Operator manual PR 6000 part 1 MÁY ĐIỆN HÀNG HẢI

I Document No. I E11-1258H I

PR-6000-ED
AUTOPILOT

OPERATOR'S

MANUAL

2006.10

TOKIMEC INC.


PR-6000-EO AUTOPILOT
COMPOSITION OF OPERATOR'S MANUAL

1.

STEERING STAND

2.

REPEAT BACK UNIT

3.

WIDE RUDDER ANGLE REPEAT BACK UNIT

PR-6000 OPERATOR'S MANUAL INDEX
PERIODICAL CHECK TABLES

I Document No. I E11-1264H I

PR-6000
STEERING STAND

OPERATOR1S

MANUAL

2006.10

TOKIMEC INC.


SAFETY PRECA UnONS

J.

Safety symbol indications and definitions used in this manual and products are as
follows.

&DANGER
AI.

Indicates an imminently hazardous situation which, if not
avoided , will result in death or serious injury.

WARNING Indicate s a potentially hazardous situation

ili

&CAUTION

which, ii not

avoided, could resull in death or serious injury.
Indicate s a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury o r property
damage accident.

( I)



4.

Safety pl'ecautions, etc., described in this manual are summarized here (pages
described are shown in parentheses.)

(1)

Warning for use of this system (Refer lO page 1·1.)

it. WARNING
.Malfunctions caused by failure of this system and mis-operation caused by operator's
mistake may cause such disasters at sea as collision with other ship or stranding.
resultant property damage and environmental contamination. and further hazardous
situation resulted in death or serious injury .

• Great care should be taken to use this syslem being well acquainted with limitalions of
performances and characteristics of this system. and familiar with the operating
method.
(2)

General items to be warned for the operating method (Refer to page 3·1 )

~WARNING
.Each steering mode of HAND, AUTO and remote (RC) has specific attention points
for use. These are shown in the corresponding clauses with .&:. CAUTION and .&:.
WARNING, etc. Observe strictly these items .
• Periodical repeated training for emergency steering should be performed to deal with
smoothly in an emergency status from anywhere in the ship.

(3)



(6)

Warning when selecting steering mode (Refer to page 3-3.)

~WARNING
• Do not use the auto steering until the gyro-compass has sellled. If not, own ship does
not set on the desired course and may cause collision or stranding .
• Before switching the steering mode, be sure to set the rudder at the center. and then
switch the mode selection switch I MODE I.
If not, an unexpected large rudder may be taken .
• Hold the mode selection switch surely with hand and turn it correctly to the mark 0
which shows the correct position.

Interrupting the selection on the way may cause malfunction.
In this case. make sure that the steering mode is switched correctly with the steering
mode display lamp ( I AUTO I, I HAND I. I NFU I. I RC I) .
• Loosened play in fixing the knobs for the mode selection switch I MODE I . system
selection switch ISYSTEM I and non-follow up lever I pc:;.S I may cause wrong
switching or operation.
Retighten the two screws fixing the knob to the switch. or contact TOKIMEC service
department.
(7)

Warning to set the maximum rudder angle (Refer to 3-8 .)

.When the rudder angle selection switch is installed. setting of the max rudder angle
selection switch should be used only in the narrow rudder angle side other than when
the steering is required a large rudder angle. Otherwise. an unexpected large rudder
angle may be taken to cause a dangerous steering situation.

(5)



(10)

Warning regarding remote aUlO steering (NAY) (Refer to page 3-\ \.)

LhWARNING
000 not use the remote auto steering (NA V) in confin ed sea areas or narrow channels as
a rule.
For using it by an y chance in such areas, suitable navigational means such as securing
safety around or reducing speed should be taken . If not, prompt action cannot be

made, and may cause collision or stranding .
• Keep a strict "look out" (watch), in particular, during remote auto steering. Careless
"look out" (watch) may cause collision or stranding .
Olf an alarm generated in the autopilot or gyro-compass, heading monitor (option),
speed log (option ) and tracking navigational equipment side during the remote auto
sleering, make sure at once of the content. When an abnormality affecting the steering
is generating, switch at once to one of the other sleering modes.
(11)

Warning regarding remote hand steering (remote control) (Refer to page 3-13 .)

