acs 400 instruction manual

Instruction Manual

ACS 400 with ACC 401Emergency Acoustic BOP Control System

ACS 400

Emergency Acoustic BOP Control System

Instruction Manual

ACS 400

4 301678/D

Document history

Rev Date Written by Checked by Approved by

D 29 February 2012 IJG JO AFu

Update manual with new DNV Type Approval certificate.

Copyright

© 2012 Kongsberg Maritime AS.

All rights reserved. The information contained in this document remains the sole

property of Kongsberg Maritime. No part of this document may be copied or

reproduced in any form or by any means, and the information contained within it is not

to be communicated to a third party, without the prior written consent of Kongsberg

Maritime.

Disclaimer

Kongsberg Maritime endeavours to ensure that all information in this document is

correct and fairly stated, but does not accept liability for any errors or omission.

Warning

The equipment to which this manual applies must only be used for the purpose for

which it was designed. Improper use or maintenance may cause damage to the

equipment and/or injury to personnel. The user must be familiar with the contents of

the appropriate manuals before attempting to operate or work on the equipment.

Kongsberg Maritime disclaims any responsibility for damage or injury caused by

improper installation, use or maintenance of the equipment.

Support

All Kongsberg Maritime products:

Phone 24 hour: +47 815 35 355

E-mail: [email protected]

HiPAP, HPR, Transponders, HAIN and ACS:

Phone 24 hour: +47 992 03 808

E-mail: [email protected]

Strandpromenaden 50

P.O.Box 111

N-3191 Horten,

Norway

Kongsberg Maritime AS

Telephone: +47 33 03 41 00

Telefax: +47 33 04 47 53

[email protected]

www.kongsberg.com

mailto:[email protected]

mailto:[email protected]

Instruction Manual

301678/D 1

Remarks

The reader

The installation information in this manual is intended for the design and installation

engineers at the shipyard performing the installation. The information is supplied as the

basis for the shipyard’s own installation drawings applicable to the vessel. On

completion of the installation, this manual must be kept on the vessel for reference

purposes during system maintenance.

The operator information in this manual is intended to be used by the system operator.

He/she should be experienced in the operation of positioning systems, or should have

attended a Kongsberg Maritime training course.

The maintenance information in this manual is intended to be used by a trained

maintenance technician or engineer, with experience of electronic and digital circuitry,

computers and electromechanical design. The level of information is based on

Kongsberg Maritime’s maintenance philosophy: The onboard technical personnel shall,

with the help of the documentation and the system’s built-in test functions, be able to

identify malfunctions, locate the fault, and replace major parts, modules and

components on the “Line Replaceable Unit” (LRU) level. He/she will however not

attempt to repair the LRUs.

ACS 400

2 301678/D

HIGH VOLTAGE SAFETY WARNING The voltages used to power this equipment are potentially lethal.

Even 110 volts can kill.

Whenever possible, the following precautionary measures

should be taken before any work is carried out inside the

equipment:

Switch off all high-voltage power supplies.

Check the operation of any door interlocks and any other

safety devices.

Completely discharge all high-voltage capacitors.

It should be noted that interlocks and safety devices are

normally located only at regular access points, and high voltages

may be exposed during dismantling.

Caution Never work alone on high-voltage equipment! Refer to general safety procedures.

Instruction Manual

301678/D 3

Table of Contents

1 ABOUT THIS DOCUMENT ................................................................................ 11

Manual content ......................................................................................................... 11

Abbreviations ........................................................................................................... 12

2 SYSTEM DESCRIPTION..................................................................................... 13

ACS 400 system - short overview ............................................................................ 14

Available system units ............................................................................................. 15

Surface system ......................................................................................................... 17

ACC 401 Control Unit .................................................................................. 17

Dunking transducer unit ............................................................................... 17

Subsea system .......................................................................................................... 18

Short subsea system description ................................................................... 18

SCU .............................................................................................................. 18

Subsea transducers ........................................................................................ 18

