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User Instruction 0001-1273

Remote Control / Towcon RT

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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Issue number Reason for Change

A First issue. This document is based on 0000-0245.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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PREFACE ............................................................................................................................. 7

1 TOWCON RT – SYSTEM DESCRIPTION..................................................................... 8

1.1 System layout........................................................................................................................ 8

1.2 Workstation .......................................................................................................................... 9

1.3 Input Devices ...................................................................................................................... 10

1.4 Portable Controller ............................................................................................................ 10

2 OPERATION................................................................................................................ 11

2.1 Prepare operation .............................................................................................................. 11

2.1.1 Precautions................................................................................................................... 11
2.1.1.2 Ensure proper training for operators of the equipment. ........................................... 11
2.1.2 Monitor pictures for operations ................................................................................... 12
2.1.2.1 Winch View ............................................................................................................ 12
2.1.2.2 Main View .............................................................................................................. 13
2.1.2.3 Dual View ............................................................................................................... 14
2.1.2.4 Command View ...................................................................................................... 15
2.1.2.5 Pumps View ............................................................................................................ 16
2.1.2.6 Setup Views ............................................................................................................ 17
2.1.2.7 Alarm View............................................................................................................. 18

2.2 Manual operation............................................................................................................... 19

2.2.1 Safety precautions ........................................................................................................ 19
2.2.2 Manual Pump Control.................................................................................................. 20
2.2.2.1 Valve Status. ............................................................................................................ 21
2.2.3 Operation of Main Servo. ............................................................................................ 22
2.2.4 Command control – remote controlled winches .......................................................... 23
2.2.5 TowCon screen – Bridge system: ................................................................................ 24
2.2.6 Winch Chair – Bridge system: ..................................................................................... 25
2.2.7 Input Device – Winch Control Chair and Bridge Panel............................................... 26
2.2.8 Controlling Brakes. ...................................................................................................... 27
2.2.8.1 Releasing the brake – check available pull force. ....................................................... 28
2.2.9 Connecting motors to a drum....................................................................................... 29
2.2.10 Double Drive Coupling / Shaft Couplings................................................................... 30
2.2.11 Speed Step – controlling oil flow to motors ................................................................ 32
2.2.12 Torque step – Manual motor cell selection.................................................................. 33
2.2.13 Tension control. ........................................................................................................... 34
2.2.14 Rendering force............................................................................................................ 34
2.2.15 Rotate the Winch.......................................................................................................... 36
2.2.16 Operating Spooling Device.......................................................................................... 37
2.2.17 Tooth wheel Lubrication.............................................................................................. 38
2.2.17.1 Lubrication System - Adjustments....................................................................... 39

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2.18 SAFETY FUNCTIONS .............................................................................................. 40
2.2.18.1 Emergency Stop. ................................................................................................. 40
2.2.18.2 Emergency Release. ............................................................................................ 40
2.2.18.3 Ultimate Release. ................................................................................................ 41
2.2.18.4 Over speed Protection. ........................................................................................ 42
2.2.18.5 Max tension when overspeed.............................................................................. 42
2.2.18.6 Bandbrakes engage when overspeed................................................................... 42
2.2.18.7 Active stop ........................................................................................................... 42

2.3 Automatic Towing Functions............................................................................................ 43

2.3.1 Prepare for Automatic Towing Operations .................................................................. 43
2.3.2 Shoot (Automatic Pay-Out) ......................................................................................... 45
2.3.3 Automatic Towing ....................................................................................................... 47
2.3.4 Towing Static ............................................................................................................... 50
2.3.5 Hoist............................................................................................................................. 51
2.3.6 Adjusting parameters for automatic functions ............................................................. 53
Auto / Manual limit: ................................................................................................................ 53
Brake Limit: ............................................................................................................................. 53
Tow / Hoist limit:..................................................................................................................... 53

2.4 Monitoring winch............................................................................................................... 54

2.4.1 Tension / Oil Pressure.................................................................................................. 54
2.4.2 Speed / wirespeed ........................................................................................................ 55
2.4.3 Length .......................................................................................................................... 55
2.4.4 Temperature ................................................................................................................. 59
2.4.5 Trend Monitoring......................................................................................................... 59
2.4.5 Trend Monitoring......................................................................................................... 60
2.4.5.1 Monitoring Wire Tension and Motor Pressure ....................................................... 60
2.4.5.2 Monitoring quality of Hydraulic Oil ....................................................................... 61
2.4.6 Coupling and Brake condition. .................................................................................... 62
2.4.7 Alarms.......................................................................................................................... 63
What went wrong? ---- Alarm monitoring.............................................................................. 63
Alarm Reset button .................................................................................................................. 64
Alarm lamp .............................................................................................................................. 64
Maxvalue logging .................................................................................................................... 64
2.4.8 Alarm List .................................................................................................................... 65
2.4.8.1 Emergency stop....................................................................................................... 65
2.4.8.2 Emergency Release ................................................................................................. 65
2.4.8.3 Mismatch on Coupling Sensor................................................................................ 65
2.4.8.4 Overspeed ............................................................................................................... 65
2.4.8.5 High oil temperature ............................................................................................... 65
2.4.8.6 High oil pressure ..................................................................................................... 65
2.4.8.7 Oil contamination – Water...................................................................................... 65
2.4.8.8 Oil contamination – Particles.................................................................................. 65
2.4.8.9 Low Gear Oil Level ................................................................................................ 65
2.4.8.10 Expansion system - Low pressure........................................................................ 66
2.4.8.11 Expansion system - Low level ............................................................................. 66
2.4.8.12 Expansion system – Filling Pump Stopped ......................................................... 66
2.4.8.13 Expansion System – Starter not in “Remote Mode”............................................ 66

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.4.8.14 Expansion System – Possible motor failure......................................................... 66
2.4.8.15 Expansion System – Motor protection tripped. ................................................... 66
2.4.8.16 Low brake pressure .............................................................................................. 66
2.4.8.17 Drum rotating with brake on................................................................................ 66
2.4.8.18 Bitter end.............................................................................................................. 66
2.4.8.19 Node nn lost ......................................................................................................... 66
2.4.8.20 Bus warning ......................................................................................................... 67
2.4.8.21 Wireguard Limit................................................................................................... 67
2.4.8.22 Grease Lubrication System – Grease Supply Failing........................................... 67
2.4.8.23 Grease Lubrication System – Malfunction .......................................................... 67
2.4.8.24 Grease Lubrication System – FAULT (Power supply) ........................................ 67
2.4.8.25 Servo System xx – Servo pump n - Tripped ........................................................ 67
2.4.8.26 Servo System xx – (Main or sub system) – High Oil Temp ................................ 67
2.4.8.27 Servo System xx – (Main or sub system) – Low Level ....................................... 67
2.4.8.28 Stern Roller Cooling System - FlowAlarm.......................................................... 68
2.4.8.29 Stern Roller Cooling System – Low Level .......................................................... 68
2.4.8.30 Stern Roller Cooling System – High Temp ......................................................... 68
2.4.8.31 Ultimate Release is activated. .............................................................................. 68
2.4.8.32 Wire tensile strength is overloaded...................................................................... 68

2.5 System addons .................................................................................................................... 69

2.5.1 ”SlowDrive” - ASD .................................................................................................... 69
2.5.2 ”Hoist Limitation” - AHL .......................................................................................... 70
2.5.3 ”Length Guard” - ALG .............................................................................................. 71
2.5.4 On screen change of overspeed limit: .......................................................................... 71
2.5.5 Shark Jaw tension reading ........................................................................................... 72
2.5.5.1 Using Tara function. ................................................................................................ 72
2.5.5.2 Selecting which loadcell pair to display................................................................... 72
2.5.5.3 Calibrating Sharkjaw load reading........................................................................... 73
2.5.6 Length Reading Stern Roller........................................................................................ 74
2.5.7 Auto Mode Chain Pull Winches .................................................................................. 76
2.5.8 Max Speed Range (MSR) ............................................................................................ 78
2.5.9 Automatic Brake Interlock ( ABI ) .............................................................................. 78

2.6 Using Cable lifters.................................................................................................................... 80

2.7 System Settings, Wire-data ............................................................................................... 84

3 SYSTEM UTILITIES - TOWCON RT .......................................................................... 85

3.1 Why doesn’t anything work ? --- Security Lock ............................................................ 85

3.2 Monitor Intensity and Cleaning ....................................................................................... 85

3.3 Input Device Illumination Control ................................................................................... 86

3.4 Password protected features ............................................................................................. 86

3.5 Transferring log files to USB stick ................................................................................... 87

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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3.5.1 Convert a log file to Excel ........................................................................................... 89

3.6 The user menu ................................................................................................................... 91

3.6.1 System info .................................................................................................................. 91
3.6.2 Set Date and Time........................................................................................................ 91

4 MMI – MAN MACHINE INTERFACE / USER CONTROLS ....................................... 92

4.1 Speed and Tension - Input Devices .................................................................................. 92

4.2 Monitor with “Touch Screen” utility. .............................................................................. 95

4.2.1 LCD Monitor ............................................................................................................... 95
4.2.1 Power Switch .......................................................................................................... 95
4.2.5 Touch Screen .......................................................................................................... 96
4.2.6 Screen adjustments.................................................................................................. 96
4.2.7 Select button............................................................................................................ 96
4.2.8 Functions with LED indicators ............................................................................... 96
4.2.9 Cleaning the screen ................................................................................................. 96
4.2.10 Calibrate Touch Screen............................................................................................ 97

4.3 Using Trackball.................................................................................................................. 99

4.4 Using a Touchscreen ........................................................................................................ 100

4.5 Screen Elements ............................................................................................................... 101

4.5.1 Folders, Tabs and Panels............................................................................................ 101
4.5.2 System Panel .............................................................................................................. 102
4.5.3 Buttons and Lamps..................................................................................................... 103
4.5.4 Digital Displays.......................................................................................................... 103
4.5.5 Bargraphs ................................................................................................................... 104
4.5.6 Meters ........................................................................................................................ 104
4.5.7 Sliders ........................................................................................................................ 104
4.5.8 Menus and Keypad..................................................................................................... 105

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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PREFACE

The monitoring and control system is developed in co-operation with our customers. We have
through many years had the opportunity to derive advantage from the immeasurable experience of
some of the world’s most influential operators. The system is designed to give the crew precise and
reliable information about the system status, as well as offering automatic functions that will enhance
the usability of the winch system.

Please Note:
Some of the illustrations (screenshots) and described functions may not apply on current installation.
The control system is in constant development, and because of that this manual may cover functions
not installed or applicable on current installation.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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1 TOWCON RT – System description

1.1 System layout

The System is configured and operated from a Computer system, which hereafter is referred
to as a workstation .The workstation consists of a rugged display unit for displaying the
operating condition and data for the winch system, and a Marine Grade Computer. The
Display also functions as an input device enabling the operator to change system parameters
and operating modes. The actual presentation and contents of the display may differ from one
application to another, depending on which information is relevant to the specific application.

Mounted in
winch Chair

Canbus Canbus

WW1

Ethernet
Eth-switch

MSI

Monitor Features:
System Redundant • Built in features for error detection.
Interface Fiber optic • The system is easy to install.
ethernet • The system reduces the need for cabling to the Bridge.
• The systems functionality is expandable.
• Built in NMEA 0183 interface.
• Optional workstations may be installed.
• Optional VGA slave colour monitor may be installed.

Eth-switch

4 x Canbus

WA1 WIO1

WA1 WIO1 spare

MC TCC OCC SCC

Portable
Installed Towing Oil Servo Control
Main
spare Control Control Control System
Cabinet
Cabinet Cabinet Cabinet

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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1.2 Workstation
The workstation is basically a marine grade monitor, computer and pointing device. The
monitor is of high-resolution type and may be equipped with a user interface realized by a
touch screen or a trackball if preferred. A combination of touch screen and a trackball may
also be used. A Workstation may have several slave monitors connected to the same
computer and they all will display the same picture.
A system may also have several workstations, which is operated totally independent of each
other in respect to screen layout and input devices.

A Workstation consists of the following components:

VGA Touch

Trackball

Ethernet Canbus

• LCD Monitor
• Trackball
• Controller

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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1.3 Input Devices

Speed Control

Tension Control

1.4 Portable Controller

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2 OPERATION

2.1 Prepare operation

This section describes the sub-systems to prepare, prior to actual operation of the winch. It
also contains general guidelines and precautions.
Please read this manual thorough. This gives You the best chance to be successful in winch
operations.

2.1.1 Precautions
Before starting any main pumps, one should always make sure that servo is running, brakes
are engaged, and that there are no open valves, filters etc due to maintenance work or other,
and that all personnel are alarmed against the danger of getting injured in chains, wires etc.
because of winches is now being used.

Before starting any pump or servo unit, make sure that no work is being carried out on winch
motors, pipes, valves or other part of the hydraulic systems!
All hydraulic pumps and servo units may be started and stopped by switches on starter
cabinets, but normal operation is remote controlled from bridge, by use of Touch Screen on
monitor for the TowCon RT control system or Winch operator chair.

Remember that the winch potentially could harm people if used wrongly, or out of
specification. Typically could a overload of the winch be dangerous. Please do not overload
or overspeed the winch motors. Overspeed could damage motors.

Please do not hesitate to contact the Rolls-Royce Service department if You are uncertain
regarding technical issues or need more information.
Contact Information:
Fax : +47 70 20 87 00
E-Mail: [email protected]
HomePage: www.rolls-royce.com

Do also strive to follow Your company policy regarding safety on deck, safety for personnel,
and safety for ship and equipment.

2.1.1.2 Ensure proper training for operators of the equipment.

It is Owner responsibility to ensure that operators of the winches have sufficient skills to
operate correct in all situations.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2 Monitor pictures for operations

2.1.2.1 Winch View

The “WINCH VIEW” gives you an overview of the main winch, with active graphical
elements to indicate the position of brake and couplings. In addition to the winch layout the
picture shows the drums tension end paid out length, both as bars and digital readout. The
bars change colors according to its state, red if its value is outside the set maximum limit. The
wire speed and motor RPM are shown only as digital readouts. Each motor-set have
indicators showing the number of active motor cells.
Ex. If ‘TOW DRUM’ is coupled to ‘PORT MOTORSET’ the drum will adapt the colour of
the motor, which in this case is green. If a drum is not connected to a motor unit it will be
coloured grey. A motor unit will be coloured grey if it has no oil supply. And if the band
brake goes on it will be coloured red. The couplings and brakes will move/change color
according to their feedback sensor.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.2 Main View

The ‘MAIN VIEW’ is the picture giving the user most information and possibilities for adjustment of
both manual and automatic operations on one main winch drum.
It gives the operator clear and concise information either in form of bars, as length and tension, but
also digital readout of secondary information such as wire speed, motor rpm and motor pressure. In
addition there are readout of oil temperature.
The drum selector enables the operator to easily switch the view between different drums, all data on
the screen will then of cause relate to the selected drum.
The full functionality will be described in detail later in the chapter concerning preparation for
operation.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.3 Dual View

The ‘DUAL VIEW’ picture gives the operator a simultaneous view of two drums, as in the ‘MAIN
VIEW’ these pictures are selected by the operator. It contains the most important information about
the operation status and is intended for manual operations. If an automatic operation is desired the
‘MAIN VIEW’ gives the operator the ability to change critical parameters such as towing pressure
and operational mode.
This view normally covers all winches that has a feature that is controlled from screen.
E.g: A tugger have pressure indication on screen. Tugger is then selectable as a drum in either left or
right screen section.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.4 Command View

The ‘COMMAND’ screen gives the operator the ability to change command stations between bridge
and deck.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.5 Pumps View

The ‘PUMPS’ screen gives the operator overview over all remote controlled pumps and valves.
By use of this view it is possible to select the right pump to start to get oil to one special winch.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.6 Setup Views

The ‘SETUP’ screen contains all parameters that are operator adjustable.
This view will differ according to drum numbers and features installed.
Some systems may have more than one Setup view.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.1.2.7 Alarm View

The ‘ALARM’ screen gives the operator overview over alarms.

