User Instructions for WRC1021D
Doc. 0001-5989
0001-5989 Rev. C
CONTENTS
1.0 INTRODUCTION TO THE WRC1021D .............................................................. 2
2.0 FUNCTIONAL DESCRIPTION............................................................................. 3
3.0 POTENTIOMETERS, SWITCHES AND INDICATORS................................... 5
4.0 CALIBRATION AND START-UP OF WRC1021B CIRCUIT BOARD ........... 7
5.0 THE FEEDBACK POTENTIOMETER................................................................ 9
6.0 SERVO SYSTEM................................................................................................... 12
7.0 ERRORS AND TROUBLESHOOTING. ............................................................ 13
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
1
0001-5989 Rev. C
1.0 INTRODUCTION TO THE WRC1021D
The WRC1021D remote controller is a replacement for the older type WRC1021
boards. It is 100% mechanical and functional compatible with the older WRC1021.
WRC1024D are designed with modern SMD technology to extend the life time.
TECHNICAL SPECIFICATIONS
Power Supply 230V AC/50 – 60 Hz
24V DC
Power Consumption 220V 0.04A (no servo valves connected)
24V 4.0A Max (depending on Output Limit alarms)
Max Output Servo Drivers 1.5A 220VAC
Max Output Limit alarms 2.0A 24VDC (Absolute max. rating).
Board Dimensions 100 x 160 mm Euro Card
Board Weight 385 grams
Item id 000070089
WRC1021D is produced with serial nr. and product revision number. Refer to these
numbers when you request for service.
Ser. No. yynnnn
PRnn
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
2
0001-5989 Rev. C
2.0 FUNCTIONAL DESCRIPTION
Order Potentiometer
Limit alarm 1
Limit alarm 2
Feedback Potentiometer
WRC
Slave Order Potentiometer 1021 Hoist valve
Lower valve
Command shift
Bypass valve
Full hoist
Option
Minimum configuration
Fig.1 Block Diagram
The WRC1021D remote controller compares current order signal with the feedback
signal. The system may have two orders one main order and one slave order, which is
selected via the Slave order signal. If order and feedback are out of balance the
WRC1021D board will set the servo valve outputs according to the signal difference.
When balance is achieved the valves will go inactive and hold this position until the
order takes a new position. The bypass will open if the order has been left in neutral
position for 7 seconds (if this option is not disabled), or an error is detected, such as
signals out of range.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
3
0001-5989 Rev. C
Fig. 2 Electrical connections.
Options
- R2 Slave potentiometer
- S1 Disconnects order [Link] and sets the manoeuvring handle in “full hoist” pos.
- S2 Disconnects main order and connects slave order input.
- S3 Reduces the speed of the manoeuvring handle.
- K1 0VDC output when the manoeuvre handle is in “alarm area 1”
- K2 0VDC output when the manoeuvre handle is in “alarm area 2”
24VDC Supply is not necessary if none of the options are connected.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
4
0001-5989 Rev. C
3.0 POTENTIOMETERS, SWITCHES AND INDICATORS
Fig. 3 Board Layout
Trim. Potentiometers Dip Switches Led Indicators
P1 Full hoist Position S1.1 Alarm2 Invert DL1 5V Indicator
P2 Full hoist Speed S1.2 Alarm1 Invert DL2 Running
P3 Alarm2 Limit S1.3 Flushing DL3 Hoist Open
P4 Alarm1 Limit S1.4 Not in use DL4 Lower Open
P5 Deadband S1.5 Creep Drive DL5 Bypass Closed
S1.6 Disable Auto Bypass DL6 Alarm2
S1.7 Set Full hoist DL7 Alarm1
S1.8 Calibration
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
5
0001-5989 Rev. C
P1 Adjusts the winch manoeuvre arms position when a “full hoist” signal is applied.
Turning the pot meter counter clockwise will move the arm against hoist. Shall
stop 3-5 mm from end-stopper on valve unit.
P2 Adjusts the winch manoeuvre arms speed, when moving to full hoist position
when a “full hoist” signal is applied. The speed increases when pot meter is
turned counter clockwise.
P3 Adjusts the position at which the Alarm2 will be activated. Since it is activated via
the feedback signal it will be fully functional even when the winch is manually
operated. The Alarm2 limit moves towards lower when pot meter is turned
clockwise. (Factory setting: approx 10% lower, terminal no. 21).
P4 Adjusts the position at which the Alarm1 will be activated. Since it is activated via
the feedback signal it will be fully functional even when the winch is manually
operated. The Alarm1 limit moves towards lower when pot meter is turned
clockwise. (Factory setting: approx 50% lower, terminal no. 20).
P5 Adjusts the systems Dead band. The Dead band increases when pot meter is
turned clockwise.
S1.1 If this switch is set Alarm2 function will be inverted. Where it was active it will
now be passive and vice versa.
S1.2 If this switch is set Alarm1 function will be inverted. Where it was active it will
now be passive and vice versa.
