07/10/2021

AQUAMASTER CONTROL
SYSTEMS
15/05/2019

JARI-PEKKA KOSKINEN

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use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing. Any authorised reproduction in whole or in part, must include this legend.
© 2018 KONGSBERG – All rights reserved.

Control Systems

• MS (Magnetic Switch) 1965 

• DF (Detector Fork) 1975 
• MC (Micro Computer) 1982 
- Micropilot
• EW (Evolution) 1990 
- FP/CP Controls, Micropilot
• DB (Distributed Bus) 2000 
- FP/CP, Micropilot
• ND (New Design) 2009 
- FP/CP

FP = Fixed Pitch
CP = Controllable Pitch

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MS Aquapilot

• First Aquapilot control system made 1965

• Control levers magnetic field is affecting to switches

• Control signal by relays

• Two turning speeds (slow and fast)

• Transmitter for feed-back (potentiometer)

• Clutch control

• RPM control with mech. cable

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DF Aquapilot

• System functions by using Gap Detectors

• Electric amplifier and relays for steering signal

• Potentiometer for feed-back

• Clutch control (elect., hydr. or pneum.)

• RPM control (mech., elect. or pneum.)

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MC Aquapilot

• MC1
- Without follow up

• MC2
- With AQM direction follow up

• MC3
- With AQM direction & RPM follow up
- Portable Aquapilot
- Micropilot

AQM = Aquamaster propulsion unit

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MC3

• Control electronics, CPU-card

• Extension-card for follow-up

• Voltage or current valves

• Feed-back transmitter (RS-422 type)

• Thrust direction indication is separate system

• Interface for external controls (Autopilot, DP)

CPU = Central processing unit

DP = Dynamic Positioning
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EW Control System

• Variations
- Basic FP control system for steering and RPM
- Separate CP control system
- Micropilot system
- Autopilot / DP interface
- Lever synchronizing

FP = Fixed Pitch
CP = Controllable Pitch
DP = Dynamic Positioning
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DB Control System

• Distributed system
- Prosessing units + distributed I/O units

• Information transfer by CAN-bus

• DB (double electronics system)

• DB-L (light construction)

• DB-A (Main + back-up)

• FP, CP, Micropilot, Autopilot, DP, SC, etc..

FP = Fixed Pitch
CP = Controllable Pitch
DP = Dynamic Positioning

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Purpose of Control System

 Thruster control
‒ Steering
‒ Clutch
‒ RPM
‒ Pitch
 Interface to external systems
‒ Autopilot
‒ JOY
‒ DP (Dynamic Positioning)
‒ Condition monitoring
‒ Prime mover
 System monitoring
‒ control levers
‒ feedback sensors
‒ control units
‒ External control signals
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Main control system: Steering

& RPM Other azimuth
thruster

• Closed loop system AQP AQP TDI

‒ Set command 100

60
30
0
10 0
60
30
0

‒ Feedback
‒ Comparison
CANopen

CANopen

• Variable steering speed

BIU BIU

Bridge
CANopen

Thruster
CANopen

room

• Independent indication system ACU

A-bus
B-bus
ACU

Other azimuth
thruster

• 4..20mA RPM command to PM

Feedback sensors

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Secondary control system: BCP

Steering & RPM

AQP TDI

• Non-followup control
• Constant speed command for valves
• Separate wiring from Secondary
Control Panel to operative
components
Bridge
• Steering Operated manually trough Thruster room

push buttons

-
ACU

• Potentiometer for PM RPM SCR

command(4...20mA)
• Clutch control in potentiometer

Modules inside units:

BCP: R/I converter Feedback sensor
ACU: SCR

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Electric driven steering

• Electric motors for turning

• Overload clutches

• Planetary gears

• Frequency drives for steering

motor control.

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Hydraulic driven steering

• Pump for steering pressure.

• Double hydraulic motors.
• Planetary gears.
• PWM controlled steering valve.

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Clutch control

 ON/OFF Clutch
Disengaged / Engaged
Prop. RPM (PM RPM idle):
Apprx.16rpm (disengaged)
Apprx. 90rpm (engaged)
 Slipping Clutch
Disengaged / Slipping / Engaged
Prop. RPM:
Apprx:16rpm (disengaged)
16…90rpm (slipping)
Apprx:90rpm (engaged)

 TwinDisc MCD clutch

4-20mA current message to the Twindisc system.

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Pitch control

• Hydraulic control for pitch.

• Pitch –10…0…30degrees.

• 0…100% thrust.

• Load control for PM protection.

• Combinator curves for pitch+RPM

control.