See section xxxxx for more details.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2 Manual operation

Before starting any pumps, one should always make sure that brakes are engaged, and that there are
no open valves, filters etc due to maintenance work or other, and that all personnel are alarmed
against the danger of getting injured in chains, wires etc. because of winches is now being used.

“Chapter 3” of the manual gives a step-by-step briefing on how to operate the main parts of the
winch installation. It does not cover maintenance or service work.
Please read carefully the complete manual to gain as much confidence with the equipment as
possible. Please do practice winch operation before actually applying load on the winch.

2.2.1 Safety precautions

Before starting any pump or servo unit, make sure that no work is being carried out on winch motors,
pipes, valves or other part of the hydraulic systems!
All hydraulic pumps and servo units may be started and stopped by switches on starter cabinets, but
normal operation is remote controlled from bridge, by use of Touch Screen on monitor for the
TowCon RT control system or Winch operator chair.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2.2 Manual Pump Control

On most vessels were TOWCON is the winch monitoring system, remote start of Servo Units and
Hydraulic Pump Units is only executed by this system. Of course operating switches on the starter
cabinets still may start all pumps, and the Emergency Stop system will always be in function.

Example: Picture for monitoring and manual operation of the hydraulic pumps.

Each pump does have a set of functions:

Pump number.
Start button with RUN indication.

Stop button.

Disable button.

Pump Number:
The number refers to the pump number on the hydraulic Piping Diagram.

Start button with RUN indication:

To start the pump, just click on the button. (See User control section 3.1/3.2)
This will start the pump. When the pump are running, the background on the button will be
green. Note that this is a manual operation, so the valves will not be operated automatically.
So the pump will be directed according to current position of the valves.
We recommend to use the Speed Step function to start the pumps.

Stop button:

To stop the pump, just click on the button. (See User control section 3.1/3.2)
The background of the “Start button” will be grey when the pump are not running.

Disable button:

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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To disable the pump, just click on the button. (See User control section 3.1/3.2)
The background of the button will turn to red. The stop signal to the starter will be activated
continuously, and the automatic functions such as Speed Step will ignore the actual pump as
long as it is disabled.

Table of “Pump Supplies”:

This table shows what winches each pump can be directed to.

Eksample:
Pump 23 can be directed to Main winch and Secondary Port.

Note: This table is only an example, and may be different on this

particular vessel.

2.2.2.1 Valve Status.

The status of the valves are shown here:

The Valve numbers refers to hydraulic piping diagram.

The lamp are grey if the coil on the valve are not energized, and
green if the coil are energized.

In the example to the left Valve 87 and 89 are energized.

Symbol description of Valves:

On the hydraulic piping diagrams there are 3 types of electrically operated valves used to
direct the oil flow to the different winches. We will describe some of these symbols to make
it easier to understand the how the pumps are directed to the different winches.

Change over valves:

Deenergized coil: Oil flows from A to B

Energized coil: Oil flows from A to C

Electrical Non Return valves:

This is a Normally Open valve:
Deenergized coil: Oil flow in direction of arrow
Energized coil: No oil flow.

This is a Normally Closed Valve:

Deenergized coil: No oil flow
Energized coil: Oil flow in direction of arrow

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2.3 Operation of Main Servo.

LONG TIME TOWING:

This vessel may from time to time use one of the main winches only for
holding the load/tow tensioned without rotating, and with brakes engaged.
In this occasions it would be convenient to stop the servo pump to
prevent the servo oil getting overheated, save fuel and reduce noise.
However, the brakes are depending on continuously servo oil pressure,
and because of a small leakage in valves etc the servo pump would even
in this occasions had to been started from time to time to maintain high
enough pressure. To make this start/stop sequence of servo automatic, the
servo unit is equipped with facilities to take care of this job of its own, if
so is wanted.
The automatic start/stop function is called ‘Long Time Towing’, and is remote controlled from the
TowCon screen on bridge. Pressing the button will make the lamp inside go yellow, indicating that
long time towing is active. When “Long Time Towing” is activated ,“Auto” is reset.
CAUTION!
When Long time Towing is active the servo unit will start automatically when pressure is
below limit for start. Keep this in mind if maintaining the servo system.

AUTO:
When this button is pressed/lit, the servo will start automatically when one or more devices in the
control system requires servo oil to operate. Typical if operator wants to operate the spooling devices,
the servo will start automatically when a LP pump for a spooling device is started. When pressing
AUTO, the “Long Time Towing” will be reset. A given time after last request for servo oil is
removed, the servo unit will stop.
START:
When pushing the “Start”-button servo unit will start necessary pumps to maintain a minimum servo
pressure. Pressing “Start” will force “Auto” and “Long Time Towing” to be reset.
STOP:
When pushing the “Stop”-button all servo pumps on unit will stop. “Auto” and “Long Time Towing”
will be reset.
P1/P2 RUN:
Running feedback from each pump on a servo unit. A typical main servo for an anchor handling
winch is always equipped with two pumps, 1 normally operating in standby.
P1/P2 TRIP:
If the motor protection on a servo pump motor is activated, a red lamp will indicate the “fault”.

SELECTING P1 or P2 as first pump to start:

The servo starter is equipped with a selector for changing between which pump to be running
continous, and which pump to operate as standby. During normal operations it is advised to monitor
the running hours on the servo pumps, and change switch so each pump accumulates the same
amount of running hours.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.4 Command control – remote controlled winches

Depending on safety scheme on vessel, operational demands etc, it may be necessary to have the
possibility to control a winch from other locations than the control devices on bridge.
Command Allocation is monitored and controlled by a special picture on the TOWCON Monitor.
An example of this is shown below. On the screen it is possible to select operation of a winch either
from bridge or from deck. In addition to this it may also be more than one control device for a
particular winch both on the bridge and on deck. As an example it may be possible to control a winch
both by a joystick on the Bridge Control Panel and by a joystick on the Winch Control Chair; and in
addition to this it may also be possible to control this by use of a Portable Controller. By use of
touch screen on monitor it is possible to allocate command to Deck, but personnel on Bridge can at
any time take over.

Premises for allocating control to Deck:

Joystick for speed controllers has to be in stop position. Tension Controller may be set to any torque
before command shift, but no adjustment can be done for 3 seconds in advance.

Activate Portable Controller:

Before a Portable Control Unit is activated, the “Take Command”-button on the controller must be
pushed. Until this is done the controller will be “Stand By”. Press the “Take Command”-button for
about 3 sec. to make an activated controller change to “Stand By”.

Changing between devices for Speed Control:

Joystick for speed control has to be in stop position to make it possible to transfer command to
another control stand or swapping command between two joysticks.

Changing between devices for Tension Control

Tension Controller may be set to any torque before command shift, but no adjustment can be done
for 3 seconds in advance.

Be aware of :
A winch may be operated from several locations, but it may be that all functions can’t be controlled
from all control stands. What functions that may be operated by each control stand is shown on the
monitor picture COMMAND. A yellow indicator shows that a function can be operated by use of a
Deck Controller ( normally a portable control unit ) Blue indicators show that a function can be
controlled by equipment on bridge. Be aware that even if command has been allocated to deck, there
may be functions on a winch that still must be controlled from bridge.
Please study example below :

Example shows :
Command is allocated to Deck System, but
control devices for use on deck can only
operate hoist/lower functions. Tension and
Speed Steps on Tugger Winches must still be
controlled by use of devices placed on bridge.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.5 TowCon screen – Bridge system:

Select the desired drum using the selector switch in MAIN or

DUAL view. The status of the drums couplings and brake will be
updated according to the selected drum. Setting of brakes and
couplings is done at the base of either the speed or tension input
device. Be sure the device is set to the correct drum.

All screen elements in screen section will address selected drum.

See example of elements below. Actual screen elements will differ according to functions
implemented.

After a longer standstill there might be need for lubrication of gears. The Force
Lubrication button activates an automatic lubrication cycle.
(See section for Forced Lubrication for more details.)

Depending on the operation at hand there will be need for more or less speed,
the operator selects the desired speed by pressing either the up or down button
and the graph shows your desired speed (blue bar) and what you actually is
getting (green bar).
(See section for speed step for more details.)

This function controls the number of active hydraulic chambers in the motor.
To decrease torque step, the tension setpoint has to be >95%.
Normally a motor operates with all three chambers activated, this gives
maximum torque on the shaft. The Increase/Decrease buttons are used to change
the number of active chambers.
(See section for torque step for more details.)

On some installations there are System Addon functions implemented:

(See section for Sys Addon for more details.)

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.6 Winch Chair – Bridge system:

On the winch chair the speed levers controls what drum to monitor and control on screen. The
difference is easily spotted. The screen selectors are removed, compared to TowCon screen.

When tension control device on left side is

controlling a different drum than the speed control
device, a sign “Caution” is lit. This is done to
remind winch operator that different drums are
selected on same side in chair.
There is no auto-follow function or interlock
between speed and tension device.
This is a choice that have been developed through
close cooperation with our customers.
Flexibility was a stronger argument than the
others.
A compromise was to incorporate a sign telling the
operator about the difference.

The sign is only installed on newer versions of

winch chair systems.
Typically the sign is lit when both speed and
tension device is in command, and are serving
different drums.
The sign is located between Speed Step and
Torque Step.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.7 Input Device – Winch Control Chair and Bridge Panel

Drum selection is performed by “cycling drums”, until wanted drum is shown in display.
“Cycling” is done simply by pressing the + or ÷ buttons. Selectable drums will then be shown on the
display, but this is not possible unless controlled device is “Stand By”. When control device is
“Stand By” there is no light in the “Activate”-button, and functions normally controlled by the device
will not be affected by buttons being pressed or joystick movement. Do not try to “cycle drums”
when there is a blue light on the “Activate”-button! When device is activated the + and ÷ buttons is
used to control torque step on winch motors.

When display on device shows the winch you want to use,

activate for operation by pressing the “Command”-button rapidly
two times. ( like double-click on a computer mouse )
If you want to use a device for controlling another winch then the
one shown on the display, press “Command”-button rapidly two
times and verify that it is “Stand By” before you select.

“Command”-button
“In Command” = Blue light
“Pause” = no light ( older models = yellow light )

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.8 Controlling Brakes.

The drums equipped with band brake can be remote operated from the Devices. These brakes may
also be manually operated at the winch, but that opportunity is normally not used under ordinary
circumstances. Please study instructions for emergency use of brakes on the name plate on
Emergency Brake Pump on winch. In case of leakage in servo pipes on Main winches, brakes will be
engaged by a accumulator on the Emergency Brake Unit, securing a minimum of brake force. Other
winches, not designed for emergency release functionality, will normally have spring brake on,
pressure off.
Please spend some time to study how the emergency systems works before releasing brakes by use of
remote control. Before releasing any brake, be sure about the precautions mentioned in chapter 1.1
concerning security of crew is carried out.
Section of Device.

Example of button and lamps for

operating brake on a drum.
Drum selected is shown in display.

Observe:
Flashing Lamp = order not fulfilled!
Red light = Brake confirmed ON.
Green light = Brake confirmed OFF.
Brake is operated by a button with integrated control lamps on the left side of the Input device.
Operate brake from ON to OFF: (Red light is lit, green in dark.)
Operate brake by double-clicking the button.
The green lamp will now start blinking, and after a few seconds it will light continuously, indicating
that brake now is completely released. The red light will be dark.
Operate brake from OFF to ON:
Operate brake by double-clicking the button.
The red lamp will now start blinking, and after a few seconds it will light continuously,
indicating fully engaged brake. Green light will be dark.

See section for coupling showing visual position indication on screen.

CAUTION!
It is inadvisable to release brake when drum is not connected to motor unit!
Always evaluate load on winch before releasing brake!

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.8.1 Releasing the brake – check available pull force.

During towing operation with engaged brake the winch has no other strain restriction than what is in
the brake. When releasing the brake wire load is being transferred from the brake arrangement to the
hydraulic motor unit, and maximum holding power is thus dependent on the adjustment of the
Tension Control. To secure that winch will not render unintentionally when brake is released, it is
therefore of great importance to check tension adjustments on beforehand. By benefit of TOWCON’s
advantages the operator is able to adjust the tension control to almost exactly the requisite pressure to
hold the load before releasing the brake.

The dotted line in the Tension bar indicates the available

power at the present tension adjustment.
Before releasing the brake, adjust tension, and verify that
the dotted line on tension bar is placed higher than the bar
indicating present load.

The dotted line in the Torque step bar indicates how high
motor pressure is allowed to increase at the present tension
adjustment. Examples shows that available pressure is
adjusted to maximum.

See section for torque step for more details about interaction
between input device for tension and torque step function.

See also section explaining about Rendering to get more

information about what happens when releasing a brake when there
is load in wire.

Automatic Brake Interlock: ( Optional )

If brake is equipped with ABI (Automatic Brake Interlock), release
of bandbrake on a drum not engaged with coupling, is delayed 30s.
An audible and visual alarm will be set off.
See section for System Addons for further details.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.9 Connecting motors to a drum.

Remote controlled couplings can be operated from device for speed or tension.
Operate by double-click on button for operation of coupling. The Input device must be “In
Command”
When the coupling position selector is operated, one of the adjacent control lamps will start blinking.
It may be necessary to rotate motor to engage/disengage coupling.
When the coupling is in right position, the control lamp will light continuously.

Section of Device showing coupling confirmed engaged. Green light in lower section of
button is lit with a green colour.
Indication glowing continuous indicates actual state. Blinking indication indicates wanted
state. Red light indicates coupling out, or in progress to go out.

NOTE ! The operation of couplings are interlocked to brake. If brake is not ON, it is not
possible to move the coupling remotely.

Visual feedback on screen:

Under the drum selector, in main and dual view, the

status for brake and coupling is shown.
It is used same colours as on the input device.

Coupling, engaged.

On winch view the brakes and coupling are also shown.

Red brake = brake engaged.
Green drum = Motor is connected to drum, and motor has pumps
running.
Green coupling = coupling engaged and motor supplied with oil.

When not active or engaged, the colours change to gray.

Brake, turned on.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.10 Double Drive Coupling / Shaft Couplings.

The operator may choose to use more than one motor unit on the same drum, giving the drum
(double) more hoisting power. The coupling is operated from TowCon screen – Main View or Winch
View. (On newer systems the Winch View is used.)
Normally, in double drive, 2 identical motorsets are connected. Therefore the name double drive.
On some winches even more motors can be connected to a drum, on a separate transmission, but this
is more rare. Coupling for these motors will be handled in the same matter as a double drive
coupling, and will be operated from screen.

Operate coupling by pressing button on screen. When button is pressed, one of the adjacent control
lamps will start blinking. When the coupling is in right position, the control lamp will be lit
continuously. It may be necessary to rotate motor to engage/disengage coupling. If of any reason one
of the couplings should move from its decided position, the control lamp will start blinking to alarm
the operator.

Section of Control Panel. ( Monitor Screen )

Illustration only!

Connect or disconnect ”Double Drive”-coupling by button on

TowCon panel

Please observe
It is not possible to disengage the drum coupling for any of the drums if the brake is released.
If interlock is active the request of operation will be ignored.
If for any reason one of the couplings should move from its decided position, the topical control lamp
will start blinking to alarm the operator.
Operating more than one drum in double drive will generate an alarm in the system
It may be necessary to rotate motor to engage/disengage coupling.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
Page31

On newer systems the double drive couplings is named Shaft Couplings. It results in the same , but is
named by function on shaft, rather than function on system.

