reduce oscillation.
Decrease this value to improve accuracy
1.0
increase
Controller gain
Increase this value to speed-up regulation
Decrease this value to reduce oscillation
1.3
Kd
Differential gain
3.0
Ki
Integral gain
0.3
steeredg+
Right steeredge
Increase this value if pitch does not respond on
small changes (e.g. +0.3 +2.0)
+0.3
steeredg-
Left steeredge
Decrease this value if pitch does not respond on
small changes (e.g. -0.3 -2.0)
-0.3
Hysterese
Hysteresis between set-point and feedback

This value is used to set the area of the deviation
alarm (not necessary to change this parameter)
20.0
41
6.2 Load Controller parameters
Current Fct
adj overflow
load regulator
reset buffer
deathzone
gain
time cons
1.0<
0.4<
7.0<
1.
2.

the menu load regulator and enter
with the push button .
Adjust these parameters with the help of the parameter adjustment

procedure (chapter 1.4). The following table explains the function of the
parameters.
(Do not adjust these parameters, only by an order from SER)
process value
description
default value
deathzone
Deadband between load and load protection
1.0
gain
Controller gain
0.4
time cons
Reset time
7.0
42
7 Error diagnostics
7.1 Alarm buffer
The alarm buffer provides information about the different
error messages which occurred during the operation.
z
z
z
z
Start from Root-Menu (no password required)

to select the menu alarm buffer
and enter with the push button
.
to scroll up and down in the alarm
buffer.
Use the push button
to return to the previous menu.
Example of an error message:

failure input
lever bridge
06/01 23:34:21
ALA NAK 0001
error type (warning, failure)

description of failure
date of last appearance
failure counter
Acknowledged / not Acknowledged
actual status (ALA = alarm, OK = no alarm)
43
7 Error diagnostics
7.2 Clearing the alarm buffer
z
This procedure is used to reset the alarm buffer with failures with the
actual status OK.
1. Start from Root-Menu.
adj overflow
load regulator
reset buffer
Store/Restore
reset buf
off*
reset buf
on*
reset buf
off<

,
to select the item
reset buffer and enter with the push button .
to activate the menu item.
Next use the push buttons ,
to set the menu
item reset buf to on and then back to the off
state.
reset buf.
to release the menu item

menu.
to return to the previous

44

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PLC display

1 SAIA DISPLAY OPERATION

1.1 Function buttons

2 HYDRAULIC AMPLIFIER ADJUSTMENT

3.1 PLC adjustment

SER Schiffselektronik Rostock GmbH

5.1 Store settings

4.1 BRIDGE lever

6.1 Pitch controller parameters

7.1 Alarm buffer

SER Schiffselektronik Rostock GmbH

SER Schiffselektronik Rostock GmbH

Adjust Hydraulic Amplifier

Use the display hdr. ampli. adjustment menu to give a

Use the display feedback adjustment menu to calibrate

Use the display lever adjustment menu to recalibrate the

SER Schiffselektronik Rostock GmbH

1 SAIA Display Operation

push button used to switch to the

push button used to switch to the

SER Schiffselektronik Rostock GmbH

push button combination used to

1 SAIA Display Operation

PASSWORD is: 1196

SER Schiffselektronik Rostock GmbH

The SAIA configuration terminal is

1 SAIA Display Operation

The input of the password is performed

After completing the input of the password

PASSWORD is: 1196

SER Schiffselektronik Rostock GmbH

1 SAIA Display Operation

SER Schiffselektronik Rostock GmbH

Press the push button

is used to enter a submenu.

1 SAIA Display Operation

Select parameter with the push buttons

Activate the selected parameter for

Increase or decrease the value of the

Accept the parameter with the push

SER Schiffselektronik Rostock GmbH

1 SAIA Display Operation

Select parameter with the push buttons

Activate the selected parameter for

Set the value of the parameter to on

Accept the parameter with the push

SER Schiffselektronik Rostock GmbH

2 Hydraulic amplifier adjustment

SER Schiffselektronik Rostock GmbH

Switch to LOCAL/REMOTE SWITCH

Start from Root-Menu

Use the push buttons

Use the push button

2 Hydraulic amplifier adjustment

SER Schiffselektronik Rostock GmbH

Use the push buttons

2 Hydraulic amplifier adjustment

SER Schiffselektronik Rostock GmbH

If the pitch does not move while the

2 Hydraulic amplifier adjustment

SER Schiffselektronik Rostock GmbH

Use the push buttons

Now set the menu item -0.3V to on.