LhWARNING
000 not use the remote hand steering (Re) in confined sea areas or narrow channels.
Prompt avoidance is not in time and may cause collision or stranding.
OOuring the remote hand steering, always confirm the rudder angle and its direction
displayed on the rudder angle receiver (indicator). If not, when failure generated in the
remote control steering line, discovering the failure may be delayed to cause collision
or stranding.
OSet the remote control steering knob at the center before switching to the remote hand
steering mode from the other steering mode. If not, a large rudder may be taken after
switching to cause collision or stranding.
Olf an alarm generated in the autopilot or remote control unit side during the remote
hand steering, make sure at once of the content. When an abnormality affecting the
steering is generating, switch at once to the other steering mode.
(12)

Warning regarding override steering (Refer to page 3-16 .)

LhWARNING
o During the override steering, if such malfunction or failure is generated that the rudder

does not function properly, inunediately reset the override steering by pushinglRESET I
switch of OVERRIDE RESET UNIT (* 1), and perform the steering according to 3.2.4
Emergency sleering method.
* 1: Reset procedure and switch name may differ depending on its specifications.



(15) Warning regarding aCitopdot mai nte n3nce (Refer to page 5-1 :,

9The steering gear connected to this amop il o[ may callse, although ,·ery r~re l y, hydro
loc k, etc., which makes the rudder disabled to steer .
• Alth ough main parts of th e autopilot co nsist of electronic circuitry having high
reliability, it cannot be said failure d oes not occur absolutd y.
Accordingly, it is absolute ly necessary to carry out check and mainte nance described
in this chapter to exclude these dangers as long as pos sible and to maintain
performance of this system.
If not, detecting sign of failure delays and it yields fa ilure of the system and may result
in collision or strandin g (refe r to clauses regarding maintenance and check of the
steering gear instruction manual).
When trouble is discovered and cannot be recovered on board , contact TOKIMEC
service department or its sales agency of your area.
( 16) Warning in installation (Refer to page 5- 8 .)

&WARNING
.Do not hang down the steering stand by passing ropes, etc., on the steering wheel or
handle for moving the steering stand in installation and so forth . The wheel or handle
should be broken due to weight of th e sleering stand, and the stand may drop (0 cause
injury.
(17) Cauti on in hand steering (Refer to page 3-6 )

&CAUTION
.Set the pointer of the order rudder angle indicator on the helm unit at the center before
turning the system selection switch to I No. I lor I No. 2 I to start the PR-6000, or
beiore turning the mode selection switch to I HAND I from the other mode. Ii not ,
taking a rudder may suddenly start and is dangerous .



(20)

Caution in override steering ( Refer 10 pa ge 3-16)

~CAUTION
.Taking a large rudder is dangerous when 5witch.ing to the external o verride unit. Pa y
, JttentLon on such a thing to w the order knob (lever) at the neutral pos ition.
OConfirm safelY around when steering with the override anit.
.When switching to the override steering during the auto steering or remote aut a
steering (AUTO-NAV), and switching again to the auto steering or remote aut o
steering from the override steering after a while, a quick turning of the ship may occu r.
Before switch.ing to the auto steering, set the ship's heading at that time as the set COUfSe
for keeping the course, and make the original set course and NA V course invalid .
When the ship is to be kept on the original course or on the new course, operate th e
course setting knob or stop the remote auto steering once and swi tc h to the remote aut o
steering (AUTO-NA V) steering again. The preset course invalid alarm is mdlcated til
this operation is performed (option).
(21) Caution when alanm generates (Refer to page 4-1.)

&CAUTION
o When the alarm generated, confirm the content of the generating alarm at once and tak e
a suitable means according to the failure phen omena list.

.\Vhen failure generates , check and take a countermeasure at non-dangerous sea are a
after confirming safety around, and with the ship stopped as a rule (Refer to page 3- 7
clause 3.2.4 Emergency steering method).
(22) Caution in troubleshooting (Refer to page 4-3.)

&CAUTION
• Turn OFF the system selection switch, and the service switch located at the upper left bott om
of the control unit before checking and replacement of fuses, removing the unit of equiplOe nt,
connectors, printed wiring boards and terminal cables.
Remaining the switch at ON position may cause electric shock and failure .
• When checking and taking necessary measures are performed for the failure, check and tak e a
countermeasure at non-dangerous sea area after confirming safety around, and with the ship
stopped as a rule .
(Refer to page 5-6.)

(23) Caution for replacement of fuses

&CAUTION
ODo not rcleas~ hands from the iacia panel tiilthe panel is fixed with the two stoppers.
If not, may cause injury .
• D,-, not give the faCia panel subject to strong vibration or shock when it is fixed with the
stopper.
Dropping the iacia panel due to loosing the stopper may C:lUse failure of i:quipment or
injury .
( I 1)



4.