The environment where the couplings are operated is intuitive and easily operated. When operator
has the “whole” picture, it is more likely to operate the shaft couplings correctly.

CAUTION!
Disengage drum coupling when towing with brake on!
Take precautions not to exceed specified max-load on cable lifters!

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.11 Speed Step – controlling oil flow to motors

Controls implemented on screen.

Depending on the operation at hand there will be need for more or less speed,
the operator selects the desired speed by pressing either the up or down button
and the graph shows your desired speed (blue bar) and what you actually is
getting (green bar).
This function will automatically start/stop the necessary pumps and set the
changeover valves to their correct position. If you do not get the desired amount
of oil, it could be because the motor/manouver limits the amount of oil in the
current situation.

The dotted line in the green bar indicates position of manouver lever on motor. It is the actual
feedback from the motor. It is scaled as 0-100% of calibrated movement on lever, where 100%
equals dotted line in top of bar.

The “CAUTION” sign is lit when:

Main Servo not running.
Main Servo not in Auto
One or more Sys Addon functions, which affect the speed step is activated.

Example of situation where the motor/manouver valve is limiting the amount of oil:

The operator wants full speed on the winch, and clicks on the up button until the blue bar are
completely blue. At this point the manouver valve are in stop position, and the manouver valve can
only handle half of the desired oil rate in this situation. Then the green bar will be green half way up,
and the rest of the oil are directed away from the motor.
The operator start hoisting and the manouver valve comes into fully hoist position, in this situation
the manouver valve can handle all the desired oil. The rest of the oil will then be automatically
directed to the motor, and the green bar will be completely green.

Block of INC when speed lever not in stop: (INC/up-arrow is removed)

If main LP pumps are not equipped with bypass-valves it is not possible to start any pumps unless
speed lever on winch motor is in stop position.

Block of INC when SlowDrive is activated : (Sys Addon)

If Slowdrive is activated on drum, it is only possible to start one pump for each motor.
See section for System addons for further details.

Block of INC when PowerSave is activated: (Sys Addon)

If PowerSave is activated on drum, it is only possible to start one pump for each motor.
See section for System addons for further details.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.12 Torque step – Manual motor cell selection

This function controls the number of

active hydraulic chambers in the motor.
(Not all motors are equipped with this
functionality).
The function is only available when
the brake is off and the coupling
engaged. Also, to decrease torque step,
the tension setpoint has to be >95%.
Normally a motor operates with all
three chambers activated, this gives maximum torque on the shaft.
Operating from Screen:
The Increase/Decrease buttons are used to change the number of active chambers. The status of the
chambers are shown to the left of the buttons. (Green indicates active. The pressure are shown in the
bar left to the chamber status. The bar are scaled from 0-100% of nominal pressure. The actual
pressure in bar is displayed between INC/DEC buttons. The example above indicates 6 bar actual
pressure on motor.
The dotted line in the green bar indicates tension order on motor. It is scaled as 0-100% , same scale
as for the tension devices. 100% equals dotted line in top of bar.
Operating from Input device:
The function is only available when the Input Device is “In Command”, the brake is off and the
coupling engaged.
The Increase/Decrease buttons are used to change the number of active chambers.
The green light in the button will indicate that it is possible to decrease/increase.

The pressure in the motor have to be less than 66% to be able to decrease number of active chambers,
this is to prevent the drum to pay out caused by reduced torque on the shaft. The black arrows the
buttons/green light in base, indicates that it is possible to decrease/increase.

Here are some figures on how the number of active chambers affects the motor:
3 active chambers gives: nominal speed nominal torque
2 active chamber gives approx.: 1,5 x nominal speed 0,67 x nominal torque
1 active chamber gives approx.: 3 x nominal speed 0,33 x nominal torque

The system is constantly monitoring the cells and denies any requests that might strain the motors
above its specification.

Note: Torque Step:

It is only possible to select 1 cell with winch rotating in hoist direction and with tension order >95%.
Not all motors have that torque step equipped. See motor-valve arrangement for more information.
When the brake is engaged the torque step always goes to 3 chambers. When releasing the brake,
operator has to press buttons, on Device or screen, to change torque step.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.2.13 Tension control.

It is possible to control the tension on drums equipped with tension

valve by limiting the oil pressure in their hydraulic motors.
Pressure is controlled by Device for tension.
The Input device must be “In command” to change tension.
To limit the pressure, turn the knob counter-clock. To allow higher
pressure, turn the knob clockwise.

Maximum pressure depends on pressure set on safety

valves on motor and system pressure.
Please notice that you may not see the pressure increase on
bar graphs etc even if you adjust the knob.
This is so because the pressure will never exceed what is
necessary to cope with the present torque on hydraulic
motors.
Please notice that it is necessary to have the Main Servo
running when using the tension control. If servo unit is
stopped, winch will have max power available, regardless
adjustment on tension control devices.

The dotted line in the Tension bar indicates the available power at
the present tension adjustment.
The dotted line in the Torque step bar indicates how high motor
pressure is allowed to increase at the present tension adjustment.
Examples shows a drum with 400t max pull, given max system
pressure.

See section for torque step for more details about interaction
between Input device for tension and torque step function.

2.2.14 Rendering force.

When rendering, the speed lever is set to stop or full-hoist.
Adjusting tension control until torque in the motors is lower than the actual load , will make the
winch start rendering. Please notice that there is a certain threshold before the winch actually is
rendering. The threshold changes as a function of Torque Step and mechanical friction.
The lowest possible rendering force depends on the set Torque Step and the mechanical transmission,
gearboxes, pinions etc. The more increasing rotating speed the more the overhead will be. An
overhead up to 25 – 30% is not abnormal. Threshold example: Tension in wire is about 110 tonnes.
Tension set point is 100 tonnes and the winch will start to render at 120 – 130 tonnes. So if the winch
shall start rendering, tension set point must be adjusted a litle lower than the actual load; probably
around 90 tonnes.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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Rendering (continued) --- “Wire Length Limit”

Before starting to pay out wire or chain, operations as described in section 2.1 must be carried out.
Shooting may be done in two different ways; either lowering by use of the speed control, or by
reducing motors stalling force by the tension control until winch is rendering.
Please study users instructions for the remote control to get more information about this.
Often when paying out wire it is decided on beforehand what the wire-length is to be when payout is
completed. Of course the operator may look after this by constantly watching the length bar graph
and digital display on the monitor, but there is also a more pleasant way to do this. By giving
TOWCON the right information, the operator may get a warning when a special wire length is
reached, and thus do not have to pay too much attention to the monitor screen during this operation.

EXAMPLE:
Wire length is to be 4800 metres when payout is completed, and towing
operation is to be carried out at that length.

Operator is preparing to pay out wire by use of the tension control. (Or
speed control) Because he’ll not be constantly watching the monitor
during payout of almost 3300 metres of wire, he is now adjusting the wire
length alarm limit to 4800 m.

Then he’ll adjust the tension control until winch starts to render, and when
the length limit is reached he’ll get an alarm on TOWCON screen in time
to concentrate merely on the winch before the determined towing length is
exceeded.

The length bar will now become red, when the alarm limit is
exceeded.
When towing length is reached, he’ll once again adjust the length alarm
limit to get a warning if the winch pays out too much during towing
operation. Normally just a few meters should suffice.

Alarm is given by the colour on length bar changing from green to

red
Normally there shall be no red bar-graphs on the screen.

Hint: Length
Want to stop exactly at the metre?
Don’t bother the length bar graph,
but rather concentrate on the
Digital Length Display

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.15 Rotate the Winch.

Motors equipped with remote controlled capabilities can be can be remote operated from an Device
for speed or by radio/cable control.
It is always possible to operate a motor by opening the bypass-throttle on the motor, and moving the
lever manually. On big winches this can be very heavy.

To pay out, push lever firmly ahead. To haul in, pull lever firmly against you. Avoid too quick
movements on control levers to minimize stress on generators, pipes, pumps and other hydraulic
equipment, and to make winch operations as little “noisy” as possible.
Releasing the lever will make the winch stop, as the lever automatically returns to stop position.

Please notice that it is necessary to have the Main Servo in service to operate as described above.
When lowering, motor pressure ( and tension ) may increase to maximum, regardless of tension
adjustment.

Picture of Device for speed control.

See part 1.3 in manual for detailed

description of device.

Operator selects which drum to operate by

pressing (+) or (-) buttons on device. When
correct drum is showing in display operator
my “engage” with drum by double-clicking
on “command” button. When in command a
blue light will be lit. When not in command
the same lamp is yellow.

Before rotating any winch, be sure about the precautions mentioned in chapter concerning security of
crew is carried out.

See section 3.8 for Speed Step for details.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.2.16 Operating Spooling Device

The spooling devices are operated by moving joystick left/right, and by use of two push buttons on aft
top section of joystick. This makes it possible to operate both Hoist/Lower and spooling at the same
time by using only one hand. Necessary pumps are automatically started when operating a device.
A given time ( 15m min. ) after last spool operation the pumps will be stopped automatically.

Select which drum to operate by cycling through the drum by pressing (+) or (-) on Input device base.
When correct drum name is shown in display, double-click on “Command”. When blue light “in
command” is lit, joystick is ready for spooling operation.

Make spooling device move to Stb by moving joystick to Stb.

Make spooling device move to Port by moving joystick to Port.
Spool rollers may be operated separately:
Make spool roller Stb move separate: Press Stb button on device, joystick in wanted direction.
Make spool roller Port move separate: Press Port button on device, joystick in wanted direction.

Picture of Device. Illustration only!

Joystick

Use ( + ) and ( - ) –buttons

Select to find the right winch.
spooling roll Use “Command” –button
to activate joystick.

(+) INC-button

(-) DEC-button

Command button
Selected drum

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.2.17 Tooth wheel Lubrication

Even though this system is automatic it is necessary to check the amount of grease on the wheels
before every winch operation. This must be done by manual inspection because the system has no
sensors that can verify that grease is in fact applied to the wheels and is not squeezed out through a
damaged pipe, or that something else has made the system failing. There are inspection lids on all
gear covers.
If inspection unveils lack of grease, extra lubrication must be supplied by manual override of the
automatic function. Push the “Force Lubrication” –button on the Towcon or Winch Chair monitor.
Grease will now be supplied continuously until drum has rotated at least one turn. The “Force Lub.”-
button will be lit when grease lubrication system actually injects grease.. The “Force Lubrication”
period cannot be interrupted from the remote control, but the function will be aborted if drum is
stopped. The control lamp on screen will be shut off immediately if the period is ended or the
function of any reason is aborted.

The lamp on the “Force Lubrication”-button will be lit when grease is applied. Please observe this
control lamp during winch operation to be sure that system is in order. If one of the drums is rotating
for longer periods without this lamp being lit there is reason to suspect that there is a malfunction in
the lubrication system, and tooth wheels must immediately be inspected.
Alarm ”Grease lubrication System xxx – winch xxx – Grease supply failing” will be set off on
TowCon screen if grease level in reservoir gets low. Action must immediately be taken to refill the
tank or unveil any fault in the system.
On the Lubrication Cabinet on winch is to be found control lamps that is lit when a gear wheel is
lubricated, and there is also a “Force Lubrication”-switch for each gear wheel. Be aware that pushing
these buttons will give continuously greasing on that gear wheel as long as the button is pressed.
These buttons will override orders given by the automatics, and makes it possible to manually
lubricate the winch even if the control system is out of order.

Control lamp and ”Force Lubrication” –button on Towcon

screen on bridge.

Section of Towcon screen: Illustration only!

Equipment on various vessels may look slightly different.

Section of button turns green when lubricating

Part of monitor picture showing an example of

how it looks like when grease is being applied.
Screen elements like these is to be found on
picture “Main” and “Dual” on the main monitor,
and also on the small monitor on Winch Chair.

Section of Towcon screen: Illustration only!

Equipment on various vessels may look slightly different.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2.17.1 Lubrication System - Adjustments

Dependent of lubricant, temperature and applied force on gear wheel, the needed amount of grease
will vary. Operator may regulate lubrication by adjusting values shown on picture “SETUP 2”
Adjusting values to give perfect result may take time, and will be a matter of experience and know-
how. These values are given as a guidance :

Number of teeth to lubricate : 240

Number of teeth to pause lubrication : 2000
Number of teeth to lubricate : 600

Adjustment of lubrication system is possible on monitor picture “SETUP 2”

See chapter 4.5.8 to brush up on how to adjust parameters.

CAUTION!
The automatic lubrication system can fail. For this reason always check the gear transmission
regularly to verify that the teeth are covered with grease.
The winch must never run without grease on gearwheels, because that may lead to excessive
wear on the gearwheels and even breakdown.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.2.18 SAFETY FUNCTIONS

2.2.18.1 Emergency Stop.

If something unexpected or dangerous should occur, demanding the winches to be stopped
immediately, there is an Emergency Stop Switch on the Control Panel on bridge. There is also one or
more of these switches placed on a small junction box on a convenient place on deck. Please make
sure that the crew is informed about where they are placed before any winch operations are started.

Section of Control Panel.

Illustration only !

Pushing down one of these switches will stop

the Servo Unit and all Main Pumps, make the
manoeuvre valves on winches go to Stop
Position, and engage all remote controlled
brakes.

2.2.18.2 Emergency Release.

If something unexpected or dangerous should occur, demanding the winches to release the load,
there is an Emergency Release Switch on the Control Panel on bridge. There is also one switch
placed on deck. Please make sure that the crew is informed about where they are placed before any
winch operations are started. One should however be ware of the rather serious consequences using
these switches may cause to ship, crew and equipment; and because of this the switches are also
protected against being pushed down by accidents. Pushing down one of these switches will cause
brakes being only smoothly engaged, with a rather weak force, just enough to prevent uncontrolled
rotation on drum resulting wire injury. In case drum is coupled to the hydraulic motors, band brake
will be completely released as long as Emergency Release is activated, owing to the fact that torque
in motors is enough to avoid spin-up on drum. However, if Towcon System estimates spin-up on
drum, actions will be taken to protect motors from overspeed.
Section of Control Panel.
Illustration only!

NOTICE!
Observe that pulling up again the activated switch
will make the brake be engaged (if it was engaged
before the Emergency Release was activated). If so
is done while there is load in wire this may cause
serious damages to winch equipment, towing wire,
ship, and even expose crew members to great
danger.

Supplementary information :
Function Specification; document 0000-9468
NOTE ! Em.release overrule Em.stop !

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.2.18.3 Ultimate Release.

If something unexpected or dangerous should occur, demanding the winches to release the load,
there is an Ultimate Release Switch on the Control Panel on bridge. There is also one switch placed
on deck. Please make sure that the crew is informed about where they are placed before any winch
operations are started. One should however be aware of the rather serious consequences using these
switches may cause to ship, crew and equipment; and because of this the switches are also protected
against being pushed down by accidents. Pushing down one of these switches will cause brakes
being released until drum rotation is detected, and then only smoothly engaged, with a rather weak
force, just enough to prevent uncontrolled rotation on drum resulting wire injury. In case drum is
coupled to the hydraulic motors, band brake will be completely released as long as Ultimate Release
is activated, owing to the fact that torque in motors is enough to avoid spin-up on drum. However,
one should be aware that, as distinct from an Emergency Release, in case of Ultimate Release
no actions will be taken to protect motors from overspeed.
Section of Control Panel.
Illustration only!

NOTICE!
Observe that pulling up again the activated switch
will make the brake be engaged (if it was engaged
before the Ultimate Release was activated). If so is
done while there is load in wire this may cause
serious damages to winch equipment, towing wire,
ship, and even expose crew members to great
danger

Supplementary information :
Function Specification; document 0000-9468
.
NOTE ! Ultimate.Release overrule Emergency Release!
Ultimate.Release overrule Emergency Stop!