S1.3 Sets the valves in flushing position, to simplify the flushing operation. Signal for
full hoist and close bypass will be set, regardless of the order and feedback pot
meter are connected or not.
S1.4 Not in use.
S1.5 This switch will enable the possibility to creep drive for special modes.
S1.6 This switch will disable the automatic bypassing function (7 sec. Auto bypass).
S1.7 Forces the winch to “full hoist” position set by P1. (Used during adjustments.)
S1.8 This switch set the card in modus for calibration. Earlier memory will be deleted
when you operate this switch. Operate the remote controls and the manoeuvre
handle to maximum range. Set the switch in off position. Calibrated values are
now saved.
L1 When lit, indicates that the circuit board power supply is delivering 5V.
L2 When blinking steadily, it indicates that the program is executing normally.
When blinking rapidly, it indicates error in order or feedback potentiometer circuit.
L3 When lit, the Hoist output is energizing the Hoist valve and opens it.
L4 When lit, the Lower output is energizing the Lower valve and opens it.
L5 When lit, the Bypass output is energizing the Bypass valve and closes it.
L6 When lit, the Alarm2 output in active.
L7 When lit, the Alarm1 output in active.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
6
0001-5989 Rev. C
4.0 CALIBRATION AND START-UP OF WRC1021D CIRCUIT BOARD
How to calibrate / adjust circuit board WRC1021D after replacing circuit
board and/or change of feedback potentiometer on winch.
NOTE:
Make sure that all main pumps are OFF and servo-pump is ON during
calibration/adjustment of WRC card.
See fig.3 for circuit board layout.
1. Calibration of control lever on winch.
Make sure that all control levers are standing in correct stop position. Activate
dipswitch number 8 on WRC card. Operate the control lever on winch to full hoist
and then to full lower. Operate joysticks on bridge panel to full hoist and then to full
lower. Operate joysticks on deck panel, if present, to full hoist and then to full
lower. Deactivate dipswitch number 8 on the WRC card to store the calibration
values into the card.
2. Calibration of dead band.
The dead band value is adjusted using pot meter number 5 on the WRC card. Clock-
wise adjustment
will result to a bigger dead band. Counter clock-wise adjustment will result to a
smaller dead band. If the control lever on the winch won’t settle in stop position,
adjust the dead band clock-wise.
3. Adjustment of full hoist position in ”auto” mode.
Use dipswitch number 7 to activate the ”full hoist” mode on the WRC card
(dipswitch number 7 activates the WRC card in the same way that a full hoist signal
from the control system). Adjust full hoist on the winch control lever by using pot
meter P1 on the WRC card. Turn dipswitch number 7 ”off” when the “full hoist”
position is properly adjusted. Use pot meter P2 to adjust the control lever movement
time from ”stop” to ”full hoist” position when “full hoist” command is activated.
Adjust the control lever movement time to approx 10 seconds.
4. Activating “Creep drive” function.
On anchor handling and towing winches the last few years, the function “creep
drive” is implemented to avoid damage on gear during coupling in. Activate
dipswitch number 5, and make sure that P2 is adjusted as described in above
chapter. Adjust movement time to approx 10 seconds.
5. Digital output channels on WRC card.
On winch deliveries during the few last years, there are mounted valves that lead
some of the oil around the winch manoeuvre valve and directly into the motor.
These valves, together with other valves on pipe- and pump-arrangement, are partly
controlled from the WRC 1021 circuit board.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
7
0001-5989 Rev. C
The WRC card uses two digital output channels called ”Alarm 1” and ”Alarm 2” to
control this function. The use of “Alarm 1” and “Alarm 2“ changes from installation
to installation. Use the circuit diagrams for each installation to determine how the
WRC card output channels are used.
The relays set point is adjusted with pot meter 4 for ”Alarm 1” and pot meter 3 for
”Alarm 2”. The relay function can be inverted using dipswitch number 2 for “Alarm
1” and dipswitch number 1 for “Alarm 2”. Diode L7 is lit when ”Alarm 1” is active
and diode L6 is lit when ”Alarm 2” is active.
Potentiometers number 3 and 4 on the WRC card (”Alarm 1” and ”Alarm 2” set
point) is normally adjusted such that the digital output channels are activated when
manoeuvre valve on winch reaches 80-90% of full hoist signal.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
8
0001-5989 Rev. C
5.0 THE FEEDBACK POTENTIOMETER.
The feedback potentiometer, usually are of 2 k ohm type. To achieve optimum
performance an original potentiometer should be used. Part no. 818-640-00, or spare
part kit including seals, part no. 000001943.
Notes: Pos no. Qty. Description
2 2 Seal Washer
1. If oil leakage, pos. no. 7. and 9. to be 4 1 O-ring
changed. 7 1 Gasket
NB! Remember to remove expansion
9 1 U-ring
pressure in the hydraulic system before
18 1 Potentiometer
dismantling!