Solenoid interfaces ................................................................................................... 21

Interface specifications ............................................................................................. 21

Telemetry frequencies .............................................................................................. 21

On deck test equipment ............................................................................................ 21

Transducer test cable .................................................................................... 21

TD Patch cable ACS 400 to portable dunking TD ....................................... 22

BOP Simulator .............................................................................................. 22

3 TECHNICAL SPECIFICATIONS....................................................................... 24

Surface system ......................................................................................................... 24

ACC 401 Control Unit .................................................................................. 24

Dunking Transducer Unit ............................................................................. 24

TDD 303 MF Dunking transducer ................................................................ 24

TDD 301 MF Dunking transducer ................................................................ 25

TDD 103 LF Dunking transducer ................................................................. 25

Hull mounted dunking 301 w/adapter plate ................................................. 25

Subsea system .......................................................................................................... 25

Subsea Control Unit...................................................................................... 25

Test cable w/cable drum ........................................................................................... 27

BOP Simulator Unit ................................................................................................. 27

ACS 400

4 301678/D

4 ACS 400 BATTERY LIFE .................................................................................... 28

5 INSTALLATION ................................................................................................... 30

Installation guidelines .............................................................................................. 31

Assistance from Kongsberg Maritime .......................................................... 31

Surface system installation ....................................................................................... 31

Subsea system installation........................................................................................ 31

SCU installation ............................................................................................ 32

Subsea transducer installation ...................................................................... 32

Transducer cables ......................................................................................... 33

Solenoid interface cable ................................................................................ 33

Pre-commissioning tests and checks ........................................................................ 34

Locations ...................................................................................................... 34

Transducer field of view ............................................................................... 34

Cables ........................................................................................................... 34

Cable connections ......................................................................................... 34

Welding procedures for the Subsea Control Unit .................................................... 34

Procedure ...................................................................................................... 34

Execute the welding ...................................................................................... 35

6 CABLES .................................................................................................................. 36

System cables ........................................................................................................... 36

Test Cables ............................................................................................................... 36

Cable specifications ................................................................................................. 37

7 SYSTEM SETUP ................................................................................................... 38

Basic information ..................................................................................................... 39

How to open the cable drum ......................................................................... 39

How to close the cable drum ........................................................................ 39

Surface system setup ................................................................................................ 40

Subsea system setup ................................................................................................. 40

8 ACC 401 UNIT FRONT PANEL.......................................................................... 41

LCD display .................................................................................................. 42

Cursor ........................................................................................................... 42

Pushbuttons ................................................................................................... 42

Connectors................................................................................................................ 43

9 OPERATION AND TEST ..................................................................................... 44

How to switch power on and off .............................................................................. 45

Instruction Manual

301678/D 5

How to get started .................................................................................................... 45

Main menu ............................................................................................................... 46

Menu description ...................................................................................................... 47

Menu system overview ............................................................................................ 48

Menu system ............................................................................................................ 49

System setup ................................................................................................. 49

BOP control .................................................................................................. 52

General for all functions ............................................................................... 53

Read BOP status ........................................................................................... 54

Show BOP status .......................................................................................... 60

Exit program ................................................................................................. 60

Operation example ................................................................................................... 61

Normal procedure for: Pipe Ram CLOSE .................................................... 61

Forcing transmission of the “Execute” command ........................................ 62

Forcing “Execute” without arm status .......................................................... 63

Aborting the command ................................................................................. 64

Errors ............................................................................................................ 65

Valve operation failed/error.......................................................................... 66

10 AUTO SHUTDOWN (OPTION) .......................................................................... 67

Valves used in the sequence ..................................................................................... 67

Sequence operation and timing ................................................................................ 67

Auto shutdown .............................................................................................. 68

Disable auto shutdown.................................................................................. 70

Enable auto shutdown ................................................................................... 71

11 STATUS INFORMATION AND MESSAGES ................................................... 72

“Status page” information ........................................................................................ 72