OBSERVE! If Ultimate Release is activated at the same time as Emergency Release, overspeed
protection will not be activated until both functions are reset.
( All switches, both “Emergency” and “Ultimate”, must be set back to “normal” position )

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.2.18.4 Over speed Protection.

If the Remote Control system detects rotation speed on a motor above allowed limit, the hydraulic
pressure in the winch motors will automatically be increased to maximum to reduce motor RPM. At
the same time the Speed Control will adjust manoeuvre valves on the topical motor units to Stop-
Position. A Brake On order will be given simultaneously to reduce the RPM under the preset limit.
If this happens one should increase the motor pressure a little next time when similar operations is to
be carried out, to prevent damages on winch motors caused by too high revolution speed.

On screen change of overspeed limit:

Segment of Alarm picture

in Towcon.

By reducing the RPM limit on the Towcon Monitoring System, over speed protection can easily be
tested. Lowest possible limit is 15RPM.
The maximum value allowed in the display equals max. allowed rpm on motor.

2.2.18.5 Max tension when overspeed

If the Remote Control system detects rotation speed on a motor above allowed limit, the power to the
proportional valve, controlling the motor tension, is cut. This causes the motor to give max tension
according to shock valves on motor. Observe that in case of Emergency Release ( or Ultimate
Release ) tension will not be increased even if overspeed is detected.

2.2.18.6 Bandbrakes engage when overspeed

If the Remote Control system detects that a motors oversped limit is exceeded, the bandbrake on
drum connected to motor is engaged. Observe that in case of Ultimate Release brake will not be
used to decrease RPM even if overspeed is detected.

2.2.18.7 Active stop

Active stop is the common name for forcing speed control order to zero (stop position), the speed
order from the operator is then superseded
It is used to protect the winch installation in various situations, such as:

No oil to motors. Not allowed to operate speed control.

Trying to run drum against brake. (Only a certain pressure is allowed)
Over speed on motor.
Overload on winch.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.3 Automatic Towing Functions

2.3.1 Prepare for Automatic Towing Operations

This section will explain briefly what to be done before winch operations are executed.
Before starting any pumps, one should always make sure that brakes are engaged,
and that there are no open valves, filters etc due to maintenance work or other, and that all
personnel are alarmed against the danger of getting injured in chains, wires etc. because of
winches is now being used. Further information is to be found in Users Instructions for
Remote Control. Take special notice of all procedures concerning safety of crew and craft.

Be aware that there are certain restrictions attended with accessibility to automatic operations.
Detailed explanations about this are to be found in document section
describing the topical operation.

Do also pay attention to the limits for wire lengths possibly needed to be adjusted.
Select monitor picture PARAMETER to get access to these settings.
These parameters should always be checked before starting any automatic function.

All automatic operations may at any time be stopped

by clicking on ”MANUAL”-button.

Hint : “Auto/Manual-limit”
“Brake limit”
“Tow/Hoist limit”

See section 2.3.5 to brush up on

how to adjust these parameters.

Clip from monitor picture ”SETUP”

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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Please observe that indicator on ”MANUAL”-button is green when this mode is

selected,
while indicator on ”Auto”-buttons is red. This is not because automatic operations
are to be considered as dangerous, but still a reminder is given so that operator shall
not forget that winch may suddenly rotate without him having even touched the
speed control lever.

All automatic operations may at any time be stopped by clicking on

”MANUAL”-button

In this part of manual adjustments of the pressure limits is

essential. Please find more information about use of the
limits in the following examples.

Click the “Down-arrow”-button decrease Pmax One click

will decrease the value by one bar. To increase the limit
value just click on the “UP-arrow”-button.
In the same way adjusting Ptow (Towing Pressure) and
Pmin is done simply by clicking the UP/Down buttons.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.3.2 Shoot (Automatic Pay-Out)

“Shoot” is introduced to take off the winch operator’s hands the unpleasant job of lowering
maybe several hundred metres of wire. This might of course be done in the traditional,
manual way but why not let Towcon take care of it?
Remember that to get access to this function, wire must on beforehand be paid out to a length
at least equal to what’s set as Auto / Manual Limit for the current drum.
Please study both the example below and the “frequently asked questions” on next page.

Example:
Vessel is to pay out 700m of wire.
Auto/Manual limit is set to 140m.

Winch operator manually pays out 150m by lowering with

speed control to get clear off the Manual/Auto Limit. Then he
lets go off the speed control lever and turns his attention to the
TOWCON monitor. First of all he takes a look at the present
motor pressure and estimates how the pressure limits should
be adjusted. He adjust tension controller firmly counter-clock
until winch starts rendering. The pressure is then about 22 Bar,
and he adjusts tension controller to maximum.

Knowing that the winch will get increased rendering force as Minimum pressure Pmin
wire is paid out, he adjust Pay-Out pressure “P-min” a little may need to be adjusted to
lower than this; at about 18 Bar. make winch render.

When TOWCON has finished the automatic Shoot it’ll swap

to the automatic function Towing. As wire length is increasing
to the Brake Length Limit; TOWCON will prepare stopping
the Shoot at the exact wanted towing length. During the last
part of the shoot TOWCON will gradual increase pressure to
Towing Pressure. Winch operator has to estimate how much
pressure the motors will need to hold the load without
rendering. He estimates this to be about 24 Bar, and adjusts
this on the tension meter on monitor screen.
Adjust wanted
Towing Length Before activating shoot he’ll have to tell TOWCON the new
700 m wanted Towing Length. This is done by adjustment on the
Observe : length bar graph on monitor screen.
Shoot completed.
Length = 150 Now everything is prepared, and winch operator starts the System has swapped to
automatic shoot by clicking the “SHOOT” –button. automatic ”TOWING”
Towcon adjusts tension to the estimated rendering pressure
Operator may at any time stop the automatic function,
simply by clicking on “MANUAL”.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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FREQUENTLY ASKED QUESTIONS : AUTOMATIC “SHOOT”

Why am I not allowed to select “SHOOT” ?

Check actual wire length on length bar graph or digital display, and also what is set as
Manual/Auto Limit on the monitor picture SETUP. If the actual displayed wire length is
shorter than Manual/Auto Limit you’ll be denied selecting automatic “SHOOT”.
Please re-adjust Auto/Manual Limit or manually pay out more wire.

Why does the winch stop so often during automatic “SHOOT”?

You may have adjusted Shoot Pressure too low. If this is so, winch will render too rapid, and
the maximum limit for motor revolution may have been exceeded. In this case TOWCON
will take action by activating the Overspeed Protection.
Check/adjust shoot Pressure.

Why isn’t TOWCON able to stop at the length, and winch continues to pay out?
You may have adjusted Towing Pressure too low, and if also maximum allowed pressure
Pmax is too low, winch doesn’t have enough power to pull in.
Check/adjust Towing Pressure and Pmax.

Refresh some concepts:

Pmin = minimum allowed pressure:

To be adjusted on “Main View” Hint:
Displayed as a digital value . Want to get a warning before winch starts
Used when paying out during braking?
auto “SHOOT”
Use the Wire Length Alarm to give you a
Towing Pressure : caution. Adjust the alarm quite a little
To be adjusted on “Main View, below the wanted Towing Length minus
Displayed as a digital value. Braking Limit.
Used when holding load during
auto “TOWING”

Towing Length :
To be adjusted on “Main View”.
Displayed as a digital value.
Used as reference-length during
auto “SHOOT”

Brake Limit:
To be adjusted on monitor picture SETUP,
to be adjusted by use of pop-up keypad,
used as braking-length in final sequence of
auto “SHOOT”

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.3.3 Automatic Towing

In section 2.3.3 is described the advantages of dynamic towing compared to towing with
brake engaged. However, the winch operator doesn’t have to look after the towing length
himself as he has TOWCON. By giving TOWCON the right instructions it’ll do the job.
On a set limit the system itself will start hoisting until wire length once more is at the
requested value. Like as for the automatic function “SHOOT” the automatic “TOWING”-
function is not either accessible unless wire length is at minimum equal to the Manual / Auto
Limit. As already mentioned in previous section, TOWCON may have swapped to automatic
“TOWING” because automatic payout has just been completed. However it is also possible to
select “TOWING” if system is in “MANUAL”-mode, the only condition is that wire length
must not exceed last adjusted Towing Length plus last adjusted Tow/Hoist Limit.
Please study both the example below and the “frequently asked questions”.

EXAMPLE:
Wire length is to be 2800 metres when shoot is completed, and towing operation is to be
carried out at that length.

Operator don’t want to be constantly watching the monitor during endless hours of towing
operation, but will take benefits of using the TOWCON system to help him keeping an eye on
the wire length. He has already adjusted the wire length limit, and will now adjust the tension
needed to hold the load. He wants the winch to pay out smoothly if tension in wire suddenly
increases, and do not want the winch to hold more than just what is necessary.

First step should be to adjust the tension control until winch just starts to render to find the
minimum necessary pressure. Then, to secure that the winch is capable of holding the load
without rendering, the tension adjustment should be increased a little.
How much extra power to be calculated must be decided by the winch operator as a result of
his experience and know-how, regarding to the present towing conditions. As a default
setting may be used the measured pressure plus 15%.

In our example let’s say that the winch renders at about 25 Bar, and that pressure variation is
between 20 and 30 Bar. Operator estimates 32 Bar to be passable. The maximum pressure in
our example system is 64 Bar. So, roughly calculated the adjustment on tension knob, which
has a scale 0 – 100, should be ca 50.

Adjust Ptow to a value that is expected to be high enough

to keep winch not paying out.

Adjust Pmax to the maximum

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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FREQUENTLY ASKED QUESTIONS: AUTOMATIC “TOWING”

Why am I not allowed to select “TOWING” ?

Check Towing Length indicator on length bar graph, and also what is set as Towing Limit on
the monitor picture PARAMETERS. If the actual displayed wire length exceeds the sum of
Towing Length plus Tow/Hoist Limit you’ll be denied selecting automatic “TOWING”
Please re-adjust Towing Length.

Why isn’t TOWCON able to keep the length, and winch continues to pay out?
You may have adjusted Towing Pressure too low, and if also maximum allowed pressure
Pmax is too low, winch doesn’t have enough power to pull in.
Check/adjust Towing Pressure and Pmax.

Why does the winch so often pull in during automatic “TOWING”?

You may have adjusted Towing Pressure too low. If this is so, winch will render too rapid,
and the allowed limit is soon exceeded. You may also have adjusted the Towing Limit too
short.
If this is the case the allowed length limit will also be too soon exceeded, and the winch will
very often have to pull in to get back on wanted length.
Check/adjust Towing Pressure and Tow/Hoist Limit.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
Page49
Refresh some concepts:

Towing Pressure :
To be adjusted on “Main View,
Displayed as a digital value.
Used when holding load during
auto “TOWING”

Pmax = maximum allowed pressure:

To be adjusted on “Main View,
Displayed as a digital value.
Used when pulling in during auto “TOWING”
( Also used in automatic “HOIST” )

Towing Length :
To be adjusted on “Main View”.
Displayed as a digital value.
Used as reference-length during
auto “SHOOT”

Tow/Hoist Limit: To be adjusted on monitor picture SETUP,

to be adjusted by use of pop-up keypad,
used as rendering-length during auto “TOWING”

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.3.4 Towing Static

During towing operation with engaged brake, the winch has no other strain restriction than
what is in the brake itself. Adjusting towing force must than be done by operation of the
vessel. The TOWCON system offers however the possibility of setting an alarm limit at a
certain load. An alarm will be given also if load exceeds this limit when brake is disengaged.
The alarm will be given by the colour on bar graph changing from green to red.

Example:
Vessel is supposed to be towing with fixed wire length.
Tension in wire is not allowed to exceed 280 tonnes.

Winch operator has adjusted wire length to agreed value and engaged the
brake. He wants TOWCON to give him a warning if wire tension
approaches the allowed maximum limit of 280 tonnes. To have some safety
margin he decides to set the alarm limit at 265 tonnes.

Adjusting alarm limit done by placing the cursor on the scale line between
green and red on the Tension Bar; and then drags the limit to the new
alarm value. This narrow part of the tension bar is also referred to as the
“tension limit bar” in this manual.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.3.5 Hoist
In other sections of this manual are described the great advantages TOWCON can offer
during towing and anchor-handling operations. Not mentioned in any other section is the
possibility of getting help when wire is to be pulled in. In fact, TOWCON can take care of the
hoisting operation on its own. Just tell the system what the new length should be, click the
“HOIST”-button and consider the job as done. Notice that there’s still a certain limitation:
you are not allowed to let the system hoist automatically unless there’s more than 100 metres
of wire remaining to be pulled in. System will stop hoisting when the Auto/Manual Limit is
reached;
and it’s not possible to adjust this limit to values lower than 100 m. In fact the automatic hoist
operation will always be stopped at the Auto/Manual Limit, so you may stop at any length you
wish, just by adjusting this limit.
Please study section 2.3.1 to learn more about limits- and parameter-settings.

Example :
Vessel has paid out a lot of wire during a towing operation, and all
this wire must now be spooled back on drum.
The present wire length is almost 2400 metres. Brake is not
engaged, and pressure in hydraulic motors is about 28 Bar.

Winch operator considers the spooling of wire to be the main thing

to concentrate on rather than holding the speed controller in hoist-
position, so he decides to let TOWCON take care of the pull-in.
Anyway, he wants to take full control of all winch operations when
there’s less than
250 metres left to be pulled in.

Knowing that the winch will need more pressure to pull in the
same load as the drum is filled with wire, he adjusts the maximum
allowed pressure Pmax high enough to compensate for this. He
estimates that 35 Bars should do.

After having adjusted the hoisting pressure, he select the picture

SETUP on monitor, and adjust the setting of Auto/Manual Limit
to 250 metres.
Maximum pressure Pmax
Now he once more selects the Towing-Drum picture on monitor,
must be adjusted to secure
Length is almost and clicks on the ”HOIST”-button.
enough pull-in force
2400 metres as TOWCON now adjusts pressure regulation valves to let pressure
”HOIST” is selected increase to maximum allowed, which operator decided to be 35
Bar, firmly adjusts manoeuvre-valves on winch motors to hoist-
position and the pull-in operation has started.

When length of wire remaining to be pulled in is only 250 metres,

TOWCON stops the winch, and system swaps to ”MANUAL”-
mode.
Hint: Auto/Manual Limit
Learn about adjusting this limit in section 2.3.5
More hints to be found on next page.

When there’s 250 m

Observe : Activate by ”clicking”
remaining to pull in
system swaps to Operator may at any time stop the automatic the ”HOIST”-button …
”MANAUAL” function, simply by clicking on “MANUAL”.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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FREQUENTLY ASKED QUESTIONS: AUTOMATIC “HOIST”

Why am I not allowed to select “HOIST”?

Check actual wire length on length bar graph or digital display, and also what is set as
Auto / Manual Limit on the monitor picture PARAMETERS. If the actual displayed wire
length is shorter than Auto / Manual Limit you’ll be denied selecting automatic “HOIST”.
Please re-adjust Auto / Manual Limit .

Why does the winch stop pulling in during automatic “HOIST”?

You may have adjusted maximum allowed pressure too low. If this is so, winch will
eventually not have enough power to continue pulling in as drum is filled by wire.
Check/adjust maximum allowed pressure, Pmax

Why does TOWCON swap to “MANUAL” when there’s still much to pull in?
You may accidentally have adjusted Auto / Manual Limit to a high value.
Check/adjust Auto / Manual Limit.

