DI-027-05_REV_1_AUTOMATION_CONTROL_AND_MONITORING_SYSTEM_REPORT.pdf

DI-027-05 Automation Control and Monitoring System Report Contract 6913G623P800007

Preliminary/Contract Design of Motor Vessel Ranger IV

Submitted by:

Loch Harbour Group 3060 Williams Drive, Suite 510

Fairfax, Virginia 22031

Preliminary/Contract Design of Motor Vessel Ranger IV

Contract No.: 6913G623P800007

CLIN-00100

DI-027-05 Automation Control and Monitoring

System Report Revision 1

Date: April 4, 2025

DISTRIBUTION Statement C: Distribution authorized to the U.S. Government agencies and their Contractors.

Other request for this document shall be referred to US Department of Transportation Volpe Center.

TABLE OF CONTENTS

ACRONYMS AND ABBREVIATIONS

REVISION TABLE

SUBMISSION SUMMARY

APPENDIX A: HYBRID BASIC SYSTEM CONFIGURATION AND FUNCTIONAL DESCRIPTION

ACRONYMS AND ABBREVIATIONS

ACRONYM DESCRIPTION

CFD Computational Fluid Dynamics TAI TAI Engineers, LLC DRL Data Requirements List

SOW Statement of Work DI Data Item

REVISION TABLE

REVISION DESCRIPTION DATE AUTHOR

0 Initial submission 09-27-24 TAI 1 General formatting edits 04-04-25 VOLPE

SUBMISSION SUMMARY

This document is submitted by Loch Harbour Group, 3060 Williams Drive, Suite 510, Fairfax, Virginia 22031, to satisfy CLIN 00100 DI-027-05 Automation Control and Monitoring System Report, of Contract No. 6913G623P800007.

The purpose of this report is to document and describe the capabilities and features of the ship’s automation, control, and monitoring systems, and cybersecurity.

The report includes:

The Automation Control and Monitoring Systems Report shall describe and depict the capabilities and features of the ship’s automation, control, and monitoring systems, and cybersecurity. The report shall include descriptions of the features and characteristics of the ship’s automation, control, and monitoring systems including propulsion control, auxiliary systems control, monitoring and alarm capability. The report shall include descriptions of system setup and operation for normal operating modes. The report shall also include descriptions of system characteristics in failure modes such as loss of generator(s) and proper recovery procedures. The report shall include discussion of cybersecurity protections for automated systems. Government REVIEW and COMMENT of this report is REQUIRED.

LHG has selected the Emerson Marex OS II/III remote control with Hybrid as the standard system, as it perfectly aligns with all the requirements outlined in the Statement of Work (SOW). With this system in mind, our understanding encompasses several critical components of the Automation Control and Monitoring Systems Report. Firstly, we recognize the importance of providing detailed descriptions and depictions of the ship's automation, control, and monitoring systems, including their various capabilities and features. This entails a thorough examination of propulsion control, auxiliary systems control, as well as monitoring and alarm capabilities. Secondly, we acknowledge the necessity of outlining system setup and operation procedures for normal operating modes, elucidating how these systems are configured and operated under typical conditions. Additionally, we understand the imperative of describing system characteristics in failure modes, such as the loss of generator(s), along with the proper recovery procedures. This involves discussing how the systems respond and recover from various failure scenarios to ensure continued operational capability. Lastly, we recognize the significance of cybersecurity protections within automated systems. Our understanding includes a discussion of the cybersecurity measures implemented within the automation, control, and monitoring systems to safeguard against potential threats and vulnerabilities.

1. Descriptions of the features and characteristics of the ship’s automation, control, and monitoring systems including propulsion control, auxiliary systems control, monitoring and alarm capability

• Marex OS II/III Remote Control System: This system is designed for the remote control of ships with one or more propulsion systems. It allows for the control of ship propulsion systems with diesel engines or petrol/gas engines (if installed outside the hazardous area). It also includes features such as engine emergency stop systems, alarm relays, and external alarm facilities for immediate notification in case of system breakdown.

• Diesel Clutch: Appendix A provides a detailed description of the Diesel Clutch system, including its components, operation, and integration with the reversing gear. It explains how the Diesel Clutch can be engaged or disengaged to control the power flow from the Diesel engine to the reversing gear.

• PTI Clutch: Similar to the Diesel Clutch, Appendix A also describes the PTI (Power Take-In) Clutch system, which is integrated into the reversing gear. It explains how the PTI Clutch can be engaged or disengaged to control the power flow from the Diesel engine to the propeller shaft.

• Hybrid Controller: Appendix A provides information about the Hybrid Controller, which is a Wago-based CAN coupler with PLC. It explains how the Hybrid Controller is responsible for the control of the Hybrid system, including the switching between different modes (e.g., Diesel Mode, Electric Mode, Hybrid Mode) and the monitoring of timeouts and alarms.