Prohibitions and notes for protection of the system (protecting equipment itse lf fr om
damage, maintaining the quality.)
Obse rve the fo llow ing for protec tion of the syste m.
For detail s. refer to corresponding pages of thi s operator's manual. COlTespond ing pages are
show n in [

1.

Prohibiti on - - - . - Items mu st not do.
( 1)

Prohibition of miss use (miss operation ) (Refer to page 3-25.)

PROHIBITION
(I )Wetling the autopil ot operation unit (faci a panel ) by water or drink may ca use

growing mold or performance reduction.
Do not steer or operate with drinking water, etc.
Wipe off liquid at once if the stand is wetted.
(2)

Prohibition of megger test (Refer to page 5-2 )

PROHIBITION
Do not use a megger, etc., for insulation test of this system. Using a megger can
break internal electric pans . Alwa ys d isconnect wirings to this sys tem be fore
testi ng related power dIstributi on line s with a megger.

(13)

(2)

~'ote for storage of autopilot (Refer to page 5-7.)

NOTE
Observe the following items for storage.
(l)

(2)

Turn all power switches of th is sys tem to OFF position, and cu t the alarm
power (DC 24V) supplied to the autopilot stand.
Storage temperature should be between _20
+55T.
0

-

A void the place with high humidity as far as possible.
High humidity may cause rust.
(3)
(4)

Prevent the storage place from generation of corrosive gas, breeding of
bacteria such as mold or intrusion of insects and small animal s.
Cover the system with a viny l sheet, etc., when generation o f du st is
considered.
When welding works, etc., are carried out near this system, be sure to mount a

suitable protection cover on the steering stand to prevent damage caused by
spark, etc.

( 15)



3.4

Description for an optional Override steering feature ...... ... .. .... .. .. .... . .... . ...... 3-31
3.4. 1 Construction ..
. .... ..3-31
3.4.2
3.4.3

Steering modes available with override steering ..... .. .... . ... .... .. .... . " .. .3 -3 I
Override steering method ......
. ................. ..... . . ................ 3-31

CHAPTER 4 TROUBLESHOOT[)JG ........ .
4. I

... .... .... .. . ... ................... ....... ...... .4-1

General.. ................. ............ .. .... .

4.2

. .. .4-1
Before troubleshooting ..... .. .. .... .. ... .. ... . ..... .. .. .. ... .... .. . ... . .... .. ... ... .. ...... ..4-2

4.3

Troubleshooting ........... .

"." ..... , ... ... , . . .. . .. .... ...... .. , ... .. ... , .... . . " ... ..4-3

4.4

Countermeasure Table ..... .

. ... ... .... .. .... .... . ....... , .... . . . ' .... ... ,' .. .. , , ... . ,.4-7

4.5

Voltage Table of Each Poin!.. .......

4.6

J:nformation [terns to TOKlMEC Service Agency ..... .. .... ......... .. ................ 4-26

. ... .................... ....... ... .4-25

CHAPTER 5 MAINTENANCE' CHECK.. . . .. .. ..... .... .. ...... .. . . . ... , .. .. .... . .. .. 5-1
5. 1 GeneraL ............... .......... . · .. · .... .. .. ·· .. · .. .. · .. · ···· .. ····· · , ... .... .. .... , ......... 5-2
5.2 Periodical Check ... " ...... ..... . ... .... ..
... . . . . . . .. .. . . . ............ 5-3
5.3

Warning Label

Check ....... , ...... . , ... , .. , ........ .. ... ........ ... .. .... , ..... ... . .

5.4

... 5-6
Replacement Method of Fuse ............ .... ...... ............... .. ...... . .. ..... , ........ 5-6

5.5

Spare Parts ...... ......... ,........... ... .. ........... .. ..... ... .. ... ...

.. ... .. ....... .. 5-7

5.6

Storage Method ......... .. .. ... .. .... .... .. . .... ...... ........ .. ......

.. ....... ...... 5-7

5.7

Disposal Method ... ... ...... .... .... . .... .

5.8

Precautions in Installation(Extraction).. ........... ...... ... . ... · ................ 5-8

CHAPTER 6
6.1

6.2

. .5-7

PRINCIPLE OF OPERATION ......... .. ... ................. ...... .. .. ..... ......... 6-1

General. .... " .......... .... , ....... . , ... , ....... ............. .. .. .... ... ........ . .... ....... ... .6-1
Principle of Operation of PR-6000 ................. .