Refresh some concepts: Hint :

Have to make a short stop ?
Pmax = maximum allowed pressure: No problem ! Just click on “MANUAL”,
do whatever you have to and click on “HOIST”
to be adjusted on pressure meter,
to re-start the automatic hoist operation.
displayed as the left end of red area on scale, You may use the speed-control for both lowering
digital value visible when adjusting, and hoisting as normal when system is in
used when pulling in during auto “HOIST” “manual”-mode without having to re-adjust
(also in automatic “TOWING” ) anything before you start the automatic hoisting
again.
Auto / Manual Limit : Hint : Auto / Manual Limit
to be adjusted on monitor picture SETUP, Find more about how to adjust this parameter
to be adjusted by use of pop-up keypad, in section 2.3.5
used as the minimum wire length to be remaining
to be pulled in when TOWCON swap from
“HOIST” to “MANUAL”
Minimum possible value = 100 metres.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.3.6 Adjusting parameters for automatic functions

In prior sections in this part of reference guide are described the use of some parameters that
TOWCON will need to do a proper job. This section will explain more in detail what these
parameters are used for, and hints of how they should be adjusted.

Auto / Manual limit:

This is a wire length that TOWCON will use to decide if it’s legal to choose an automatic
function or not. Value is to be entered in metres. If the limit is adjusted to high, it’ll exclude
all auto-functions. The limit is meant to stop hoisting automatically the last few metres of
wire, as well as preventing automatic pay-out to be started by an accident when there’s
possibly wire handling work carried out on deck. But even though the limit is meant to secure
that there must be a human controlling the winch when end of wire is onboard or very near to
the vessel, it may even be used to lock all access to automatic functions completely. It’s not
possibly to adjust this limit to values lower than 100 metres.

Brake Limit:
This parameter decides how firmly the winch will stop when wire is paid out to a certain
length automatically by the “SHOOT” function. Value is to be entered in metres.
A long braking length will give a very firm stop, but it’ll take some more time. Too short
braking length may however give a rather brutal stop, especially if shoot speed is high.
TOWCON will use the braking length to increase pressure from being the shoot pressure
Pmin to being the on beforehand-adjusted Towing Pressure. Adjustment of this value must be
based on experience and skills of the crew.

Tow / Hoist limit:

This parameter is only used during automatic “TOWING”. Parameter is to be entered in
metres and is used to describe how big deviation is tolerated to the wanted towing length
unless it has to be corrected. As soon as deviation to Towing Length exceeds this limit,
TOWCON will try to pull in wire to get length back on wanted value.
Adjusting this limit to very small values will make the winch keep the length very tight up to
the wanted Towing Length, but at the same time this’ll also make the towing operation a lot
noisier as the winch will start and stop very often. Of cause this depends on weather
conditions and wire tension as well as other circumstances. Again, it must be said that
adjustment of this value should be based on experience and skills of the crew.

Notice that on this example illustration

the Auto / Man limit is adjusted to
minimum possible value. If you adjust a
lower value and click on “enter”, the
value will change to 100m as soon as the
keypad disappears.

Illustration shows keypad opened to adjust Auto / Man limit

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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2.4 Monitoring winch

2.4.1 Tension / Oil Pressure

Monitor wire tension --- “ Tension Alarm “

During towing operation with engaged brake, the winch has no other strain restriction than
what is in the brake itself. Adjusting towing force must than be done by operation of the
vessel. The TOWCON system offers however the possibility of setting an alarm limit at a
certain load. An alarm will be given also if load exceeds this limit when brake is disengaged.

Example:
Vessel is supposed to be towing with fixed wire length.
Tension in wire is not allowed to exceed 280 tonnes.

Winch operator has adjusted wire length to agreed value and engaged the
brake. He wants TOWCON to give him a warning if wire tension
approaches the allowed maximum limit of 280 tonnes. To have some
safety margin he decides to set the alarm limit at 265 tonnes.

Adjusting alarm limit is done by placing the cursor on the scale line
between green and red on the Tension Bar; and then drags the limit to the
new alarm value. This narrow part of the tension bar is also referred to as
the “tension limit bar” in this manual.

Pressure is shown as a part of the torque step

function.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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2.4.2 Speed / wirespeed

Avoid motor breakdown -- Over speed Protection

Although the remote control system has a built-in over speed protection facility to prevent
hydraulic motors being damaged by too high revolution speed, it’s absolutely advisable to
keep in mind RPM-values when operating the winches. Especially when lowering or letting
the winch pay out by rendering this should be carefully watched. TOWCON will take action
if too high revolution speed is detected. If the automatic over speed protection comes into
force the winch motors will be stopped, motor pressure will be adjusted to maximum and
finally the brake will be engaged.

Example:
Vessel is to set an anchor,
and will have to lower about 1800m.

Winch operator has adjusted tension and the winch is rendering at acceptable speed. As wire
is paid out the necessary load to make the winch render will increase.
To compensate this tension control will have to be continuous adjusted during the shoot. At
the same time load on wire caused by the vessels propulsion may vary, and will also influence
on the necessary rendering force on winch. As a result of this, the tension control may
accidentally be adjusted to low, and the rendering speed may exceed the maximum limit.
If the over speed protection system is activated it’s not a special pleasant event, because it
may cause a rather severe yank in the towing line. It should therefore be avoided as far as
possible by keeping a watchful eye on the tension settings.

2.4.3 Length
Manual pay-out --- “Wire Length Limit”
Before starting to pay out wire or chain, operations as described in section 2.1.2 must be
carried out. Shooting may be done in two different ways; either lowering by use of the speed
control, or by reducing motors stalling force by the tension control until winch is rendering.
Please study users instructions for the remote control to get more information about this.
Often when paying out wire it is decided on beforehand what the wire-length is to be when
payout is completed. Of course the operator may look after this by constantly watching the
length bar graph and digital display on the monitor, but there is also a more pleasant way to
do this. By giving TOWCON the right information, the operator may get a warning when a
special wire length is reached, and thus do not have to pay too much attention to the monitor
screen during this operation.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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EXAMPLE:
Wire length is to be 4800 metres when payout is completed, and towing
operation is to be carried out at that length.

Operator is preparing to pay out wire by use of the tension control. (Or
speed control) Because he’ll not be constantly watching the monitor
during payout of almost 3300 metres of wire, he is now adjusting the wire
length alarm limit to 4800 m.

Then he’ll adjust the tension control until winch starts to render, and when
the length limit is reached he’ll get an audible alarm from TOWCON in
time to concentrate merely on the winch before the determined towing
length is exceeded.

The length bar will now become red, when the alarm limit is
exceeded.
When towing length is reached, he’ll once again adjust the length alarm
limit to get a warning if the winch pays out too much during towing
operation. Normally just a few meters should suffice.

Hint: Length
Want to stop exactly at the metre?
Don’t bother the length bar graph,
but rather concentrate on the
Digital Length Display

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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Measuring wire length (Length continued)
All calculations TOWCON executes are dependent on the few basic parameters concerning
wire data. These parameters may be individual for wire on each drum, and they are available
by selecting monitor picture PARAMETERS.
It’s of coarse no problem to adjust all parameters needed to calculate wire length correct when
they are known. But what is to be done when you don’t know the wire length? Entering a
faulty value as wire length will most likely have influence also on tension calculations.
Following example will give some hints of how to deal with such problems.

Example :
Vessel has to take onboard an unknown length of wire, which later on is to be paid out again
when placing a buoy. All that’s known about wire is that diameter is 76mm, and that length
can’t possibly be more than 2400 metres. Most likely length is something between 2000 and
2300 metres. First part of wire is already spooled up on Stb Common-Handling Drum. About
5 turns on first layer is now on drum.

Winch operator decides to measure length of wire as it’s pulled in.

First thing to be done is to adjust wire data, so he selects monitor picture PARAMETERS.

First-layer diameter: 1390 mm

On drum: 5 turns
5turns= 1,390×3,14×5=21,8m

Wire length out:

3000m-21,8m=2978,2metres

Wire diameter is known to be 76 mm, so that’s no problem.

Remember Assuming that wire is much shorter than this, he adjusts
to click ”Reset Length” Wire length to 3000 metres.
each time Length Out How much wire that’s still to be pulled in must than be the
has been corrected. difference between what’s already on drum and the fictious total
length of 3000 metres.
He’ll have to calculate this and put the value into the ”Wire
length out”-box.

Calculation must be based on the diameter of drum on first layer

and the 5 turns of wire that’s already on drum.
Knowing this winch operator is able to calculate length of wire on
As the Stb CH –picture drum fairly accurate to be 21,8 metres; and hence Wire length
shows up on the monitor out must be 2978,2 metres. Operator enters this wire data and
screen he can see that wire clicks on “RESET LENGTH” before selecting monitor picture for
length display indicates 22 Stb Common Handling Drum.
metres. Pull in of wire can
now be started.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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--- example from previous page continuous ----

All wire is pulled in …….

When all wire is pulled in Length Display still indicates that
there’s 978 metres left. This only shows that the winch operator
was right when assuming that the wire was quite a lot shorter than
3000m.
Now he has to select the PARAMETER-picture once more and re-
adjust the wire parameters. ”Wire length” is 3000m minus the 978
978m should be left, but end
of wire still lays on deck…….

Estimated wire-length: 3000m

Still indicated, end on deck: 978m

Actual length=3000-978=2022m

Don’t forget to click

”Reset Length”
each time Length Out
has been corrected.

When wire now later on is paid out, length will be displayed correctly
as contents on drum shrinks. Digital display and Length Bar will
indicate length of wire paid out.

Please observe:
TOWCON doesn’t know anything about the outer
diameter of the drums. This means that the estimated
wire length may be adjusted much longer than what
As the Stb CH –picture shows up on the drum actually can take.
the monitor screen he can see that So you don’t have to estimate length very carefully,
wire length display indicates 0 just decide on a length that you are sure is too long.
metres. This is correct because all
wire now is spooled up on the drum

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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2.4.4 Temperature

Keep an eye on Oil Temperature.

During long lasting winch operation hydraulic oil will sometimes get rather warm, and to
avoid further heating action will have to be taken. Some vessels have automatic cooling
systems, while on other crafts the crew will have to look after this. Anyway, the winch
operator should always keep an eye on the oil temperature, because severe damages may arise
in motors and pumps if oil gets too hot. Alarm limit is pre-set at 65 deg. Celsius.
Too quick variation in oil temperature may also harm motors and pumps; and should be
avoided. A typical problem is that temperature drops too fast when water is being let into a
water/oil cooler, which may cause that cold oil pour into a rather warm hydraulic motor. An
even more serious problem is that hot oil is led into a cold motor by operation of a change
over valve.
If this can’t be avoided oil should be allowed to just flow through the manoeuvre valve for a
short time before rotating the winch. Heat from oil will then spread to the motor.

It is also possible to watch out for unexpected variations in oil temperature

on the Oil Temperature Trend on the monitor picture “OIL”

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

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2.4.5 Trend Monitoring

What happened some minutes ago?

During long lasting towing operations, winch operator will of course have other things to do
than just gawping at the TOWCON monitor. Even in these situations when the operator has to
concentrate on other duties for some minutes, the TOWCON system will come to his
assistance. Trend Displays will give a rather good picture of what has happened during the
last minutes.

2.4.5.1 Monitoring Wire Tension and Motor Pressure

During towing operation with disengaged brake one will derive advantage from the low-
pressure hydraulics’ special quality of being a strain restrictive braking device.
If pressure in hydraulic motors exceeds a certain limit the winch will render,
and in this way it’s possible to control how powerful the winch should be.

Scale used on vertical axis on Tension Trend is always in Tonnes,

while scale used on vertical axis on Pressure Trend is always in Bar.
Scale on horizontal axis is always minutes.

Example :
Vessel has been towing for a period with brake engaged to keep the wire length fixed.
Now the winch operator is told to concentrate on avoiding heavy jerks in wire.
It is however not necessary to keep the length fixed any longer.
Winch operator may then look at the trend display showing how the tension has varied the
last minutes to get an idea of the holding power the winch motors will have to cope with.
He’ll then be able to adjust tension according to this before releasing the brake.

The dotted line in the Torque step bar indicates how high
motor pressure is allowed to increase at the present tension
adjustment.

Adjust Tension Controller to adjust

the dotted line according to what is
shown on the Pressure Trend.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.4.5.2 Monitoring quality of Hydraulic Oil

Towcon includes a picture specific made to monitor oil condition.The system is equipped
with sensors for monitoring both temperature and quality of the hydraulic oil.

Digital value below the trend window shows the actual

measurement at the moment.

Bottom line of trend windows shows time in minutes.

Looking at the graph just above the digit 5 will then indicate
measurement 5 minutes ago.

Below the lower right corner of the trend window that

monitors particles and water saturation in oil, there is a small
box where the alarm limit value is displayed. If measured
level exceeds this limit an alarm will be set off.
It is possible to adjust the limit by “double-clicking” in this
box, and by use of the on-screen keyboard that then appears,
set a new value.

Vertical axis :
Oil temperature is measured in degrees Celsius.
Scale on axis is 0 – 100 degrees.
Oil contamination, particles : according to NAS –values.
Scale on axis is 0 – 14 NAS
Oil contamination, water : percent of the saturation value.
The value is corrected according to the oil temperature.
Scale on axis is 0 – 100 %

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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2.4.6 Coupling and Brake condition.

See screen example below. The “picture” is taken from the Winches tab in TowCon.

It shows the status for couplings and brakes for the main winch. The motors and shaft turns
green when the motor is fed by a pump. WRK PRT is shown engaged, with motor ready for
operation and with brake engaged. The coupling at top of WRK PRT is the double drive
coupling. The double drive coupling is shown in passive state.

Picture below is from the dual-view tab.

It shows the status for drum 0 – A.H. (Anchor Handling Drum). The coupling is engaged and
the brake is on.
The status for couplings and brakes are also shown on the input devices.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

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2.4.7 Alarms
What went wrong? ---- Alarm monitoring
No matter how proficient and experienced the winch operator is, accidents may still occur.
It’s than valuable to have the opportunity to subsequently get detailed information from TOWCON
about what actually happened. All alarms will be stored in a log-file, and be available later on, so that
winch operator can concentrate fully on solving the problem instead of spending time on trying to
read alarm-texts before they possibly disappears.
When an alarm is activated, the sound will not go off unless someone “clicks” the Alarm Reset –
button on the monitor. The Alarm-Reset –button is to be found only on the “ALARM”-picture. A
text line on this monitor picture will give detailed information about what’s wrong. Alarm texts will
not be deleted from list even if the reason to the alarm given is clarified. As alarms may be given
from time to time, new lines will be written on top of the list while old ones will finally disappear at
the bottom. All monitor pictures has an alarm-indicator that turns red when an alarm is activated and
not yet acknowledged by pressing “Reset Alarm”-button.
The reason why an alarm is activated is often quite obvious and easy to identify even without looking
for the explaining text-line on the Alarm-picture, because it’s also clearly indicated on other pictures.
As an example the colour in the Digital Display showing wire length will turn to red if the adjusted
wire length limit is exceeded. Otherwise, there may also be given alarms not detectable no other
place than on the ALARM –picture; such as “Emergency Stop” or “Low Level in expansion tank”.

Example :
Vessel is to keep a specified distance to the object it’s towing, and the winch operator has engaged
the brake.
Suddenly a hose on the brake cylinder blows, servo oil is flushed out on deck; and level in oil
reservoir on servo unit decreases in a short time to a minimum.

Because the hose blew, servo pump couldn’t maintain pressure in servo system. TOWCON detected
this and activated the audible alarm. Winch operator changed to the picture
“ALARMS” to see what was wrong, and pressed Alarm Reset –button. He found the message LOW
BRAKE PRESSURE, but didn’t stop servo pump unit. Then he got a new alarm, LOW OIL LEVEL
- MAIN SERVO. He’d had to press the Alarm Reset button once more to get rid off the audible
alarm given because of the oil level. Before so is done, the explaining text will be red. On the
monitor picture in our example we can see that there also was an alarm earlier the same day, because
someone activated Emergency Stop. That situation has obviously been clarified, because the text has
turned to grey.