• Station Configuration: Appendix A describes the different types of control heads, operating units, and displays that can be used in the system. It explains how these components can be configured to control and monitor the propulsion and auxiliary systems. It also mentions the availability of different station layouts and options for customization.

• Monitoring and Alarm Capability: Appendix A mentions the monitoring and alarm functions of the Marex OS II/III system. It explains how the system is designed to comply with safety regulations and includes features such as RPM feedback, load feedback, fuel feedback, engine running status, and engine emergency stop systems. It also provides information about the signal list and the visualizations on the display for monitoring and control purposes.

2. Description of system setup and operation for normal operating modes

• Appendix A mentions the standard modes of operation for the Hybrid system, which include OFF Mode, Diesel Mode, and Electric Mode. These modes are described in detail and explain how the system functions in each mode.

• Appendix A also mentions the Extended Modes, which are additional modes that can be customized based on specific requirements. These modes include Boost Mode, Generator Mode, and Hybrid Mode. Appendix A provides a brief description of each mode and how they can be activated.

• Appendix A describes the functionality of the control head, which includes preset RPM command values and gear directions for AHEAD and ASTERN. It explains how the control head is used to command the moving direction and speed of the ship.

• Appendix A explains the functionality of the display type 230, which provides illuminated buttons and a jogdial for control functions. It mentions that the display is not a touch screen but can be used for indication or control functions.

• Appendix A provides information about the different types of operating units that can be used in the system, such as the standard operating unit, engine operating unit, and free configurable operating unit. It explains the functions and features of each operating unit.

• Appendix A mentions the system configuration, including the hardware components such as the MPC control unit, control head, display, and operating modules. It also describes the different station configurations and the options for cabinet sizes.

• Appendix A provides a checklist that includes the Marex Hybrid Checkliste, which lists the different modes and functions that can be activated in the system. It also mentions the signal list, which provides a detailed overview of the different signals and their visualizations on the display or lamps.

• Appendix A includes diagrams and tables that illustrate the system setup and configuration, such as the Engine Room Configuration, Standard Cabinet, and MPC MAREX OSII/III cabinet. These diagrams provide a visual representation of how the components are connected and installed in the system.

3. Description of system characteristics in failure modes such as loss of generator and proper recovery procedures

• Appendix A provides information on safety instructions and general safety precautions to be followed during system operation and maintenance. These instructions are essential for preventing failures and ensuring safe operation.

• In case of a failure or loss of generator(s), Appendix A emphasizes the importance of regular system checks and maintenance. It mentions that the responsible shipmaster should check the remote control system prior to each journey and perform a general functional test to ensure system integrity.

• Appendix A also highlights the need for external alarm facilities on all control stations to immediately notify the shipmaster in case of a breakdown of the control head. This ensures prompt action can be taken to address any failures or issues with the system.

4. Discussion of cybersecurity protections for automated systems

a. Safety Instructions: Appendix A includes a section on safety instructions, which provides guidelines for safe installation, commissioning, maintenance, and servicing of the Marex OS II/III remote control system. These safety instructions are in place to prevent damage to persons or property if not observed.

b. Personnel Qualification: Appendix A states that the operator of the Marex OS II/III remote control system must have sufficient seamanship skills and authority to steer a ship. This ensures that only qualified personnel are operating the system, enhancing security and safety.

c. General Safety Instructions: Appendix A includes a section on general safety instructions, which provides guidelines for the installation, commissioning, and maintenance of the Marex OS II/III system. These instructions ensure that the system is installed and maintained in compliance with Appendix Aation and authorized components, reducing the risk of accidents or malfunctions.

d. Product and Technology-Related Safety Instructions: Appendix A includes a section on product and technology-related safety instructions, which provides guidelines for the range of applications, IP protection classes, and installation of the Marex OS II/III remote control system. These instructions ensure that the system is used in a safe and appropriate manner, considering factors such as hazardous areas and protection classes.

Appendix A: Hybrid Basic System Configuration and Functional Description

25.05.2021

AVENTICS | 336 103 xxx 0 – Hybrid | Configuration + Description 3

Imprint

Imprint

The copyright of this user manual remains the property of AVENTICS GmbH.

This manual contains instructions and technical drawings, which may not be reproduced or copied either in part or whole, nor may they be distributed or used for competition purposes or told to third parties.

The diagrams and drawings used in this manual are for guidelines only and are not binding for the actual design.