6.3

. ........... ........ 6-2
AUTO-ADPT Operation (Auto Steering, Adaptive Control) (option) ...... . .......... 6-3

6.4

AUTO-PID Operation (Auto Steering, PID Control) .............. ................. .. . 6-6

6.5

HAND operation (Steering Wheel Steering) ....... ............. ... .. .. .. .. .... .... ....... 6-7

6.6

Non-Follow Up Control Operation (NFU Lever Steering) ........ .... .... .. .......... 6-7

CHAPTER 7 GLOSSARy ..... ... .... ... .... .. ............. . .. ...... . ......... .. .. . ......... . .. ...... 7- 1

(I 7)

CHAPTER 1

GENERAL DESCRIPTION

it. WARNING
.Malfunctions caused by failure of this system and mi s-operation cau sed by operator's
mi stake may cause such disasters at sea as collision with other ship or stranding ,
resultant property damage and environmental contamination, and further hazardous
situation resulted in death or serious injury.
_Great care should be taken to use this system being well acquainted with limitations of
performances and characteristics of thi s sys tem , and familiar with the operating
method.

NOTE
This system is an extremely important navigational equipment which controls the
rudder to determine the advancing course of the ship.
Although safety designs such 3S providing alarm functions for failure and mi ss
operation, etc., are considered , a complete safet y equipment is not available at
present.
In addition , because this sy stem has a lot of important functions (multi functional
equipment), anyone cannot always use thi s system without failure.
Failure or miss handling of this system may cause disasters at sea. Accordingly ,
full attention should be paid on use of this system .
And for safety navigation, e)(ecution of navigational technol ogy and cautions are
user's obligation which are not reduced or exempted at all by using this equipment.
In particular, the "look out" (watch ) is indispensable for steering in any steerin g
mode of the autopilot
In addition, observe the following notes.

\.
Be sure to perform daily c heck to keep equipment condition normal.
2.
When abnormality is discovered as the result of daily check, investigate and
repair it at once to recover it to the normal condition. If necessary, request an
advice of TO KIMEC service engineer.
3.
The steering modes of this system are AUTO steering, HAND steering,
REMOTE steering and NON-FOLLOW UP steering . Be familiar with and
skilled in every steering modes.
4.
Be skilled in the emergency steering method to keep quite cool in emergency
situation.
5.
When the alarm system operates, be sure to check it to confirm the cause, and
repair the troubled point

t -J



CD

T ype o f steering stand
•

Shows the steering stand type . The gy lot type contains the gyro-com pass in it.
I : Stand type (stand alone type without a built-in gyro -compass)
:: . Gylot type (s tand alone type with a built-in gyro-compass)

3 • Console type (collective tab le type with a built-in gyro- compass)
4 : Unit type (unH assembled type without a built-in gyro-compass)

5: Console type (collective table type without a built-In gyro-compass)
7 : Gylot type (stand alone type with dual built-in gyro-compasses)
S. Console type (c ollective table type with dual built-in gyro-com pa sses)

9: Unit type (unit assembled in type wllh dual built-in gyro-co mpasses)

@)

T ype of gyro -compass
The gyro-compass azimuth signal is to be serial.

TOKlMEC TG-6000ffG-8000 gyro-

compass outputs serial signal.
NONE : TG-6000

G>

A

• TG-8000

B

• TG-8500

Type of steering gear co ntrol sys tem

Shows the type of steering gear control system combined.
Note. PR-6000 output signal is shown in (
OM

).

Single loop steering gear made by MITSUBISHI HEAV Y IND . and
HITACHI SHIP BUILD.
(Torque motor fmation control signal)

OW . Single loop steering gear made by KAWASAKI HEAVY IND.
(T orque motor rotation control signal)
DT

Single loop steering gear made by HATLAPA.
(Proporti onal solenoid valve control signal)

DB

Single loop steering gear made in Russia.
(Megger torque mo tor rotation control signal)

EO : Solenoid valve control type (Solenoid valve control signal)
EO: Dry contact point only (potential free)
EI: 11 OV AC ON • OFF signal

E2: 24VDC ON· OFF sig nal
E3: IIOVDC ON· OFF signal - - - Pow er should be supplied by steerin g
gear maker.
Lo : Electro hydraulic type (C ylinder reciprocating signal - - - mec hanica i stroke;

Note : Uses vane pumps.
LS : L type standard
LL : L type with the Low level alarm
LP : L type with the Low pressure alarm - - - for LR rule
LF

pO.

L type with the Low level and Low pressure alarms

Electric type steering gear made by MITUBISHI HEAVY IND . (Pis ton
reciprocating signal - - - mechanical stroke)
PS
P type standard
PL : P type with limit switch - - - for LR ru le
I·3