Example from ALARM-picture

Hint : Alarm Texts - Colours

Red New alarm detected “Alarm Reset” is not yet
pressed.
Yellow “Alarm-Reset” is pressed, Cause of alarm is still
present
Grey Old alarm, Cause of alarm is clarified

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

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 0001-1273
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By pressing the ALARM tab at top of the screen the picture changes to the alarm folder where
alarms are shown, both currenent and past. The alarms have 3 different statuses differentiated
by color.
Red alarms are new alarms not yet acknowledged.
Yellow alarms are acknowledged by user but the situation is not resolved.
Gray alarms are acknowledged by the user and is no longer valid.
All alarms recorded and kept on the screen until they disappear at the bottom of the alarm
window. In addition to the alarms mentioned in the following chapters a Towcon system may
have several customer specific alarms.

Alarm Reset button

By pressing the ALARM RESET button at the bottom right corner of the screen the user
resets the audible alarm (if any) and signals to the system that he is aware of the situation.if
alarm is still active ( Valid ) it will turn Yellow otherwise it will turn Black.
In other words this button resets all current alarms.

Alarm lamp
The alarm lamp turns red as soon as an alarm situation has occurred. And switches to grey as
soon as the operator have pressed the reset alarm button. This is basically to inform the
operator that there is a new alarm situation that needs his attention.

Maxvalue logging
The system is also equipped with an internal logging system that keeps track of the maximum
pressures, speeds and temperatures of the systems winches.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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2.4.8 Alarm List

2.4.8.1 Emergency stop

If one or more of the emergency stop switches has been pressed the system responds by
setting off both visual and audible alarm.

2.4.8.2 Emergency Release

If one or more of the emergency release switches has been pressed the system responds by
setting off both visual and audible alarm.

2.4.8.3 Mismatch on Coupling Sensor

On each coupling there are four position sensors, two sensors to detect coupling in position
“IN” and two sensors to detect coupling in position “OUT”. If the two sensors in one of the
pairs do not give the same detection, this will be warned about by an alarm.
Example : Mismatch on Feedback sensors - Coupling In on A.H. Drum

2.4.8.4 Overspeed
There is three different overspeed limits. The Overspeed Limit is adjustable, and may be set
to a lower value than the max limit for hydraulic motors, but not higher. Hi and HiHi limits
are factory preset depending on type of motor. The three different alarms produce individual
texts in the alarm picture so they can easily be separated. The Hi and HiHi alarms may also on
some systems activate rpm slowdown or system shutdown functions.

2.4.8.5 High oil temperature

There is two different temperature limits; Hi and HiHi limits, which are factory preset. The
thwo different alarms produce individual texts in the alarm picture so they can easily be
separated. The Hi and HiHi alarms may also on some systems activate rpm slowdown or
system shutdown functions.

2.4.8.6 High oil pressure

If the oil pressure has exceeded the system pressure + 1bar, an alarm will be trigged. When
trigged it gives both visual and audible warning.

2.4.8.7 Oil contamination – Water

The system includes a contamination sensor that will set off an alarm if hydraulic oil
contains too much water. Alarm limit is adjustable.

2.4.8.8 Oil contamination – Particles

The system includes a contamination sensor that will set off an alarm if hydraulic oil
contains too much particles. Alarm limit is adjustable.

2.4.8.9 Low Gear Oil Level

There is mounted sensors on gearboxes to give an alarm in case the gear oil level should
of any reason become to low to secure proper lubrication of gear wheels. Text on screen will
tell exactly which gearbox that is the problem. Example : Low Gear Oil Level – Stb Motors

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

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 0001-1273
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2.4.8.10 Expansion system - Low pressure

Indicates that the pressure in the oil expansion tank has dropped below the set limit, and both
a visual and audible alarm is set off.

2.4.8.11 Expansion system - Low level

Indicates that the oil level in the expansion tank has sunken below the set limit, and both a
visual and audible alarm is set off.

2.4.8.12 Expansion system – Filling Pump Stopped

Indicates that the Filling Pump for re-filling of the expansion tank has been running for more
than 3 minutes, and has automatically been stopped. Possible leakage. Visual inspection is
needed. Both a visual and audible alarm is set off.

2.4.8.13 Expansion System – Starter not in “Remote Mode”

This is a warning to tell that the selector on the Expansion Starter is not in normal mode for
remote operation. The possible selections are “Remote” , “Auto” and “Local”
Both a visual and audible alarm is set off. Audible alarm will sound for 3 seconds.

2.4.8.14 Expansion System – Possible motor failure

This is a warning to tell that the remote control system has tried to start the Expansion Pump
but there is no feedback from the starter to tell that the pump is running. Inspection is needed.
Both a visual and audible alarm is set off.

2.4.8.15 Expansion System – Motor protection tripped.

This is a warning to tell that the motor protection relay in the Expansion Starter has tripped,
and thus the pump can not be started.. Inspection is needed.
Both a visual and audible alarm is set off.

2.4.8.16 Low brake pressure

This alarm is activated if the pressure in the servo unit goes below a certain value. Check the
servo unit and accumulators.

2.4.8.17 Drum rotating with brake on.

This alarm is activated if the drum starts moving while the brake is activated.

2.4.8.18 Bitter end

Is active at all times and informs the operation that he is within a 100 meters from the end of
the wire, and is likely to loose it if he continues to pay out. The alarm is both visual and
audible.

2.4.8.19 Node nn lost

Informs the operator that the operator station has lost communication with one of the system
nodes (distributed control units).

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2.4.8.20 Bus warning

Informs the operator that there has been registered an abnormal amount of communication
errors.

2.4.8.21 Wireguard Limit

Is active during towing mode and is trigged if the wire length exceeds towing length set point
+ towing length limit + wireguard limit. Towing length limit and wireguard limit is set on the
parameter screen; towing length set point is set on the wire length bar.

2.4.8.22 Grease Lubrication System – Grease Supply Failing

Indicates that there is a problem with the supply of grease to the lubrication pump, most likely
because of an EMPTY can of grease. Both a visual and audible alarm is set off.
Grease can must be refilled, and a visual inspection is needed.

2.4.8.23 Grease Lubrication System – Malfunction

Indicates that there is a problem with the supply of grease to one of the gear wheels that
should at the time be lubricated.. It could be a faulty pump, valve, hose or EMPTY can of
grease, and both a visual and audible alarm is set off. Visual inspection is needed.
Example : Malfunction on Lubrication point for A.H. Drum

2.4.8.24 Grease Lubrication System – FAULT (Power supply)

Indicates that there is a problem with the power supply to the grease control cabinet. , and that
the system do not get a feedback confirming that the motor is running.
Both a visual and audible alarm is set off.

2.4.8.25 Servo System xx – Servo pump n - Tripped

Indicates that motor protection is tripped, and the pump is not available for the control
system. Both a visual and audible alarm is set off.

2.4.8.26 Servo System xx – (Main or sub system) – High Oil Temp

Indicates that servo oil temperature is above critical value. Both a visual and audible alarm is
set off.

2.4.8.27 Servo System xx – (Main or sub system) – Low Level

Indicates that servo oil tank level is running low. Check for leakage and refill as necessary
Both a visual and audible alarm is set off.

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 0001-1273
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2.4.8.28 Stern Roller Cooling System - FlowAlarm

Indicates that stern roller cooling system is missing indication from the flow-sensor when
cooling pump is running. Both a visual and audible alarm is set off.

2.4.8.29 Stern Roller Cooling System – Low Level

Indicates that stern roller cooling system expansion tank level is running low. Both a visual
and audible alarm is set off.

2.4.8.30 Stern Roller Cooling System – High Temp

Indicates that stern roller cooling system temp is running high. Both a visual and audible
alarm is set off.

2.4.8.31 Ultimate Release is activated.

If one or more of the emergency release switches has been pressed the system responds by
setting off both visual and audible alarm.

2.4.8.32 Wire tensile strength is overloaded.

If load in a wire exceeds what is specified on the “Setup Screen” the crew will be warned by
an audible alarm and a text on the alarm list.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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 0001-1273
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2.5 System addons

PLEASE NOTE:
The following describes what functions that are currently available in addition to “standard” winch
control. These functions are not required by all shipowners, hence they may not be available on all
installations.

2.5.1 ”SlowDrive” - ASD

All pumps to selected drum,but one is stopped, motor is forced to run on three cells

Will force only one pump, and three chambers on motor. Used in
conjunction with ALG, a very controlled movement is ensured.
It is not possible to start more than one pump for a given motor. In double
drive each motor will have one pump each.
Screenshot below shows ALG (Length Guard) turned on at the same time as ASD.

Yellow lamp is lit indicating that

SlowDrive is activated.

Three cells active. Not allowed to

change Torque Step.

Speed step INC is disabled. Only

allowed to start one pump.

Caution sign turned on to indicate that

Speed step function is affected by one
or more system addon functions.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.2 ”Hoist Limitation” - AHL

Drum is stopping to hoist when limit given in ReReel SWL limit is reached.
Bar graph in top shows how many % of SWL winch actually is paying in
with. (SWL = Safe Work Load.) The hoisting force in Cable lifter mode is
also limited to max allowed hoisting force, for the selected cable lifter.
See screenshot below showing max allowed hoisting force for cable lifter.

Picture below shows AHL function activated. Approx 66% of the SWL set in Setup tab is utilized.

PLEASE NOTE !
The continuous allowed load on the Re reel sheave is 30t. The sheave has to be sprayed constantly
with water, to ensure sufficient cooling.

It is not possible to activate AHL when in CABLAR mode.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.3 ”Length Guard” - ALG

Used to allow only very small movement on a drum.

Typically used when drum is working with parts on deck.
Parameter in TowCon setup canvas limits movement.
Press button to activate. Red lamp in button indicates that function is
activated. See screenshot below.

ALG function used in conjunction with ASD will give the best condition
to operate the winch in a very slow and controlled manner.

Accurate display of movement since

function activated. Relative value.

Bar display of movement.

Max scale is 100cm
Red lamp indicating
that function is active

Red bar is used for wire being hauled in. Yellow bar is used for wire being payed out.

When the limit set in Setup tab is reached, active stop is activated and the band brake is turned on.
See screenshot below. Limit is in current picture set to 65cm.

NOTE !
It is not possible to turn off the brake when ALG limit is reached. The button has to be pressed, thus
function disabled/reset, to allow brake to be turned off, once turned on by ALG.

2.5.4 On screen change of overspeed limit:

Segment of Alarm picture

in Towcon.

By reducing the RPM limit on the Towcon Monitoring System, over speed protection can
easily be tested. Lowest possible limit is 15RPM.
The maximum value allowed in the display equals max. allowed rpm on motor.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.5 Shark Jaw tension reading

The tension in the shark jaws is displayed in 3 different locations:

- In the Winch view tab

- In the Main view and the Dual view tab

2.5.5.1 Using Tara function.

If the load reading at no load is not showing zero tonnes, the TARA button can be pressed.
This is the same function as in normal weight reading systems. It does not alter the
calibration, it only shifts the entire curve so when TARA is pressed it does display zero
tonnes.
Pressing TARA button will make the
reading in actual load situation display
zero tonnes.

NOTE!
There is one TARA button for each
Sharkjaw.

2.5.5.2 Selecting which loadcell pair to display.

Operator has to select either A or B set to be displayed in the normal tabs. The selected pair
will also be used for transmission to DP system or similar. See chapter 3.15.5.3 for more
details.

Pressing button will select Pair B for

display. A lamp will be lit when B-pair is
selected. On winch view tab the actual
selection A or B is indicated by lamps
adjacent to the load reading.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.5.3 Calibrating Sharkjaw load reading
The control system is able of displaying and calibrating load reading from loadcells in the
RRM Sjarkjaws. Each Sharkjaw is equipped with 1 redundant/two separate load cell sets.
The sets are named A and B. The display below is found in the Setup tab. Description that
follow will describe how MMI is realized for two – 2 – Sharkjaws. One STB and one on
PORT side.
CALIBRATION PROCEDURE:
Activate button to calibrate/display PORT
Sharkjaw. A red lamp in button will be lit
when PORT is selected. Otherwise STB is
selected.

The RAW values from the loadcells should

be from ~100 at zero to 10000 when the
Sharkjaw is max tensioned.

Press Cal mode to enter CAL. Mode. A red

lamp will be lit in button when cal mode is
active.

When tensioned up to f.ex. 200t on

reference reading, enter 200 in “MAX
VAL” window and press “SET MAX”
At zero load set 0 in the MIN VAL window
and press “SET MIN”

The easiest way to calibrate Sharkjaw is to use the bandbrake on the main winch as reference.
• Run the Sharkjaw to calibrate 90% to the top. Use a crowbar or similar to rotate the
Sharkjaw 180° clockwise.
• Run the Sharkjaw completely to the top. Insert the socket of wire/chain to the
Sharkjaw. Remember to secure the connection so it does not damage anything if it
slips.
• Adjust loadcell so the RAW VALUE is displaying ~100. Press “SET MIN” on
Sharkjaw – in calibrating mode.
• Tension up the Sharkjaw with the winch. Hold the speed lever in hoist while engaging
the brake. Wait for some seconds after the brake FB on is received.
• Read value on reference loadreading system (TowCon screen). Enter the value in
MAX VAL window. Press “SET MAX”. The ACTUAL SCALED” display should
now be reading the same number as entered in the “MAX VAL” window.
• The calibration is now completed. Press “CAL MODE” button to leave cal mode.
• Run Sharkjaw down to 90%, and use a crowbar or similar to rotate the Sharkjaw 180°
anti-clockwise.
• The load cell should be tensioned as much as possible. If “MAX VAL” is a very low
value, the calibration may be of poor quality.
• The “SET INIT” value and button is for initial setup only. If no calibration is done the
“INIT” values will be entered into the calculation. Only to be used for “getting
started”.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.6 Length Reading Stern Roller

On stern rollers equipped with rpm detectors the control system can keep track of movement
of the stern roller.
This application is typically used when winch operator wants to spool chain directly to a
drum. Length counting on drum will be suspended when length counting on stern roller is
activated.

Selecting dimension on chain :

For the length counting to be optimal operator has to give input to TowCon regarding chain diameter.
Please see section 2.1.2.2

Select the correct cable lifter size compared to what chain is going to
be spooled on to drum.
If actual chain dimension is not to be found in the table, select the
closest match.

USING SCREEN CONTROLS

Operator “Select” which part, the drum is to be ”connected”

to, by pressing left or right arrow.
When “Select” is pressed, the drum is locked on to selected
stern roller.

“Activate” is pressed to start counting on stern roller.

TowCon no longer counts on drum.

“Reset” is the same as reset length. Initial length is put into

length register for stern roller length.

This screen element is located in main view and dual view.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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Start counting length on SternRoller: -Suspend drum counting
When pressing “activate”, the lamp will be blinking until 1m is reached.
If the drum is paying out before 1 meter is reached, the length counting will still be locked on the
SternRoller.
When 1m is reached, the lamp “activate” will be lit constant.

Suspend counting on sternroller:

When pressing “activate” while length is >1m, the counting will be suspended. The “Activate” lamp
will be blinking. Pressing “activate” once more will resume counting on sternroller and suspend
counting on drum.

Resume counting on drum:

When paying out chain, and length reading reaches zero, TowCon automatically resumes counting on
drum. Also when pressing “activate” the counting on the drum will be resumed, and length counting
on sternroller will be suspended.

Reset:
When pressing reset, the number in “start length” will be entered into the sternroller counter.
Thus length on sternroller will be set to “start length”.

Please note:
The length is ”stored” on the sternroller. If same sternroller is used for different chain spooled on
different drum, operator manually has to keep track of actual length spooled on to a drum.