Stack operation result messages ............................................................................... 76

“BOP Control” status messages ............................................................................... 77

“Read BOP status” messages ................................................................................... 77

BOP acknowledge messages .................................................................................... 78

Auto Shutdown status messages .............................................................................. 79

12 ON DECK TEST/TEST IN AIR ........................................................................... 81

Acoustic communication .......................................................................................... 81

Alternative 1 ................................................................................................. 82

Alternative 2 (Preferred option) ................................................................... 82

On deck test of ACS 400 with HiPAP ..................................................................... 84

ACS 400

6 301678/D

13 MAINTENANCE ................................................................................................... 86

Surface system ......................................................................................................... 87

ACC Control Unit electronics rack .............................................................. 87

Charging the ACC Control Unit battery ....................................................... 88

Opening the ACC Control Unit .................................................................... 89

How to replace the ACC Control Unit circuit boards .................................. 89

Dunking Transducer Unit ............................................................................. 92

Subsea system .......................................................................................................... 94

Subsea Control Unit...................................................................................... 94

Opening the Subsea Control Unit ................................................................. 97

Subsea Control Unit electronics rack ........................................................... 98

Subsea Control Unit battery packs ............................................................. 101

How to replace the Subsea Control Unit circuit boards ............................. 102

How to replace the Subsea Control Unit batteries ...................................... 105

Closing the Subsea Control Unit ................................................................ 108

Inter-seal test port (option) ..................................................................................... 110

Subsea (BOP) transducers ...................................................................................... 112

Cleaning the transducers ............................................................................. 112

Replacing a subsea transducer .................................................................... 112

14 INTERNAL UNITS ............................................................................................. 114

Front panel unit ...................................................................................................... 115

Front panel connectors ................................................................................ 116

Flylead connectors ...................................................................................... 116

Transmitter board (Tx) ............................................................................... 117

Receiver board (Rx) .................................................................................... 117

Microcontroller board ................................................................................. 118

Battery charger board (Charger-2) ............................................................. 121

AC power supply ........................................................................................ 123

Internal battery ............................................................................................ 124

Motherboard ............................................................................................... 125

Solenoid and sensor interface board (SSIB) ............................................... 127

15 SPARE PARTS..................................................................................................... 129

Codes used ............................................................................................................. 129

Surface system ....................................................................................................... 130

BOP Simulator Unit ............................................................................................... 130

Subsea system ........................................................................................................ 131

Instruction Manual

301678/D 7

16 EQUIPMENT HANDLING ................................................................................ 132

Equipment responsibility ....................................................................................... 133

Transportation ........................................................................................................ 133

Unpacking, lifting and handling ............................................................................. 133

Inspection ............................................................................................................... 134

Storage .................................................................................................................... 134

17 PRINCIPLES OF OPERATION ........................................................................ 136

Telemetry communication ..................................................................................... 136

Acoustic coding principle ........................................................................... 136

Standard telemetry telegram ....................................................................... 136

Acoustic telegram transmission sequence .................................................. 137

Power settings ............................................................................................. 139

“Wake up” telegram timing ........................................................................ 140

Message telegram ....................................................................................... 141

Frequencies for the telemetry messages ..................................................... 141

Wake-up frequencies .................................................................................. 141

Acoustical address ...................................................................................... 142

Surface/subsea communication .................................................................. 142

Solenoid operation ...................................................................................... 144

Interfaces .................................................................................................... 145

18 DRAWING FILE ................................................................................................. 146

Drawings ................................................................................................................ 146

Dunking Transducer (TD) Unit - outline dimensions ................................ 147

TDD 303 MF dunking TD - outline dimensions ........................................ 148

TDD 301 MF dunking TD - outline dimensions ........................................ 149

TDD 103 LF dunking TD - outline dimensions ......................................... 150

Hull mounted dunking 301 w/adapter plate ............................................... 151

ACC 401 – outline dimensions ................................................................... 152