2. If only potentiometer pos. no. 18 to be
changed, removal of expansion pressure is
not necessary, as long as Device housing
is not dismantled.
3. When finished replacing the potentiometer, the
lever is to be moved in fully hoist/lower position.
This is to ensure proper mechanical function of
the feedback potentiometer.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
9
0001-5989 Rev. C
Earlier feedback potentiometer has a different mechanical solution, see Fig. 4.
100 ohm feedback potentiometer has item no. 240-682. 1 Kohm has item no. 151-604-
04. To upgrade the complete housing to the new version, use item 403-732-00.
Fig. 4 Feedback potentiometer adjustments
If a potentiometer on the control lever must be replaced, following procedure shall be
used.
1- Stop the pumps.
2- Let out the expansion pressure to prevent an oil leakage through the o-ring in
figure no.4
3- Remove the cover and indicator housing fastened by the four bolts.
4- Make sure that the wires are marked before disconnecting them.
5- Carefully pull out the indicator housing.
6- Replace the potentiometer, to avoid damage of potentiometer and oil spill, make
sure the potentiometer pin and O-ring are correctly fitted before the bolts are
tightened.
7- Potentiometer to be adjusted in centre when lever is in stop position.
8- Readjust the feedback as described in chapter 4.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
10
0001-5989 Rev. C
If the system for some reason is not letting itself be calibrated check the following
points.
1- Feedback potentiometer is incorrectly connected, the two endpoint connections
has been switched. This is easily checked with a voltmeter at the rear of the
WRC1021 rack system, see fig. 2 (electrical connections).
Place the black (0V) measuring pin at '9' and the red (+) at '8', now get someone to
move the manouver arm against hoist, the voltage should now be decreasing. If
not the endpoints must be switched. And while you are at it check the Order and
Slave order signals if any. You can keep the black measuring pin at '9' and the red
at '11' for Order and '14' for Slave order. The result should be the same, decreasing
voltage in hoist, if not take corrective measures accordingly.
2- The servo oil lines are crossed. This must be checked by actuating the valves by
means of a screwdriver at the end of solenoid see Fig.5 and visually check that the
manouver arm moved correctly.
PS. You have to activate the Bypass valve as well, keeping it from bypassing.
Make sure the manoeuvre arm is moving against hoist when the A solenoid is
manually activated and Lower when B is activated.
3- The servo valves electrical connections have been switched. Try switching the
solenoid connectors.
When the arm is moving correctly, turn the indicator housing until the manoeuvre arm is
exactly in STOP position, then tighten the 4 cover bolts carefully.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
11
0001-5989 Rev. C
6.0 SERVO SYSTEM
Fig. 5 Servo system R8B and R8
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
12
0001-5989 Rev. C
7.0 ERRORS AND TROUBLESHOOTING.
Even when an installation is correctly installed problems may turn up after while. To
help during faultfinding we will here present a troubleshooting chart, covering the most
common symptoms and causes. The system is divided into an electronic part and a
hydraulic part. Simply follow the pointer until the error is located or end of procedure.
Start
Servo on No Switch on
Only this Check main
L1 on No No Check wiring
card fuse
Yes
Check fuses Check supply Replace
on card and wiring WRC1021
L2 blinking Switch power Blinking fast Replace
No No L2 on
Slow (1Hz) off then on (10 Hz) WRC1021
Yes
Set order in Check order
Recalibrate
stop and feedback
Check
Is L3 or L4 Recalibrate/ Goto chart
Yes potmeter
blinking adjust for hydraulics
wirings
Move order
to hoist Check that
check L3 is No voltage across
blinking and 9-11 (order)
L5 is on 9-8 (feedback)
Check Goto start for
9-14 (slaveorder)
potmeter hydraulics
Move order is following
to hoist potmeter position
check L4 is No
blinking and Ref. page 12 Replace
L5 is on potmeter
Goto chart
for hydraulics
Fig. 6 Trouble-shooting chart electronics
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
13
0001-5989 Rev. C
Start
Servo on No Switch on
Motor Check supply voltage
No
running and thermal protection
Are pressure
according to No Check servo
system
Replace
Manually solenoid
activate Check valve for
bypass valve No bypass valve bypass and/
and lower (B- on winch or hoist/lower
coil) Check valve
bypass valve
and hoist/
Manually lower valve
activate Check Service/
Check
bypass valve No bypass valve replace
sylinder
and hoist (A- on winch sylinder
coil)
Move order
in hoist. Check
No
Manouver solenoid A
arm in hoist? Replace
Check
WRC1021
bypass
And/or
solenoid.
solenoid
Check wiring
Move order valves
in lower. Check
No
Manouver solenoid B
arm in lower?
Call Service
OK? No
department
Fig.8 Trouble-shooting chart hydraulics.
Ref. to page 13, servo system principle drawings.
Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 87 00.
dept. Deck Machinery - Brattvaag E-mail: [Link]@[Link]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: [Link]
14