This edition supersedes all previous ones. No part of this edition may be reproduced without our prior permission

4 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Tracking Changes

Tracking Changes

Revision Departement/ Name

Date Remarks

AA MarineCustPro – Mudroch 05.02.2021 creation

AB MarineCustPro – Mudroch 21.05.2021 changed to common Hybrid added functional description

AVENTICS | 336 103 xxx 0 – Hybrid | Configuration + Description 5

Contents

About this manual Validity of the manual Required and additional documentation

Safety instructions About this chapter Intended use Improper use Personnel qualification General safety instructions Product and technology-related safety instructions

General Introduction Diesel Clutch PTI Clutch

Standard Configuration Hardware Partslist Overview DIESEL Overview PTI Checklist

Marex Hybrid Checkliste Signal list Stations

Engine Room Configuration Standard Cabinet Optional Cabinet MPC MAREX OSII/III Standard MPC MAREX OSII/III cabinet Hybrid Controller

Standard Configuration

Station Configuration Control head

Control head (type 230) CAN IO (type 230) Control head (type 244)

Operating units Standard operating unit (type 231) Engine operating unit (type 231) Free config. operating unit (type 231) Engine operating unit (type 242) Free config. operating unit (type 242)

Display (type 230) Control functions of the display Indications

Functionality Standard Modes

OFF Mode Diesel Mode

6 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Electric Mode Extended Modes

Generator Mode Boost Mode Hybrid Mode

System Informations

Index

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 7

About this manual | Validity of the manual

About this manual

Validity of the manual

The manual “Devices and adjustments” applies to the following components of the Marex OS II/III remote control system:

MPC control unit

Control head (types 230, 244, 251, Marex OS CAN I/O light)

I2C bargraph indicators and operating modules

CAN operating module

EPU

I/O extension modules (series 750)

Electric actuators (4–20mA; direct activation)

Actuator controller

This manual describes the operation of the remote control Marex OS II/III. The individual operating and display elements, such as are present in this system are explained.

Read this manual, especially chapter “Safety Instructions”, before you use the remote control Marex OS II the first time.

Required and additional documentation

Related documentation ► Observe the instructions in the manuals for the individual components.

► Additionally observe the following manuals:

the operating manual of the ship the service manual for the Marex OS II/III remote control system

8 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Safety instructions| About this chapter

Safety instructions

About this chapter

All components of the Marex OS II/III remote control system have been manufactured in strict compliance with the generally accepted rules of technology. However, this does not exclude the risk of damage to persons or property if the general safety instructions in this chapter and the safety instructions preceding the steps of the procedures in this service manual are not observed.

► Read this service manual completely and carefully before starting to service or repair the product.

► Keep this service manual in a location where it is accessible to all users at any time.

Intended use

The Marex OS II/III remote control system is designed for the remote control of ships with one or more propulsion systems.

You may use the components of the Marex OS II/III remote control systems as follows:

for controlling ship propulsion systems with diesel engines for controlling ship propulsion systems with petrol or gas engines, if it is ensured that all components of the Marex

OS II/III remote control system are installed outside the hazardous area on condition that all control stations are provided with an engine emergency stop system that is independent of the

Marex OS II/III remote control system the output of the MPC control unit's alarm relay must be connected to an external alarm system or to a comparable infrastructure to ensure that the shipmaster is immediately notified in case of a breakdown of the Marex OS II/III remote control system all control stations must have external alarm facilities which acoustically and/or optically signal the breakdown of the control head so that the shipmaster can immediately react to this situation

Intended use includes having fully read and understood the chapter “Safety instructions”.

Improper use

Any use of the product not in accordance with the above-described intended use is improper and, thus, inadmissible.

If unsuitable products should be installed or used in safety-related applications, unintended operating states may occur in the application and cause personnel injury and/or property damage. For this reason, you may only use the product in safety-related applications if this use is explicitly specified and allowed in the documentation of the product. This applies, for example, to the use in hazardous areas with potentially explosive atmospheres or the use in safety-related components of a control system (functional safety).

AVENTICS GmbH declines any responsibility for damage resulting from improper use.

The user of the equipment is fully responsible for any risk arising from improper use of the product.

Personnel qualification

The operator of the Marex OS II/III remote control system must have sufficient seamanship skills and authority to steer a ship and must be well familiar with the Marex OS II/III remote control system. This includes having read and understood the operating manual and knowing and being able to use all important functions of the Marex OS II/III remote control system.

In special cases, this service manual may be insufficient to service bigger ship remote control systems. You should therefore find out if further operating instructions are available, for example from the shipyard, and ask a specialist to familiarize you with the remote control system.

Qualified personnel are in a position to recognize possible hazards and institute appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant conditions pertaining to the work to be done. Qualified personnel must observe the subject-specific rules.

Additionally, the operator of the Marex OS II/III remote control system must be familiar with the ship-specific equipment in such a way that he is able to manually operate and steer the ship safely in the event that the ship remote control system should fail.

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 9

Safety instructions | General safety instructions

General safety instructions

Observe instructions! When installing and commissioning the Marex OS II/III system, strictly observe the following instructions. Non-observance of these instructions will void any and all legal and warranty claims against AVENTICS GmbH.

Marex OS II/III documentation

Exclusively install, start and maintain the system and its components in compliance with the instructions in the Marex OS II/III documentation. The Marex OS II/III documentation includes three manuals: “Devices and adjustments“ manual, “Operating manual” and “Service manual”.

Authorized components Exclusively connect those components to the Marex OS II/III system that have been approved by AVENTICS GmbH. All components described in the manuals of the Marex OS II/III system are deemed to be authorized for use.