BOP Simulator Unit – outline dimensions ................................................. 153

Subsea Control Unit (SCU) - outline dimensions ...................................... 154

SCU mounting brackets - outline dimensions ............................................ 155

TDA 331 MF subsea (BOP) Transducer - outline dimensions .................. 156

TDA 324 MF subsea (BOP) Transducer - outline dimensions .................. 157

TDA 133 LF subsea (BOP) Transducer - outline dimensions.................... 158

BOP transducer cable, pin connections ...................................................... 159

SCU rack wiring 8 channel system............................................................. 160

SCU rack wiring 16 channel system........................................................... 161

ACS 400

8 301678/D

19 LITHIUM BATTERIES SAFETY PROCEDURES ........................................ 162

Identification of the products and company ........................................................... 163

Product name .............................................................................................. 163

Range of products ....................................................................................... 163

Company address ........................................................................................ 163

Emergency contact ..................................................................................... 163

Composition and information on ingredients ......................................................... 164

Battery chemistry ........................................................................................ 164

Battery weight and lithium content ............................................................ 164

Battery cell manufacturers/types ................................................................ 164

Battery design ............................................................................................. 165

Hazards identification ............................................................................................ 165

Danger of explosions .................................................................................. 165

Noxious gases ............................................................................................. 166

First-aid measures .................................................................................................. 166

Fire-fighting measures ........................................................................................... 166

Accidental release measures .................................................................................. 167

Handling and storage .............................................................................................. 167

Recovering a ”functioning” transponder .................................................... 167

Recovering a ”failing” transponder ............................................................ 167

Handling a heated or self-heated transponder ............................................ 168

Handling a transponder if relief valve opens .............................................. 168

Opening a transponder with defect/possible defect battery ........................ 169

Opening a “functioning” transponder ......................................................... 169

Handling heated or warm separate battery ................................................. 169

Handling transponders and separate transponder batteries in case of an

external fire ................................................................................................. 170

Storage ........................................................................................................ 170

Exposure controls and personals protection ........................................................... 171

Physical and chemical properties ........................................................................... 171

Stability and reactivity ........................................................................................... 171

Ecological information ........................................................................................... 172

Disposal considerations .......................................................................................... 172

Transport information ............................................................................................ 172

Regulatory information .......................................................................................... 173

Other information ................................................................................................... 173

Instruction Manual

301678/D 9

20 CERTIFICATES .................................................................................................. 174

21 INDEX ................................................................................................................... 181

About this document

301678/D 11

1 ABOUT THIS DOCUMENT This is the standard Instruction manual for the complete

Emergency Acoustic BOP Control System (ACS 400).

Warning The Subsea Control Unit contains Lithium

batteries. - Safety information about the batteries, refer to

section Lithium batteries safety procedures on page 21.

Manual content

The manual contains descriptions, specifications, procedures and

illustrations required to install and maintain the ACS 400 system

units.

The manual also defines the equipment responsibility, and

provides general information about preservation, packing and

storage of the units.

The system is described down to circuit board level, named as

the Line Replaceable Units (LRUs). Block diagrams and

drawings are used to simplify the descriptions.

ACS 400

12 301678/D

Abbreviations ACC Acoustic Control Command unit (topside)

ACS Acoustic Control System (complete system)

BOP Blow Out Preventor

CPU Central Processing Unit

EDP Emergency Disconnect Package

LCD Liquid Crystal Display

LED Light emitting diode

LF Low frequency

Max Maximum

MC Microcontroller

MIN Minimum

MF Medium frequency

MUNAV Modular underwater navigation

MUTRAN Modular underwater transponder

ROV Remotely operated vehicle

RX Receive / reception

S. no. Serial number

SSIB Solenoid and Sensor Interface Board

SCU Subsea Control Unit

N/A Not Applicable

TD TransDucer

TX Transmit / transmission

System description

301678/D 13

2 SYSTEM DESCRIPTION This chapter gives an overall description of the ACS 400

system.