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OVERVIEW

AQUAPILOT ND
CONTROL SYSTEM

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ND Control System

• CanOpen standard protocol for operation components

• CanMan protocol for controller + IO data transfer

• ND-B (Basic)

• ND-L (Light)

• ND-X (interface for ext. systems)

• FP, CP, Micropilot, Autopilot, DP, SC, etc..

FP = Fixed Pitch
CP = Controllable Pitch
DP = Dynamic Positioning

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ND Control System

• ND = Basic ND system

• NDX = Partial ND system, External remote control

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Main Control System Other azimuth

thruster
AQP AQP TDI

100 100
60 60
30 30
0 0

• Follow-up control with closed loop

• Variable steering speed

CANopen

CANopen
• Aquapilot ND control lever for thruster control
BIU BIU
• Aquapilot ND panels for mode selection etc. Bridge

CANopen
Thruster
• CCN-02 controller in ACU for system functions

CANopen
room

A-bus
ACU B-bus
ACU

Other azimuth
thruster

CCN = CAN Controller Node

ACU = Aquamaster Control Unit
Feedback sensors
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System Structure
BCP TDI ACP AQP

230
23 0

Rolls-Royce 100

100
0
6
0
6
0
3
0
Rolls-R oyc e
0
3

Rolls-R oyc e 0

Rolls-R oyc e

Rolls-Roy ce

Autopilot / DP
Rolls -Royce

• CanOpen BUS between main control equipment & AHP

BIU MAIN CONTROL STATION BIU

controller 24 VDC power supply 24 VDC power supply

(UPS type) Bus cable (UPS type)

• Separate, analog secondary control system 230 230

• Separate indication system

WHEELHOUSE

THRUSTER ROOM

• Aquamaster Control Unit (ACU) for thruster control

MC

& functions
ACU ACU

• Bridge Interface Unit (BIU) for external systems &

24 VDC power supply 24 VDC power supply
(UPS type) (UPS type)

other connections CONTROL AND INTERFACE UNITS

ACU = AZIMUTH THRUSTER CONTROL UNIT
BIU = BRIDGE INTERFACE UNIT
PANELS, LEVERS AND INDICATORS
AQP = AQUAPILOT CONTROL LEVER
BCP = BACK-UP CONTROL PANEL
ACP = AZIMUTH THRUSTER CONTROL PANEL
AHP = AZIMUTH THRUSTER HYDRAULIC P UMP PANEL
MC = LOCAL / MAINTENANCE C ONTROLLER
TDI = THRUST DIRECTION INDICATOR

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Aquapilot ND control lever

• New technology
‒ Digital CanOpen interface

• New layout
‒ Smaller
‒ Smoother
‒ More quiet

• Improved calibration
‒ No loosening wires

• Thrust: Two adjustable feeling points

‒ Default points 0% & 30%

• Steering: Non adjustable feelingpoints at

90 degree intervals
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ND control system panels

• CanOpen interface
• Informative colors
• LED-Indications
‒ Activation
‒ Warnings

• Push buttons
‒ Control selections
‒ Mode selections

• Address setting

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Marine Controller CCN-02

• Types:H6029 & H6045

• PC-type processor

• Linux based firmware

• Special application for thrusters

• Web interface for software update

• Individual controller for each thruster:

‒ Application & parameters vary

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Marine Controller

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Web interface

• Connection via web browser

• Requires Web key file for user

identification

• Application maintenance

• Transaction log for Web interface

users

• Advantages:
‒ Application upgrade easier
‒ Back-up feature for upgrade
‒ Parameter setting for node
‒ Log-file erase

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Serial linked I/O module

SLIO-02

 Translates analogue or digital signals

into a serial code that CCN units
understand

 Only sends and receives data (no

intelligent instructions) on the SLIO bus

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APPLICATION &
I/O-CABINETS

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use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing. Any authorised reproduction in whole or in part, must include this legend.
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Bridge Interface Unit, BIU

• Bridge I/O External systems interface (DP, AUPI, JOY)

- Command signals (analog)
- Interface signals (digital)

• CanOpen repeaters

• *HHT Interface

• Voltage supply for bridge components

- Aquapilot motors
- *HHT connection
- Repeaters
* = Not anymore in new deliveries
DP = Dynamic Positioning
AUPI = Autopilot
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JOY = Joystick 28

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Aquamaster Control Unit, ACU

• Handling aquamaster and bridge I/O • Voltage supply input for control unit &
- Interface signals I/O node
- Feedback inputs
- Outputs to panels, ext. systems etc. • Thruster control
- Outputs to thruster unit (steering & - Turning
clutch control valves, RPM command to PM) - PM RPM control
• Aquamaster supervision - External Pump control
- Maintenance control
- Alarms
- Node supervis (SLIO node, ACU node)
- Signals supervis
PM = Prime Mover, engine, electric motor
SLIO = Serial Link I/O
ACU = Aquamaster Control Unit
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ACU