When resuming operation on a drum, after the sternroller has been used for other purposes or a
different drum, please be sure to set the correct start length on sternroller.
Screen dump below shows the location of this information.
Initially the start length on a sternroller is set to zero.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.5.7 Auto Mode Chain Pull Winches
On winch plants equipped with remote controlled Chain Pull Winches (CPW), it is possible
to use an automatic function in Main Winch view. See screenshot below. AUTO mode
makes the CPW to act as a back-tension device for the main winch cable lifters.

Chain Pull Winches (CPW) are often mounted on top of chain locker. This makes it possible
to have the chain lockers in some distance from the winch.

Activating AUTO mode:

The CPW will go into full hoist with given tension 3 seconds after the Auto button is pressed
for longer than 3 seconds. The “pulling” lamp, on screen, will be blinking 15 seconds after
the function is activated.
De-activating AUTO mode:
The auto mode is cancelled when one or more of the points for making READY lamp grey
are present, or Auto button is pressed again (toggle function). See page below.

Screenshot above shows a configuration where both chain pull winches are using same main
pump, thus there is only one SpeedStep function element. Current picture shows STB CPW is
in auto mode and pulling with 68% tension, and Port CPW is ready and waiting for operator.

No screen elements in the CPW function will be blinking for more than 15 seconds.
Elements will be blinking when operator attention is wanted, but is lit or turned off, if no
operator action within 15 seconds.

The chain pull winches give the ability to:

1. Keep constant back-tension on chain while using cable lifter.
2. Pulling chain from cable lifter to chain locker. Thus location of chain locker is not
dependent of winch location.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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READY: (Lamp)
Gray: Winch not ready. Caused by one or more missing:
Low Pressure Pump
Servo Unit
Cabelar Mode on winch
Brake Not Off on main drum
Blinking: Cable Lifter Mode Selected, Brake OFF AND:
One or more main LP pumps for CPW or Servo is running.
Steady: Winch is ready to be operated
Colour: Green / Gray

AUTO: (Btn & Lamp)

Gray: Not active.
Blinking: Auto selected, Alarm Horn Active – pulling is soon to be activated
Steady: Auto selected and active.
Colour: Yellow / Gray

Not possible to select AUTO mode when ready lamp not lit.
When AUTO is selected the CPW start to hoist, with given tension order.

Pulling: (Lamp)
Gray: Not active.
Blinking: CPW is pulling in hoist direction with given tension setpoint. Under 15 sec
since function was activated.
Steady: CPW pulling – active for more than 15 sec.
Colour: Yellow / Gray

TENSION SET: (Digital)

Show tension order on CPW : 0 to 100%

Speed Step
Used for requesting oil to given winches. On some plants it will be dedicated pumps, on other
the pumps are shared with other winches.

Outputs on winch control system

Each CPW has 2 outputs each from +OCC cabinet. Check +OCC documentation for exact
wiring details. There is one output for sound and one for alarm/warning lamp. The outputs
are both potential free and rated for (24VDC/2A). – Capable of powering 2A continuous per
output.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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2.5.8 Max Speed Range (MSR)
PLEASE NOTE: Function is currently available only on systems with winch chair
Winches operated/selected from speed device on winch chair can utilize MSR function.
Below is screenshot from a typical winch chair.
Function is developed to give steady manoeuvre valve orders also with other values than
100%. Each hydraulic motor is equipped with manoeuvre valves giving operator the ability to
control the RPM on the motor. The number in the MSR window indicates max manoeuvre
valve position when operator moves speed lever fully to hoist or lower. It rescales the entire
range of the speed lever. Giving 70% percent speed order will make the manoeuvre valve to
operate to maximum 70% in either hoist or lower direction. The actual RPM on the motor
depends on how many hydraulic pumps that are running, the set tension order and the actual
tension in the wire/chain.

The yellow bargraph indicates speed order set to

on manoeuvre valve. The dotted line inside the
MSR is actual position FB on the manoeuvre
valve. The number between UP and Down
arrow indicates actual max speed order value.
Pressing UP will increase value with 10.
Pressing DOWN will decrease value with 10.
Lowest possible value is 10. On some winches
MSR of 10 will cause the winch not to rotate at
all.

2.5.9 Automatic Brake Interlock ( ABI )

This function is introduced to lessen the risk of releasing a brake by a mistake, which can be
very dangerous if there is load on wire and the motor is uncoupled.
Releasing the brake on a drum that is uncoupled will set off an audible alarm, and there will
also be shown a warning text on the Towcon screen. After 30 seconds the alarm will be shut
off, and the brake will be released. During the warning period of 30 seconds the “Release
Brake” command can be cancelled, simply by selecting “Brake On”.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.6 Using Cable lifters

When handling rig-chain TOWCON will give almost the same advantages as
described for dealing with wire operations, although not all topics mentioned
are equally relevant.
However the monitoring functions like length, tension, motor pressure and so
on are available just like they are when dealing with wire. All alarm limits
may also be adjusted like described earlier in this reference guide. Just remember to click the
“CABLE LIFTER”-button, and don’t forget to choose the right pitch diameter and to reset the
length. Do also remember that when using cable lifters there are certain load limitations that
must not be exceeded !

Select ”SETUP” –picture on the Towcon Monitor

and then select Cable Lifter dimension.
Find more about this in chapter 2.1.2.2

NOTE ! Always remember to enter correct length and press RESET

LENGTH, when changing between drum and cable lifter. The button is
found on the Setup-picture. There is one button for each drum/cable
lifter

Built-in Safety Function :

When allowed max pull is reached, according to limit in the Cable Lifter Table; the control
system forces the speed order to stop the winch. This helps operator not to overload the cable
lifters.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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Example :
Vessel is to pull in a 70 mm rig chain. It’s essential to know how much chain that’s being
pulled in. Cable Lifter is already mounted on Port Towing drum and the first few links has Select
been pulled in. Cable lifter
Before starting to pull in and meassure the rig chain operator will have to choose the rigth
pitch diameter and enter this in the parameter settings for the topical winch.

First of all the winch operator selects the monitor picture for Port Towing Drum and clicks
on the ”Cable Lifter”-button. Then he selects the monitor picture SETUP to select the correct
chain. Next step is to enter 0 (zero) in the”Wire Length” –box. Then ”Reset Length” must be
clicked to tell TOWCON to start using the new values. ( ”Wire diameter” and “Wire Length
Out” will now not be used, so what’s ever displayed in this box doesn’t matter )

Remember to click
”Reset Length”
each time Length Out
has been corrected.

When this is done he’ll have to estimate how much chain has
already been pulled in. The first few chain links has just
reached the bottom of the chain locker, and he reckons the
length to be about 15m from there and through the chain pipes
to the cable lifter. He makes a note of this to have it available
later on

Chain :
Pulled in before Reset
about 15 m.

Selection of Cable Lifter Type

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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example from previous page continues ……

Winch operator now selects the monitor picture for Port Towing Drum, and starts the pull-in operation When pull-in of
chain stops, the digital display shows -345m. Measuring is now completed, and length indicated on monitor screen will
show how much chain is pulled in. To find the total length of the chain, operator now has to add the first part of chain
( 15m ) that were pulled in before measuring started.

Chain :
Pulled in before “Reset
Reset”
Reset :
about 15 m.
Meassured : -345 m

Total chain length:

345+15 = 360m

Hint : Negative sign before Length value

When pulling in a chain it is recommended to reset the length
counting before start. If this is done a negative sign will appear in
front of the value. This will be like this because the normal thinking
of chain or wire length is the part of it that is no longer on the ship,
but has been paid out astern.

Hint : Length Alarm

Want a reminder before chain length left in locker
becomes indefensible short ?
Study section 4.1.4 / 4.1.5 about how to use Length
Alarm

The negative value shows that

the winch has pulled in this
length since the last time length
measuring was reset.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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Example 2:

Vessel is to pull in an anchor attached to a 100 mm rig chain.

Cable Lifter is mounted, correct pitch diameter is selected and length is reset
before starting to pull in. Some chain is pulled in when operation has to be
stopped.
Anchor is obviously stuck in something on seabed. Brake is now engaged.

Winch operator is aware of the limitation on this special winch to be just 370
Tonnes when operating with this chain dimension.
To be on the safe side he wants an alarm if tension of any reason should approach
to even levels far beneath this. In fact he don’t expect tension to exceed 250
tonnes, so he decides to adjust the tension alarm to just 230 tonnes.

If this limit is exceeded he’ll get an audible alarm as well as the Tension Bar
being red on his monitor picture.

Hint : “Tension Alarm”

See section 4.1.7 to brush up on how to adjust tension alarm.
See section 3.3.7 to refresh how you should operate sliders.

General when using Cable Lifter:

All limits related to length, RPM, tension, and pressure is applicable,
and may be used as explained in other sections of this reference guide.
Pay special attention to what’s discussed in the section MANUAL OPERATION,
but don’t forget that even Automatic Functions are available.
Special caution has to be performed if automatic functions are executed.
Tension alarm limit should be used consistently to give an alarm at a value safely below
what is described as maximum allowed for the topical cable lifter. Do remember that
when using cable lifters there are certain load limitations that must not be exceeded!
When pulling in, winch will be stopped if maximum allowed load is exceeded!

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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2.7 System Settings, Wire-data

All calculations TOWCON executes are dependent on the few basic parameters concerning
wire data. These parameters may be individual for wire on each drum, and they are available
by selecting monitor picture SETUP.

Wire Data : Auto Limits :

Wire length : Pay-out brake length :
to be adjusted by use of pop-up keypad, to be adjusted by use of pop-up keypad,
total length of wire on topical drum used as braking-length in final sequence
Wire length out: of automatic “PAYOUT”
to be adjusted by use of pop-up keypad, Tow/Hoist Limit :
length of wire paid out, measured from drum. to be adjusted by use of pop-up keypad,
Wire diameter: used as rendering-length during auto “TOWING”
to be adjusted by use of pop-up keypad, Auto / Manual Limit :
check that value is correct according actual wire. to be adjusted by use of pop-up keypad,
Cable lifter dimension: used as the minimum wire length remaining
to be selected by use of the “Left”- and “Right”- to be pulled in when TOWCON swap
buttons. Remember to “click” the button marked Set from “HOIST” to “MANUAL”
Cable Lifter Diameter to verify your selection. Minimum possible value = 100 metres.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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3 System Utilities - TowCon RT

3.1 Why doesn’t anything work ? --- Security Lock

When touch screen or trackball has not been used for at least 5 minutes, the Security Lock
will be activated. This is made like this to prevent faulty operations to be executed because
someone accidentally touches surface of monitor screen (if it’s a Touch-Screen)
or the Left Key on trackball. Security Lock will be presented on monitor picture as a red hand
in the upper right corner. As long as this image is visible it’s not possible to execute any other
operation from neither touch-screen nor trackball than just unlocking the system. You can still
move cursor around, but trying to execute some kind of operation by clicking on one of the
images on the picture will not have any effect.

Illustration to the left shows how it looks

like when Security Lock is activated.

Unlock like this:

Place cursor on Red Hand and click on it.
Red Hand will now move to left upper
corner.

Now complete the unlock operation by

placing cursor on the left Red Hand and
click on it.
The left Red Hand disappears, and
system is ready for use.

Hint :
Click on the first one as soon as it appears.
Then just one click on the left Red Hand is needed to get you online!
However, take care; you’ve already lowered the security precautions.

3.2 Monitor Intensity and Cleaning

In the SETUP picture contains also the monitors day / night

adjustments, these are presented as % where 0% is almost black
and 100% is full intensity. 100% gives the best contrast and
readability during daytime and approximately 25% gives a
suitable intensity for nighttime.

In addition the disabling of the touch screen is located here, this

mode gives the operator the ability to clean the LCD screen
without unintentionally activating system functions. This is a time limited operation and
times out in 30 sec. The count is clearly visible on the screen.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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3.3 Input Device Illumination Control

The light intensity on all input devices ( Joystick and

Tension controllers) connected to the workstation
are controlled from this picture. The alphanumeric
display and the indication led’s have separate
adjustments, as for the mains LCD, are the intensity
levels given in % , 0 being the lowest and 100 the
highest intensity.

3.4 Password protected features

Some features on screen are password protected. This is to protect them from unintended
change.
Password for these features is : 9173 – Looking at the keypad it is the corner numbers entered
in a “diagonally” order.
Under is a screenshot from the SETUP-canvas
Wire Strength Lim is a Class Society
demand. The value entered is the actual
breaking force of the wire. An alarm will
be generated at 0.5x this value.

When changing this value the operator

changes the winch strength.
Example: Entering 200tonnes will make
the winch a 200 tonnes winch, not able to
pay in with a higher tension than 200
tonnes.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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3.5 Transferring log files to USB stick

Insert a USB stick into any of the USB ports on the workstation controller on the bridge. After 1-2
seconds the following dialog box is displayed on the main screen. It shows the number of available
log files and how much disk space they require. Press the OK button to transfer the log files to the
USB stick, or the Cancel button to abort the operation.

If the OK button is pressed the log files will be transferred to the USB stick. The progress of each file
is displayed on the screen.

The following message is displayed when the log files have been transferred to the USB stick. Press
the OK button to close it.

The log files are now removed from the workstation controller and stored on the USB stick in a
folder called yyyy.mm.dd_hh.mm_Logs, where yyyy.mm.dd and hh.mm is the current date and time.
For example 2006.08.30_15.30_Logs.

If there is no log files available the following message is displayed. Press the Cancel button to close
it. Then remove the USB stick.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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If there is not enough free space on the USB stick to hold the log files the following message is
displayed. In this case none of the log files are transferred to the USB stick. Remove files from the
USB stick to make room for the log files. Then reinsert the USB stick in the workstation controller to
retry the operation.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
 0001-1273
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3.5.1 Convert a log file to Excel

The retrieved log file is a semicolon delimited text file in the format .txt. This is an Excel compatible
format.

To convert from .txt to Excel you must open the log.txt file from Excel

To view the file you must select text files as file type.

Select the log file and press open.

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When you try to open the .txt file an Import Wizard will appear. In step 1 in the wizard you shall
select Delimited as the type to describe your data, and then press next.

In step 2 of the wizard you must select semicolon as the delimiter, and then press next.

In step 3 of the Import Wizard you don’t need to change any thing. Only press finish to complete the
import wizard.

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dep. Deck Machinery - Brattvaag E-mail: [email protected]
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When the import is completed you will see the imported information in the excel sheet like this:

The first column tells the date and time of the stored values, column B only indicates that the log is
activated by a user. The rest of the columns tell the length, tension, pressure and rpm for the Port
Tow Drum.

3.6 The user menu

A double-click on the canvas tab will display the user menu. This menu
gives the user the possibility to view some system information, adjust the
date and time, and calibrate the touchscreens.
This menu also gives the operator viewing access to the database, copying
log files and wash screen function.

3.6.1 System info

The System Info window displays some information about the state of the system. This
information is intended to service personnel, but you might be asked to read or write down
this information in case of troubleshooting via phone/fax.

3.6.2 Set Date and Time.

Use this dialog box to adjust the date and time on the system.
Double clicking on the date/time field on the status line will
also open this dialog.

Click on the number you want to change. The keypad will pop
up. Then type the new value and click the ENTER-button to
apply it to the system.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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4 MMI – Man Machine Interface / USER CONTROLS

Like so many other systems that surround us today, the monitoring and control system is
based on computer technology. The operator will usually identify the control system with the
Monitor and the Trackball, which he’ll use in his daily work, but even the well known speed
control joystick and the knob for adjusting tension are connected to the computer system,.
All communication between the operator and the control system will be confined to these
units. This is what is often called the MMI; the Man Machine Interface.
There are several possible options to choose from when selecting the MMI units, hence the
configuration described in this manual may not be equal to the one of your system. The two
MMI-units used for “system adjustments” are a Trackball and/or a Monitor with built-in
Touch-screen facility. Your system may include either options, or only a trackball and an
ordinary monitor. If your system includes both options, they will both be usable at the same
time.