Structural modifications and misuse

Do not subject the components described in this manual to structural modifications or misuse.

Product and technology-related safety instructions

Range of applications The Marex OS II/III system has been designed for controlling diesel engines.

For use with petrol or gas engines the system components must be installed outside the hazardous area. Strictly observe the regulations for hazardous areas.

IP protection classes Observe the IP protection class of the devices.

Exclusively install and use all devices in accordance with the corresponding IP protection class.

Devices with protection class IP20 may be used in cabinets or consoles, only.

Devices with protection class IP54 may be used in the engine room.

Only use devices with protection class IP67 in external areas.

Installing the Marex OS II/III remote control system in a propulsion system

Engine emergency stop Operation of the system is only permissible with a separate engine emergency stop system on all control stations.

Engine emergency control It is recommended to install a supplementary, independent engine emergency control system in addition to the Marex OS II/III remote control system.

Twin engine systems with one control station

Twin engine systems with one control station should be equipped with single control heads of types 244 or with twin control heads of type 230. For twin control heads of type 244, 251 errors can affect both sides and, thus, both propulsion systems, due to their construction and design.

Installation works Installation works may only be performed when the system is not under power. Take the appropriate measures to prevent inadvertent switch-on of the supply voltage.

Setting up and checking the Marex OS II/III remote control system

Modification of control parameters

Only modify the control parameters when the propulsion system is not running. The vessel must not move. It must be anchored or moored.

Fine-tuning Any fine tuning during a sea trial must be coordinated with the shipmaster. The safety of the crew and other traffic participants must not be endangered. Take the appropriate measures to make sure that erroneous entries in the course of the parameterization process do not result in a loss of control of the vessel.

Checking the remote control system

The responsible shipmaster is obliged to check the remote control system prior to each journey.

Additionally, the entire ship control system must be checked on a regular basis in compliance with the seaman's duty. This overall check includes testing the control of the propulsion system, checking the control stations, checking the exterior control stations for leakage, performing a general functional test and examining the entire system for integrity.

Maintaining and servicing the Marex OS II/III remote control system

Battery replacement Keep in mind the danger of a “load dump”. Batteries may only be replaced after the devices have been disconnected from power supply. Otherwise the devices may be destroyed. Switch the devices off and disconnect the supply lines before replacing the batteries.

10 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Safety instructions| Product and technology-related safety instructions

Checking the cover foils Check the cover foils of the control head's display area for intactness. Even minor damages may result in salt water penetrating the housing and affecting the electronics or causing short-circuits. When a foil is damaged, the control head must not get in contact with water spray and should be replaced as soon as possible.

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 11

General | Introduction

General

Introduction

This document describes the hardware configuration and functionality of the Marex OS II/III remote control with Hybrid for a standard system. As the Hybrid device can be mechanically connected by two major clutch systems the differences of this fact will be shown and explained.

The possible options for the commanding lever, displays or operating modules on the stations will also be explained. There is a big amount of combinations of designing the station layout with different kind of levers depending on the type of station and the requirements of the customer.

Furthermore it will be shown what kind of options are possible to extend the MAREX OS II/III control system with additional I/O modules to fit the required functionality.

Diesel Clutch

The Diesel Clutch consists of two parts, a reducer part and an electro-magnetic clutch.

The output shaft of it is connected to the input shaft of the Reversing Gear.

The output shaft of the Diesel engine is connected to the el.-magn. Clutch and the electro motor is fixed on the transmission shaft.

The electro motor is always connected to the input line of the gear and can always be used as a motor or a generator.

If the el.-magn. Clutch is engaged the power of the Diesel engine is connected to the input shaft of the reversing gear. It is ready to operate on the reversing gear clutch and is also energizing the transmission shaft. In this case the Hybrid can work like a generator although the reversing gear clutch is not engaged.

If the el.-magn Clutch is disengaged the Hybrid works as a motor.

To run in parallel the Diesel engine must be synchronized to the speed of the Hybrid divided by the ration of the transmission shaft.

The attached gear oil pump is operating on the input shaft of the reversing gear. That’s why also the Hybrid needs to have a minimum speed. Both propulsors will build up pressure in the gear for the reversing clutch.

For the remote control there are to different motors in reversing gear operation.

To operate the Hybrid from 0 speed an additional electric pump is necessary to provide pressure for the clutch to the point when the attached pump is taking-over. To avoid interruption of pressure both pumps must run in parallel.

Contact the gear manufacturer to ensure the parallel operation of attached and electric pump.

12 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality General| PTI Clutch

PTI Clutch

The PTI Clutch is integrated in the reversing gear.

The input shaft is connected to the Diesel and the output shaft to the propeller shaft.

As long as the reversing gear is disengaged the PTI is not moving.

Only when the Diesel engine is running, the PTI clutch can be actuated. Otherwise a separate electrical

Pump is necessary. We recommend to clutch the PTI clutch as soon the Diesel is engaging and keep the clutch closed all the time until the “OFF” mode is pressed.