Topics

ACS 400 system - short overview on page 13

Available system units on page 15

Surface system on page 17

Subsea system on page 18

Solenoid interfaces on page 21

Interface specifications on page 21

Telemetry frequencies on page 21

Transducer test cable on page 21

BOP Simulator on page 22

ACS 400

14 301678/D

ACS 400 system - short overview

The Emergency Acoustic BOP Control System is divided into

two main parts:

Surface system (portable)

Subsea system

Additional equipment

ACS simulator and test cable with test transducer

Figure 1 Acoustic Control System for BOP operation

System description

301678/D 15

Available system units

The following units are available for Acoustic Control System

(ACS) systems.

Note Only the primary hardware items are listed.

Units delivered for your system - see the Registration form

(separate document).

Unit name Unit P/N Order P/N

Surface system

Acoustic Control Command (ACC 401) unit - MF 125-217498 ACC-219601

Acoustic Control Command (ACC 401) unit - LF ACC-219600

Dunking transducer TDD 301-MF, with cable drum

(3000 m)

129-220871 023-220877

Dunking transducer TDD 303-MF, with cable drum

(1500 m)

301518 023-220878

Dunking transducer TDD 103-LF, with cable drum 312844 023-220879

Hull mounted dunking 301 w/adapter plate 332392 332392

Subsea system

Subsea Control Unit (SCU) – MF/LF, 8 Ch 129-215265 AS4-215266

Subsea Control Unit (SCU) – MF/LF, 10/16 Ch 129-216151 AS4-216150

Interface cable DRY + S/N Ref. Registration form

Interface cable PBOF + S/N (Oil filled) Ref. Registration form

Subsea transducer TDA 324 – MF (1500 m) 100-211373 100-211373

Subsea transducer TDA 331 – MF (3000 m) 100-210123 100-210123

Subsea transducer TDA 133 - LF 100-102841 TDL-103175

On deck test equipment

TD patch cable ACS 400 to portable Dunking TD 334868 334868

Transducer test cable for Deck-test 380-103277 380-103277

BOP Simulator Unit 8 Channel 313237 313237

BOP Simulator Unit 10 Channel (Obsolete) 109-081009 TES-103183

BOP Simulator Unit test cable Ref. Registration form

ACS 400

16 301678/D

Cable 1,transducer

ACC 401 Control Unit

Cable drumwith 70 m cable

Dunkingtransducer

(CD34027a)

Cable 2,simulator

Figure 2 ACS 400 surface units

Cable 4,transducer

Cable 5,interface

Cable 3,transducer

To solenoid pack

Subsea Control Unit (SCU)

Subsea transducer 1

Subsea transducer 2

(Cd

340

29)

Figure 3 ACS 400 subsea units

System description

301678/D 17

Surface system

The portable system comprises:

One ACC 401 Control Unit

One Dunking Transducer Unit w/ cable winch and dunking

transducer.


The ACC 401 Control Unit is delivered in a splash-proof

portable container light enough to be carried by one person.

It is operated by the use of pushbuttons and a menu system

displayed on a small LCD screen. It has an internal rechargeable

battery and battery charger. A fully charged battery will provide

approximately 300 operations.

Dunking transducer unit

The dunking transducer unit is a separate unit which also can be

carried by one person. It consists of a cable drum with cable and

a transducer.

The cable drum holds 70 m of transducer cable, and has a

transducer connected to the “outer” end. The other end of the

cable must be connected into the front of the unit.

The transducer is placed in a suitable basket, and secured with a

strap.

The cable drum is fitted with a handle for cable roll-out / roll-up

on one side, and a cable locking-pin on the other side.

The following dunking transducers delivered with cable

drum are available:

TDD 301-MF dunking transducer

TDD 303-MF dunking transducer

TDD 103-LF dunking transducer

ACS 400

18 301678/D

Subsea system

The ACS subsea system is the interface between the ACC 401

control system and the subsea hydraulic valve control unit on the

BOP.