4.1 Speed and Tension - Input Devices

The system is mainly operated from ‘Input Devices’ which replaces much of the functionality
that earlier where sets of switches and indicators on the control panel itself. Each input device
has a built in set of standard functions in the base. The functions are the same in both speed
and tension device.

Speed Control Tension Control

Spooling Device
Move Stb / Port by tilting
the joystick sideways.

Select spooling roll Display

Decrement Increment

Brake on/off Coupling in/out

Command

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• Input Devices for Tension
Rotate the knob clockwise to increase the tension limit on the winch, and counter clockwise to
decrease. This function is only available when the Input Device is in command.
Inside the Input Device there is a electrically controlled “brake”. This “brake” will be activated
when trying to go lower than 0% or higher than 100%.

• Input Devices for Speed

The joystick can be tilted in four directions:

Rotate the drum in Lower direction

Move the Spooling device to Stb Move the Spooling device to Port

Rotate the drum in Hoist direction

To operate one single spooling roll at the time, just press one of the buttons on top of the joystick
to select which spooling roll to be operated and tilt the joystick in the direction you want the roll
to move. These functions are only available when the Input Device is in command.

• Functions in the base (Common for both types)

Display:
The display will in general show the selected drum. But some status changes will be
displayed for some seconds. E.g when the coupling are fully engaged, the text “Coupling In”
will pop up.

Command button:
To activate the command on the selected drum double click at the button, and it will be
illuminated by a blue light. If the button still gets no blue light, the drum may be operated
from another Input Device.

To deactivate the command just double click again, and the light in the button will go off.
When the input device is not in command the “select drum” is the only function active.

Note : some older input devices have a yellow light when they are not activated.

Select Drum:
This function is only available when the Input Device is not in command. To select a drum,
just press the Increment or Decrement buttons to cycle through the drums until wanted drum
is displayed.

Torque Step:
The function is only available when the Input Device is in command, the brake is off and the
coupling engaged.

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Brake ON/OFF:
The function is only available when the Input Device is in command.
To alter the Brake between On/Off, just double click on the button.
The red light indicates that the brake is ON. If the red light flashes, the brake is not fully
engaged yet.
The green light indicates that the brake is OFF. If the green light flashes, the brake is not
released yet.

Brake : Coupling :
Red light = Brake ON Red light = Coupling OUT
Green light = Brake OFF Green light = Coupling IN

Coupling IN/OUT:
The function is only available when the Input Device is in command and the brake is ON.
To alter the coupling between IN/OUT, just double click on the button.
The red light indicates that the coupling is OUT. If the red light flashes, the coupling is not
fully released yet.
The green light indicates that the coupling is IN. If the green light flashes, the coupling is not
fully engaged yet.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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4.2 Monitor with “Touch Screen” utility.

There are several possible options to choose from when selecting the MMI units, hence the
configuration described in this manual may not be equal to the one of your system. The two
units used for MMI are a Trackball and/or a monitor with built-in Touch-screen facility. Your
system may include either options, or only a trackball and an ordinary monitor. If your system
includes both options, they will both be usable at the same time.

4.2.1 LCD Monitor

TOUCH SCREEN

CONTRAST POWER INDICATION LAMP

BRIGHTNESS POWER SWITCH

COVER FOR GEOMETRY CONTROLS

4.2.1 Power Switch

The power switch turns the monitor and touchscreen (if fitted) on and off.
The switch does not turn off the PC or the interface board.

4.2.2 Power on lamp : Is lit when monitor is switched on and power cord is connected.

4.2.3 Contrast Control : Adjusts the image brightness in relation to the background.

4.2.4 Brightness Control : Adjusts the overall image and background screen brightness.

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4.2.5 Touch Screen

The whole screen is covered in a touch sensitive film , which presents the operator with an
intuitive and straightforward interface to the systems different settings and operating modes.

4.2.6 Screen adjustments

Remove the cover on the left side of the monitor and the controls will be visible.
NB! If screen geometry is adjusted the touch screen needs to be recalibrated, this because the
touchscreen is relative to the front of the LCD panel. And will therefore stay in the same
position even if the picture itself is moved .

RESET BUTTON

CONTROL +

SELECT BUTTON CONTROL -

LED INDICATORS

4.2.7 Select button

Select control proceeds to the next control selection. Move the led indicators across the
adjustment controls from left to right.

4.2.8 Functions with LED indicators

Starting from left the controls are as follows:
• Horizontal position control adjusts the horizontal position of the image.
• Vertical position control adjusts the vertical position of the image.
• Horizontal size control adjusts the horizontal size of the image.
• Vertical size control adjusts the vertical size of the image.
• Side pin cushion control, adjusts the appearance of curved edges of the display image
either inwards or outwards
• +/- Button : Increases or decreases the adjustment of the selected control function.
• Reset-button : Resets the image settings back to factory setting.

4.2.9 Cleaning the screen

Monitors need to be cleaned for dust and fingerprints at regular.
If the monitor is fitted with a touch screen one can obviously not touch the screen without the
risk of changing parameter and statuses unintentionally, therefore it has to be turned off first.
It is also possible to clean the monitor without shutting it off. See chapter 3.2.
The screen should be cleaned with special cleaning towels or a cloth moistened with weak
soap water. Never use any strong solvents for cleaning the screen!

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4.2.10 Calibrate Touch Screen

The Calibrate Touch button in the User menu will let you calibrate all connected touch
screens.

Press and release point 1. It will turn yellow as long as you press it, and disappear when you
release it. Now the second calibration point (number 2 in the picture above) is displayed.
Repeat the procedure for this one. Finally, when you have pressed the third calibration point
(number 3 in the picture above), the result of the calibration is displayed. This is shown in the
next picture

A successful calibration will be reported like the following picture. It also gives some system
information about which Com-port it is connected to.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

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Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
Årsundveien 24, N-6270 Brattvåg, Norway Homepage: www.rolls-royce.com
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4.3 Using Trackball

If you are familiar to using a PC you may most likely have used a trackball before,
or you’ll pretty soon find out by yourself how it works.

However, if you are new to using this type of equipment, here are some hints :

• Look at the picture on the monitor, and try to find the Cursor.
Move
Keep an eye on the cursor and at the same time rotate the ball on the Trackball.
Cursor
You should now see the cursor moving on your screen.
Try to move the cursor to and from definite places on the picture to get used to its
movements.

• Now move the cursor to the top of the screen and place it on one of the tabs.
Press the left key on the Trackball. The picture on your screen will now change according to
”Click” your selection. Try to change between the different pictures to get the ‘feel’ of how this
works. This is what is called a “click”

• Move the cursor to the lower right corner and place it on the Clock-panel.
Press the left key on the trackball rapidly two times.
”Double- This is what is called “double-click”
Click” Your screen should now contain a panel with the heading “Adjust Time”.
Move the cursor to the “OK”-button and press the left key once more. The panel disappears.
Try this a number of times to get used to “click” and “double-click”

• Move the cursor to the dotted line on the bar-area on a bargraph. Press left key on trackball,
and observe a digital value corresponding to the bargraph scale being displayed. While
keeping the key pressed, move cursor up or down to move the limit-line to a new position.

Left key Right key

Ball

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4.4 Using a Touchscreen

You have probably been using a touch-screen quite a lot of times without even thinking about
what is behind the surface. What is common for all types of touchscreens is that they all
display some kind of “buttons” on a monitor screen. The most familiar is maybe the type you
find on some ATM’s and Infosystems at various airports. In the way of use, they are all the
same: simply press your finger on the “button” on the screen.

However, if you are new to using this type of equipment, here are some hints :

• Look at the picture on the monitor, and try to find the Cursor.
Move Keep an eye on the cursor and tap your finger somewhere else on the screen. Not on a
Cursor “button” this time. Notice that when you withdraw your hand the cursor has now moved to
where you tapped your finger. Try to move the cursor to and from definite places on the
picture to get used to its movements. Be careful not to hit one of the “buttons”.

• Now press your finger on the cursor and move it upwards while keeping a light pressure on
the screen, then move down an around the screen. Be careful not to cross one of the
“buttons”. Notice that the cursor now follows your fingertip and when you withdraw your
hand it remains where you last touched the screen.

• Tap your finger on one of the tabs or labels at the top of the screen, the picture on your
screen will now immediately change according to your selection.
”Click” .Try to change between the different pictures to get the ‘feel’ of how this works. This is what
is called “click” when operating the touchscreen.

• Move the cursor to the lower right corner and place it on the Clock-panel by touching the
screen at that point. Tap on the panel rapidly two times. You may also tap two times on the
”Double- panel at once. This is what is called “double-click” when operating the touchscreen.
Click” Your screen should now contain a panel with the heading “Adjust Time”.
Tap with your finger on the “OK”-button. The panel disappears.
Try this a number of times to get used to “click” and “double-click”

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4.5 Screen Elements

This section will explain briefly about the different elements you’ll find on the monitor
pictures. The monitor is not only used to display information; it is in fact more like a control
console. As described in earlier the monitor is the systems most important
MMI-element. Getting familiar with the MMI and the several picture elements is essential to
the comprehension of how to use the system. It is advisable to study this part of the manual
before proceeding to the more advanced functions.

4.5.1 Folders, Tabs and Panels

Unlike many other systems this system has no pulldown menus. This means that you never
need to change from one picture to another just to get access to the one you really wanted.
Your monitor screen may be compared to a file cabinet with an open drawer. Just “click” on
one of the tabs at the top of the picture, and the folder you have selected will display its
contents on the screen. You may open any folder at any time just by one “click” on its tab.
Every monitor picture is made up of numerous elements. You’ll see that the picture is divided
into separate parts, called Panels. Each panel have its own special function; and some panels
are even “pop-ups” that presents itself to you only when it is needed..

”Panel” ”Folder” ”Tab”

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4.5.2 System Panel

The System Panel occupies a narrow section across the lower part of all pictures, and is
mainly intended to display the System’s condition..

At the left side of this panel, there is an text field showing the operational status of the
system, if the system is fully operational the window will be empty , otherwise the system is
showing either CONFIG or PARAM mode. This means they are in a maintainance mode,
which is only used by service engineers.

Next to the operation mode-indicators there is a small box with a text like “ 125/50 “. The
digit will vary according to the traffic on the bus, first digit shows the number of received
messages per second and the last sendt messages. A low value will indicate that the traffic at
the moment is moderate. That’ll be typical when winches are not used. The value may be very
low (50 /8) if no operations has been executed for a long time. When hoisting heavy loads in
rough weather, with wire tension constantly changing, the bus traffic pick up and he value in
the traffic indicator window will then be considerably higher. This indicator is only useful for
service engineers.

Next to the right is a box displaying a percentage of free memory left in the system.. The
value displayed will normally be changing, but variation should be insignificant. This
indicator is only useful for service engineers.

On the right part of the System Panel there is a box displaying time and date.
The clock may be adjusted at any time to synchronise with other systems.

Operational Input/Output Last Alarms Memory Indicator Date &

Status Messages in Percent Time

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4.5.3 Buttons and Lamps

As described earlier in this manual the monitor screen is the main part of the systems MMI . The
pictures on the screen are more like control panels rather than just illustrations.
Graphic techniques are used to make it look like the screen contains real push-buttons and indicator
lamps. To activate a Button you should “click” on it as described in section 3.1 and 3.2. Buttons may
have several different shapes, but they all have in common that you’ll see some kind of alternation
when you activate them. Some buttons will change appearance permanently as you activate or
deactivate them, while others will go back to their original look as soon as you release the left key on
the trackball. ( or moves your finger away from the touchscreen ). It may seem difficult to discern
between Lamps and Buttons. This doesn’t really matter, because nothing will happen if you “click”
on a lamp. Lamps are only used to display changes in some kind of operation, and have no influence
on the winch control.

4.5.4 Digital Displays

Some pictures introduce important information in Digital Displays. This is boxes of different extent
displaying a digital value of some measured and calculated indicator signal. Typical use is
presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm
limit related to the topical measuring result, the display’s background colour will change if calculated
value is too high (or too low).

”Lamps”

”Buttons”
”Digital Display”

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4.5.5 Bargraphs

On other pictures, measuring results may be displayed as Bar Graphs. This is boxes of different
extent, containing a coloured bar with adjacent scale lines and dimension text. Typical use is
presentation of oil temperature, motor pressure/RPM and wire length. If there is defined an alarm
limit related to the topical measuring result, the bar’s colour will change if calculated value is too
high ( or too low ).

4.5.6 Meters

Some measuring results may even be displayed as Panel Meters. This is images having an appearance
more or less like those good, old-fashioned circular dial instruments that were used on control panels
some years ago. Typical use is presentation of oil temperature, motor pressure/RPM and wire length.
The dial plate may be divided in sectors with different colours,
indicating for instance “low”-values, normal operation and “high”-values.

4.5.7 Sliders

Both Bar Graphs, Trend Displays and Meters may have attached “Sliders”. A Slider is an image
that may be moved in certain directions along a specified path, typical along the outer circle of a
meter. How to “drag” sliders is explained in chapter 4.3 and 4.4 . As a slider is moved, the
appurtenant meter/bar’s appearance will change. As an example the size of the sectors on a meter
may be adjusted in this way. As long as the slider is moving, there’ll also be a digital value displayed
to show its position at the moment.

On these examples is shown how it

looks like when a slider is being
moved on a Meter and on a Bar
Graph. Notice the black cursors
and the digital values.
It is also indicated by cursors in
other colours where cursor must be
placed to ”get a grip” on the other
sliders.

Hint :
If you think it’s difficult to ”get a
grip” of the slider you want to
move, try to place the cursor on the
”bar-area” and move it towards the
limit you want to change.

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4.5.8 Menus and Keypad

To be able to adjust wire lengths, wire diameters, or maybe just correct the system clock,
a keypad is needed. The keypad is a “pop-up” that’ll be accessible by double-clicking on the right
elements on certain monitor pictures. What may be adjusted by use of the numeric keypad is
described in other sections of this manual. Notice that the pop-up menu for correcting the system
clock is made special for this purpose, and don’t look exactly like the numeric keypad.
Nevertheless, they are quite similar in the way they are used.
Keypad is only accessible on monitor pictures showing system parameters such as mentioned above.
These parameters are normally displayed on special pictures, and are most easily recognised as a text
followed by a small, black on white digital display, and behind that some unit of measure. These
picture images’s will in this manual be referred to as executing elements. When opening the keypad,
place the cursor on the executing element on screen and double-click on it. The keypad will then
open and be accessible until you click on the “enter”-button.

Illustration shows keypad

opened to correct value
for Wire Length.
Notice that keypad
becomes accessible both
when double-clicking on
the text-line and on the
digital display box,
because they are both
executing elements for
this winch parameter.

To get access to the keypad, double-click on one of the lines or its topical digital display.
On this clip you can see the text-cursor in the display box for Wire Length. This is the only
mark that for sure is indicating what digital value you are about to adjust.
Click on the ”Cancel”-button if you have opened the wrong digital display,
or if you after all decide not to change the value.
Keypad will then close, and the digital value’ll remain unchanged.
To adjust a value, click on the CLR-button until you have deleted what was wrong and then
write in the correct value by using the number-buttons. As you clear faulty digits or write in
the correct ones you’ll see the contents of the digital display change.
When you have changed the value and can see in the digital display box that it’s correct, just
click ”ENTER” and the keypad’ll close. The correct value is now stored in the system.

Rolls-Royce Marine AS Tel.: +47 815 20 070. Fax: +47 70 20 86 00.

dep. Deck Machinery - Brattvaag E-mail: [email protected]
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