The clutch needs to be monitored for the feedback. Clutching is only possible in Neutral lever position or with a synchronized Hybrid revolution.

When in Electro mode it has to be ensured, that the PTI clutch can be actuated in 0 Speed.

To run in parallel the Diesel engine must be synchronized to the speed of the Hybrid divided by the ratio of the transmission shaft.

The attached gear oil pump is operating on the input shaft of the reversing gear. Only the Diesel engine can build up pressure. For PTI operation an additional pump is required.

Contact the gear manufacturer to ensure that the PTI clutch can be engaged when the input shaft of the reversing gear is not moving.

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 13

Standard Configuration | Hardware

Standard Configuration

Hardware

The standard hardware configuration is identically for systems with Diesel clutch or PTI clutch.

Both systems consist of an additional clutch to control. The interface to the Diesel engine, to the reversing gear and the Hybrid system is the same.

On the remote control station the standard configuration consists of a lever type 244 with the buttons:

1) Command

2) Synchro

3) Dim

4) LProp

Furthermore a display type 230 for each propulsion side is required.

14 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Standard Configuration| Partslist

Partslist

7291 DC-IA/ESM12

AA 26.04.2021 E1242500 7291 DC-IA/ESM12

Ind

Change / Aend

DDMMYYYY Drawn / Gez.

Checked /

Gepr.

Releas./Freig. BWN Resp. Dept./ Verantw.

Abt. Add. Info. / Zus. Info.

Lang/Sp

r. Wght./Gew.

Marex OS II Hybrid

- / - List of apparatures / Artikelsummenstückliste

Crit.P

Scale / M.stab

Doc. Type

3361034200 - STL

DP/T

D Ind.

Forma t

Mat.meets / Stoffe s.

Syst. MPA

MNR - / - Repl. For Repl.

by

Formular: Version

1,00 Ersteller: zen1la

© Aventics GmbH 2015 Verantwortlic h:

ESM12 / andrjuen

Quantity / Menge

Part number / Artikelnummer

Description / Bezeichnung

1 8946054852 ANSCHLUSSLEITUNG / CAN CABLE M12 30M

1 8946054802 ANSCHLUSSLEITUNG / CAN CABLE M12 2M

1 8946054842 ANSCHLUSSLEITUNG / CAN CABLE M12 20M

1 R419300732 STEUERGERAET / CONTROL UNIT MAREX-DISPLAY-TYP230

2 R417003375 KOMMANDOGEBER / COMMAND HEAD T244-EG-SW-LP/DIM-AV&

1 8941054264 ABSCHLUSSWIDERSTAN / TERMINATION M12 120 OHM MALE

1 R417003600 STEUERGERAET / CONTROL UNIT OSII STD HYB E/A

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 15

Standard Configuration | Overview DIESEL

Overview DIESEL

16 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Standard Configuration| Overview PTI

Overview PTI

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 17

Standard Configuration | Checklist

Checklist

Marex Hybrid Checkliste

Possible Modes (Wording)

In general:

The switch over between the modes is only allowed in NEUTRAL (standard) The functions can be activated any time.

Different Gear boxes:

E-engine without clutch o E-Engine always clutched in o Easy to handle

E-Engine with clutch o RPM matching between the engines is needed o Complex

E-Engine and Diesel with separate clutches o RPM matching between the engines is needed o Lub oil pump needed o Complex

OFF Mode (Standard)

All Propulsion off

Diesel Mode (Standard)

Diesel engine only

Electric Mode (Standard)

Hybrid only

Hybrid mode (on request)

Manually switch between Diesel and E-Mode by pressed button e.g.:

Low RPM: E-Engine / middle RPM: Diesel / high RPM: E and D Engine or Low RPM: E-Engine / middle RPM: D Engine as Propulsor and E-Engine as generator … Automatically switch between Diesel and E-Mode according a defined sequence e.g.:

Low RPM: E-Engine / middle RPM: Diesel / high RPM: E and D Engine or Low RPM: E-Engine / middle RPM: D Engine as Propulsor and E-Engine as generator

Function:

Generator mode (on request)

Diesel engine with PTO for E-Engine Activated by button Inside allowed RPM-range

Function:

Boost mode (on request)

Diesel engine with PTI for E-Engine Activated by button Inside allowed RPM-range

18 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Standard Configuration| Checklist