The ACS subsea system consists of:

The Subsea Control Unit (SCU), holding the batteries (two

battery packs) and two cylindrical circuit board racks

(subsea control electronics).

Two communication transducers, with cables and water-

proof connectors.

Interface cable to the solenoid pack

Short subsea system description

The SCU (subsea system) is the transceiver interface between

the ACU system (topside system) and the subsea hydraulic valve

control unit on the BOP.

It is mounted on the BOP, and receives acoustic control signals

from the ACC 401 Control Unit. It translates the signals into

operational commands, then acts on those commands, sending

control signals to solenoids which in turn open or close

hydraulic control valves on the BOP. Once the command signal

has been acted upon, a confirmation signal is transmitted by the

Subsea Control Unit to the topside unit.

The control system can also read the status of the Subsea

Control Unit and the various hydraulic control valves and

sensors.

The ACS system is dual redundant, which means that there are

two communication transducers and two complete sets of

electronic circuit boards, to provide 100% redundancy. The

transceivers are powered by separate replaceable batteries.

SCU

The container is secured to the BOP using a mounting bracket.

The mounting bracket hooks onto studs welded onto the BOP,

and are then secured with bolts.

Subsea transducers

The two transducers transmit and receive acoustic signals to and

from the surface.

The two transducers are mounted on the ends of booms which

are located on opposite sides of the BOP structure.

System description

301678/D 19

The two transducers are completely independent of each other.

Each transducer connects to its own electronic rack via a cable.

The cables are connected into water-proof connector at the base

of the SCU.

The following subsea transducers are available:

TDA 324 MF subsea transducer


TDA 133 LF transducer

Hull mounted dunking 301 w/adapter plate


This transducer is designed for use in water depths down to

1500 m.

(Cd34032)

Figure 4 TDA 324 MF transducer with cable



3000 metres.

(Cd34061)

Figure 5 TDA 331 MF transducer with cable

ACS 400

20 301678/D

TDA 133 LF transducer


3000 m.

Figure 6 TDA 133 LF transducer


This transducer is for hull mounting. The transducer unit

consists of 331 transducers, adapter plate and 70 meter cable.

The cable is prepared with connector for connecting to ACC401

transducer plug.

The transducer can be mounted on/in a fixed transducer shaft.

(Cd34087b)

Figure 7 Hull mounted dunking 301 w/adapter plate

System description

301678/D 21

Solenoid interfaces

The interfaces to the hydraulic solenoids on the BOP are

connected in parallel, thus seen from the BOP they constitute

one single interface.

All BOP command functions can be executed using either of the

two controller channels. The channel to be used is selected via

the topside menu system.

Interface specifications

Interface specifications for your system - see the System

Registration Form (separate document).

Telemetry frequencies

Telemetry frequencies for your system - see the System


On deck test equipment

Transducer test cable

The transducer test cable (30 m) is used for "on deck testing" of

the ACS when the SCU containers are not in water.

(Cd34098)

Figure 8 Transducer test cable on cable drum

The test cable:

Can only be used for testing one single SCU at the time.

Will perform a stable acoustic connection for ACS

function testing of ACC and SCU.

Test in air on page 81

ACS 400

22 301678/D

TD Patch cable ACS 400 to portable

dunking TD

This cable (30 m) is connected to the Portable dunking

transducer and the Subsea control unit.

On deck test of ACS 400 with the use of HiPAP on page 84

Figure 9 TD Patch cable ACS 400 to portable dunking TD

BOP Simulator

The BOP Simulator (for simulating the BOP) with test cable is

supplied with each delivery.

Simulation procedure on page 82

A(CD34060)

Figure 10 BOP Simulator indicating test cable connector (A)

Note The SCU must be at the surface when the simulator is used.

System description

301678/D 23

The simulator is configured with the parameters for the actual

BOP it will be simulating, and contains loads that correspond to

the nominal loads of the solenoids to be controlled.