• Controller unit CCN-02 (HHT connection)

• I/O Modules SLIO-02

• Supply filters & fuses

• Back-up control relays

• Back-up units SCR-3 for steering and pitch

control

• Isolator for RPM-command

• Supply switch CCN = CAN controller node

HHT = Hand held terminal
SLIO = Serial Linker I/O
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Steering Transmitter Box, X2

• Located on top of thruster unit

• Steering angle from slewing ring

• Two identical ATC-T angle feedback encoders

• Limit switch for zero angle

• Pulse amplifier SPA-1 for RPM feedback.

• Alternate:
- Sin-Cos potentiometer for DP-system steering feedback or
Analog TDI-indicator ATC-T = Aquamaster angle transmitter
TDI = Thrust Direction Indicator
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Pitch Transmitter Box, XC12

• Located on top of thruster unit

• Pitch angle from feedback rod

• ATC-T for indication system

• Limit switches for max, zero and min. blade angles

• Possibility for ext. feedback.

• Three stacks in potentiometer:

- System feedback
- Analog indicator feedback
- Spare
ATC-T = Aquamaster angle transmitter
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Steering Transmitter Box, X2

New solution

• Same basic construction

• Smaller overall design

• Two CanOpen VERT-X encoder

• Electrical zero positioning setting by wire connection

• Can be used in current CanMan control system

• Alternate:
- Sin-Cos potentiometer for DP-system steering feedback or Analog
TDI-indicator
DP = Dynamic Positioning
TDI = Thrust Direction Indicator
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Pitch Transmitter Box, XC12

New solution

• Same basic construction

• Smaller overall design

• Two CanOpen VERT-X encoder

• Electrical zero positioning setting by wire

connection

• Can be used in current CanMan control system

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INDICATION SYSTEMS

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use is prohibited if not otherwise explicitly agreed with KONGSBERG in writing. Any authorised reproduction in whole or in part, must include this legend.
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Digital Indication System

• Thrust direction

• RPM indication

• Thurst bar

• Pitch angle

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Analog Indication System

• Thrust direction

• RPM indication

• Pitch indication

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XDI Indicators
• A high quality display replaces the mechanical scale and pointer combination
• Multiple indicators can be stored in the memory of the XDI and can be selected and adjusted during installation

XDI 144 Multi configured for ECR installation XDI 192 configured for bridge installation

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ALARM SYSTEM

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Alarm system

 Ships central alarm system

• Electrical alarms
• Temperature alarms
• Pressure alarms
• Level alarms

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Alarm monitoring
• Electrical alarms
‒ ACU Warning
‒ ACU Failure

• Temperature alarms
‒ AQM oil temp. high
‒ Hydraulic oil temp. High

• Pressure alarms
‒ Booster pressure low
‒ Lubr. oil filter clogged
‒ lubr. oil pressure low
‒ Hydr. filter(1 or 2) clogged
‒ Pitch operating pressure
‒ Clutch operating pressure

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Hand Held Terminal (HHT) 42

• Free Signal Browsing without Password

• Signals can be found from Process Drawings

• For example ACU Failure Troubleshooting 

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REAL VALUE = 2

BFD=BIT FIELD DECOMPRESS

DECOMPRESS THE INPUT REAL VALUE TO
BINARY PATTERN
0 = 0000
1 = 0001
2 = 0010
3 = 0011
4 = 0100
5 = 0101
etc

ALARMS PROCESS
3350089-A-031

Rolls-Royce
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OR BLOCK: INV BLOCK:

ONE OF THE INPUT IS ON INVERTS THE INPUT
OUTPUT IS ON INPUT IS OFF

Rolls-Royce
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DP-SET-F FAILURE  SOMETHING WRONG IN DP-SET-V COMMAND FROM KONGSBERG

POSSIBLE CAUSES
-WIRE BRAKE
-COMMAND OUT OF LIMITS! (4..20mA)
-SLIO COMPONENT FAILURE Rolls-Royce
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SIGNAL TYPE A3 (input 4..20mA)

SLIO NUMBER 0

CHANNEL NUMBER 4

Rolls-Royce
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SLIO NUMBER 0
47

PIN NUMBER 5
CHANNEL NUMBER 4

Rolls-Royce
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SLIO NUMBER 0

CHANNEL 4

PIN 5

Rolls-Royce
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QUESTIONS?

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