Signal list

Signal Visualisation Display/Lamp Manual/Auto

Diesel engine

Interface RPM

RPM feedback

Load feedback

Fuel feedback

Start release

Start

Stop

Engine running

Engine EM and/or Safety Stop

E-engine

Interface RPM

RPM feedback

Load signal

Request Start Gen. mode

Request Stop Gen. mode

Request Start Prop. mode

Request Stop Prop. mode

FB Generator mode active

FB Propulsion mode active

FB Hybrid On

Clutched ahead

Clutched astern

Diesel Clutch disengaged

PMS

Activate Mode1

Activate Mode2

Activate Mode3

Mode 1 active

Mode 2 active

Mode 3 active

Gearbox

CMD Clutch ahead

CMD Clutch astern

FB Clutch in ahead

FB Clutch in astern

CMD Diesel Clutch engage

CMD Diesel Clutch disengage

FB Diesel Clutch engaged

FB Diesel Clutch disengaged

CMD PTI Clutch engage

CMD PTI Clutch disengage

FB PTI Clutch engaged

FB PTI Clutch disengaged

CMD engage shaftbrake

FB shaftbrake engaged

CMD engage PTI brake

FB PTI engaged

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 19

Standard Configuration | Checklist

Stations

ECR Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup up Yes No

Bridge Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup Yes No

Port Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup Yes No

Starboard Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup Yes No

Fly Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup Yes No

Aft Lever Type 230 Black or Chrome Follow up system 244 Black or Chrome Display Y N Operating Modules Ahead Neutral Astern Warming up Start Stopp Free Free Free Free Free Free Backup Yes No

20 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Engine Room Configuration| Standard Cabinet

Engine Room Configuration

Standard Cabinet

In the Engine Room near the engines a cabinet (HxWxD:500x400x210mm) should be installed. It contains the MPC MAREX OS II/III, the I/O extension with Hybrid Control Software, terminals for the power supply and space for relays or converters.

The external ship cable will be directly connected to the respective modules.

It is equipped with the M12 connections for the CAN Bus which are installed in the flange at the bottom of the cabinet. There are also metric holes for cable glands that are closed by rubber dummy plugs.

Figure 1 Figure 2

Figure 3

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 21

Engine Room Configuration | Optional Cabinet

Optional Cabinet

As an option the cabinet is also available in bigger version (HxWxD:600x600x210mm). The additional space can be used for terminals, relays, converters or other devices.

The flange is also prepared like the standard version.

Figure 4 Figure 5

MPC MAREX OSII/III Standard

The MAREX OSII/III in the -modular- version (Figure 6) is installed at the four fixing points inside the cabinet.

At the screw connection terminals external ship cable can be directly connected.

Figure 6

22 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Engine Room Configuration| MPC MAREX OSII/III cabinet

The MAREX OSII/III is main controller in the system.

It is the CAN Master device in the network and responsible for the station configuration handling, the interface to the display type 230 and the interface to the Hybrid controller. All this signalizing is executed via the CAN Bus.

It is also the main control for characteristic switch-over and alarms.

MPC MAREX OSII/III cabinet

The MAREX OSII/III is also available as a cabinet version.

Then the Hybrid controller must be placed in a separate box.

Figure 7

Hybrid Controller

The Hybrid Controller is a Wago based CAN coupler with PLC (Figure 8). It contains the customized software for the Hybrid control. It is also used for the extension of I/Os. Due to the modularity extension modules can be easily added.

Different kind of modules are available if required. A CAN-gateway module for the engine interface J1939 or a Serial Interface RS422/485 to connect to a VDR, a Conning system or an external Monitoring system can be insert. The integration must be programmed into the Software of the Hybrid Controller.

Figure 8

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 23

Engine Room Configuration | Hybrid Controller

Standard Configuration

The Standard Hybrid Controller always consists of the following modules:

1) The Coupler, which acts as a CAN Bus device and which includes the program.

2) The Filter Terminal, which is necessary for Marine Application.

3) Two Digital Input modules, 8-Ch, 24V, not isolated.

4) Two Digital Output modules, 8-Ch, 24V, semiconductor.

5) One Analog Input module, 4-Ch, 0-20mA, isolated.

6) One Analog Output module, 4-Ch, 0-20mA, isolated.

7) The Terminal module, which is always required.

For the Digital Output modules additional relays for galvanic isolation will be provided.

For the Analog Input/Output modules additional converters will be provided.

24 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Station Configuration| Control head

Station Configuration

There are several different station configurations possible. At least one Control head is necessary.This can be either a lever type244, type230 or a CAN I/O type 230. The types of lever can also be mixed whenever necessary.

Only the lever type230 has a lever follow-up functionality. These levers are often installed on the main station as the lever position is always indicating the actual command although another station has the active command.

For the control of functions operating devices are available. These can be only buttons with indication lamp or a display type230. With the display analog values can be indicated. The display is not a Touch Screen but it provides 4 illuminated buttons and a jogdial.

Control head

The RPM command value and the gear direction AHEAD and ASTERN are preset on the control head. The

NEUTRAL detent corresponds to idle speed and NEUTRAL clutch. The 1st detent AHEAD corresponds to idle speed and gear direction AHEAD while the 1st detent ASTERN corresponds to idle speed and gear direction ASTERN.

Control head (type 230)

The RPM command value and the gear direction AHEAD and ASTERN are preset on the control head. The

NEUTRAL detent corresponds to idle speed and NEUTRAL clutch. The 1st detent AHEAD corresponds to idle speed and gear direction AHEAD while the 1st detent ASTERN corresponds to idle speed and gear direction ASTERN.

The control head consists of the lever, an illuminated scale and an electronic component. With the lever the ships master can command the moving direction ahead and astern with the requested ship speed. The lever position is evaluated via a potentiometer to the electronics from where it is connected with a CAN bus line to the MPC.

Figure 9

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 25

Station Configuration | Control head

On the backside of the control head type230 all connections and operating elements are located.

Connection Description X1, X5* connector power supply 24 V DC X2, X6* binary input X11, X21* CAN in- / output X12, X22* CAN out- / input X4, X8* connector I2C-bus S4, S3, S8*, S7* CAN-bus address S2, S6* special operation H3, H6* CAN-bus status H2, H5* power supply status *only on control heads with two levers

CAN IO (type 230)

The CAN IO type 230 is a small converter box. It includes the PCB of the lever type 230. It provides the control of a 3rd party lever with potentiometer for only ONE propulsion side.

Via teach-in procedure the lever behaves like a lever type 230.

Figure 10

26 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Station Configuration| Operating units

Control head (type 244)

The control head type 244 features four buttons and is thus also referred to as four-button control head. The four buttons are made of metal and are no membrane keys. Also, the control head type 244 has additional LED displays.

The control head type 244 is monitored by the CAN bus using the ”heartbeat” function.

The power supply is integrated in the Bus cable.

The power supply by the MPC can fed max. 4 devices.

It is also available with short levers for Wing stations.

Figure 11

On the backside of the control head only the CAN Bus connections for PS

(X21/22) and SB (X11/12) are located.

The device ID is taught by the MPC.

Operating units

There are two types of operating units.

The operating unit type231 must be connected to the lever type230 or the CAN IO.

The operating unit type242 is normally connected to the lever type242 but can also be connected to the other types.

Both type of units provides 4 buttons. The button type231 are illuminated, the type242 has a separate LED.

The function texts can be customized for the free config operating units.

Standard operating unit (type 231)

The standard operating unit is always necessary for lever type230 or CAN IO.

It provides the standard commands for command take-over, dimming and alarm.

Figure 12

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Station Configuration | Operating units

Engine operating unit (type 231)

The engine operating unit can be used for Start/Stop functionality. Two buttons are free configurable.

Figure 13

Free config. operating unit (type 231)

The free configurable operating unit can be used for any functionality. All buttons are free configurable.

Figure 14

The free configurable operating unit can be used for any functionality. All buttons are free configurable.

Engine operating unit (type 242)

The Engine operating unit has a green, a red and two yellow LEDs. All texts can be customized

Free config. operating unit (type 242)

The Free configurable operating unit has 4 yellow LEDs. All texts can be customized

Figure 15

28 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Station Configuration| Display (type 230)

Display (type 230)

The display type230 is used for indication or control functions. It provides 4 illuminated buttons and a jogdial with 3 axis. It is not a touch display and can also be used on outside stations.

It has two isolated CAN Bus connection which can be used differently.

All signals provided by the MPC can be indicated on a customized graphic.

Control functions of the display

Jogdial

The Jogdial is a small joystick with several moving options.

Jogdial horizontal/vertical

The Jogdial can be pushed in horizontal (X-position) or vertical (Y-position) direction.

It acts as a push button on the end position of the moving direction.

Push buttons 1 - 4

Push buttons 1 - 4

AVENTICS

AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration 29

Station Configuration | Display (type 230)

Jogdial Down

The Jogdial can be pushed in down (Z-position) direction. It acts as a push button on the end position.

Jogdial Turn

The Jogdial can be turned in increments.

Indications

For the indication standardized graphics are available. There is mostly a circular tachometer for the indication of Shaft speed or Engine speed, analog indication which shows a value, binary state with LED or

Selector indications that changes the text.

30 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality Functionality| Standard Modes

Functionality

The system contains of two different controllers. The Marex OS II MPC (Marine Propulsion Controller) is the

Master CAN device and responsible for the speed control of the system and the reversing gear clutch control. It contains the speed output characteristics with ramp timings for the motors and the proper clutch control of the reversing gear. It handles the monitoring of all CAN devices and is the interface to the levers, the display 230 and the Hybrid controller. The Hybrid controller is handling the change of modes under the proper conditions. It is also working as an I/O extension to the different interfaces. During the mode changes it is monitoring the timeouts and the respective alarms.

Standard Modes

There can be several different operating modes in a Hybrid system.

The 3 standard modes which are integrated in the standard software are the OFF mode, Diesel mode and

Electric mode.

The selection of the modes can be executed on the display 230 or on an operating unit with the respective button.

The standard procedure for changing the modes is in lever position NEUTRAL.

OFF Mode

If the lever is in NEUTRAL position the controller is switching off the propulsion in the correct order.

First the Hybrid is switched off with its required sub devices (oil pump).

After this the Diesel is stopped and at last the Diesel clutch is disengaged.

Diesel Mode

If the lever is in NEUTRAL position the controller is engaging the Diesel clutch before starting the Diesel engine. If the clutch is engaged the Diesel is started.

For Diesel clutch systems the Hybrid is now also rotating. The external Hybrid System can now handle the device for their requirements. With binary state signals form the Hybrid, the remote control can adapt the output characteristics to the Diesel engine. (generator operation)

For PTI systems the PTI clutch is engaged. After the engaged feedback of the PTI the reversing gear is actuated according to the lever position. With binary state signals form the Hybrid, the remote control can adapt the output characteristics to the Diesel engine. (generator operation)

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Functionality | Extended Modes

Electric Mode

If the lever is in NEUTRAL position the controller is starting/activating the Hybrid system. As soon as the feedback is received the maneuvering can be started. It is ensured that the Diesel Clutch is disengaged.

For Diesel clutch systems the Hybrid needs to ramp up to its idle speed to build up enough pressure for the reversing gear. The Hybrid behaves like a standard engine. Moving the lever AHEAD will engage the clutch in AHEAD and the same with ASTERN. The speed output to the Hybrid is 4..20mA with an additional direction command (AHEAD or ASTERN).

If the Hybrid shall start from 0-Speed an additional electrical oil pump is needed. (not Standard)

For PTI systems the oil pump is started before the Hybrid system.

For some gears it is not allowed to clutch in the PTI clutch in 0-Speed. This engagement is executed when the lever is moved the first time to a detent AHEAD or ASTERN. The electro motor is ramped up to engagement speed, the PTI clutch is closed and with engaged clutch the speed can be reduced to 0-Speed.

In this mode the reversing gear is not actuated anymore. The speed output to the Hybrid is 4..20mA with an additional direction command (AHEAD or ASTERN).

Extended Modes

Additionally to the standard modes it is also possible to design a customized functionality.

Therefore additionally programming is necessary. It depends on the complexity of the function.

It is also helpful to specify the requested function and the required error handling.

What happens if one device fails.

Generator Mode

Pressing a button or on a certain lever position the generator function will be activated.

For Diesel clutch systems the Hybrid is still rotating. The generator function must be requested.

For PTI systems it is considered that the clutch is engaged. The PTO function must be requested.

Boost Mode

Pressing a button or on a certain lever position the boost function will be activated.

For Diesel clutch systems the Hybrid is still rotating. The boost function must be requested.

For PTI systems it is considered that the clutch is engaged. The boost function must be requested.

32 AVENTICS | 336 103 xxx 0 – Hybrid | Basic System Configuration

Functionality | System Informations

Hybrid Mode

The Hybrid function is a more complex function. Depending on the lever position the propulsion starts in

Electric Mode and is switching manually by a button press or automatically to the Diesel Mode when possible. While in Diesel Mode the Hybrid generates power. On a certain lever position it will switch to boost to support the Diesel at the end of the torque curve.

For this mode it is necessary that the speed of Diesel and Hybrid match at a certain lever range to avoid unexpected thrust.

For Diesel clutch systems the Hybrid is still rotating. The different function must be requested according to the active lever position. It is possible to jump over the power generation when the lever is moved quickly to the end position.

For PTI systems it is considered that the clutch is engaged. The different function must be requested according to the active lever position.

System Informations

To design a suitable display visualization informations about the maximum speeds of the Diesel engine and the Hybrid are needed. With the provided gear ratios of the reversing gear the required values can be calculated. For the preadjustment of the system also the engaging speeds are helpful.

In case the Hybrid Mode is requested these informations are essential to design a proper mode change.

For Diesel clutch systems the fixed ratio of the reduction gear has to be provided.

For PTI systems the ratio to Diesel and Shaft is necessary.

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Index | System Informations

Index

E Engine Room Configuration

Cabinet MPC Hybrid Controller

Standard Optional Cabinet Standard Cabinet Standard MPC

F Functionality

Extended Modes Boost Mode Generator Mode Hybrid Mode

Standard Modes Diesel Mode Electric Mode OFF Mode

System Informations Functionality

G General

Diesel Clutch Introduction PTI Clutch

M Manual

Required and additional documentation Safety instructions Validity

S Safety instructions

Battery replacement Engine emergency control Engine emergency stop General safety instructions Improper use Intended use IP protection classes Modification of control parameters Personnel qualification Product and technology-related safety instructions ... 9

Standard Configuration Checklist Hardware Overview DIESEL Overview PTI Partslist

Station Configuration Control Head

CAN IO

type230 type244

Display Controls Indications

Operating units type231 Engine type231 free type231 Standard type242 Engine type242 free

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Further addresses:

www.aventics.com

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging.

An example configuration is depicted on the title page. The delivered product may thus vary from that in the illustration.

Translation of the original operating instructions. The original operating instructions were created in the German language.

Subject to modifications. © All rights reserved by AVENTICS GmbH, even and especially in cases of proprietary rights applications. It may not be reproduced or given to third parties without its consent.