The simulator contains a current sensor circuit that lights an

LED if the solenoid current is too low. The simulator is marked

with the names of the actual valves. When performing a valve

operation, the LED corresponding to the valve function will

light up for the specified period of time.

If the system is equipped with feedback sensors, the sensors are

simulated by switches for each valve.

ACS 400

24 301678/D

3 TECHNICAL SPECIFICATIONS This chapter gives the technical specifications of the ACS

system units.

Topics

ACC 401 Portable surface system on page 24

ACS Subsea system on page 25

Surface system


Dimensions: on page 151

Weight: 14 kg

Batteries:

Number of batteries: 1

Cells per battery: 18

Type of cells: sealed, rechargeable, lead/acid

Operating voltage: 35 to 41 Vdc

Transmission power: 300 W

Electrical details, AC power supply:

Input voltage: 100 to 240 Vac (47 to 63 Hz)

Output voltage: 48 Vdc

Environmental conditions:

Operation temperature: 0 to 55° C

Storage temperature: -40°C to +70°C

Splash proof: IP64

Dunking Transducer Unit


Length of cable: 70 m

TDD 303 MF Dunking transducer


Beamwidth: (approx) 60 at -3dB

Operating frequency: 25 kHz

Technical specifications

301678/D 25

TDD 301 MF Dunking transducer




TDD 103 LF Dunking transducer



Operating frequency: 12.5 kHz


Same specifications as for TDD 301 MF Dunking

transducer, plus an adapter plate.

Length of cable: 70 m

Adapter plate dimensions: on page 151

Subsea system

Subsea Control Unit


Operating depth (max): 3000 m

Weight in air / water: 300 kg / (approx) 230 kg

Material, body: ST 52 steel

Material, flange: Super duplex

Splash proof: IP64

Electronic details:

Operating temperature (electronics): 0°C to 55°C

Channels: 2 redundant electronic controller channels

Communication principle: Multi-frequency shift keying

Operating frequencies:

24000 - 26500 Hz in steps of 125 Hz

Wake-up frequencies:

Channel 76: 24 and 23.5 kHz

Channel 86: 24.5 and 23.5 kHz

Transmission power: 500 W

ACS 400

26 301678/D

Batteries:

Number of batteries: 2 (L10/50 units)

Cells per battery: 54 -

(divided into groups of 42 and 12 cells)

Type of cells: sealed, non-rechargeable, lithium

Battery outputs: 49 V and 10.5 Vdc

Total battery energy content (49 V): 1800 Wh

Total battery energy content (10 V): 500 Wh

Battery life, in operation: Calculations on request

Battery life, in storage: (approx) 10 years

with (approx) 15% loss of capacity, see below

The batteries may be stored for up to 10 years with little loss of

capacity, the losses being approximately according to the figures

below:

1st year: - 3%

Next 9 years: - 1.5% per year

The total capacity lost over 10 years will therefore be

approximately 15%.

Caution The batteries must be stored upright.

Mounting brackets

Two mounting brackets are welded to the Subsea Control Unit at

30° on either side of the “zero” position. The brackets are

manufactured of the same material, and have undergone the

same surface treatments, as the unit.


Thickness: 10 mm

Mounting holes: 3 holes 13 mm Ø, one slotted





Material: aluminium-bronze





301678/D 27



TDA 133 LF subsea transducer

Beamwidth: approx. 60 at -3dB

Operating frequency: 12.5 kHz



Test cable w/cable drum

Weight: 7.5 kg

Cable length: 30 m

BOP Simulator Unit


Weight: 1.5 kg

ACS 400

28 301678/D

4 ACS 400 BATTERY LIFE Important parameters for ACS battery calculations are:

"solenoid on time"

"nominal solenoid current"

an assumption regarding how often the system shall be used

expected power level to be used

The ACS 400 battery consists of a combined 10 V battery with

approx. 550 Wh (Watt hours) and a 48 V battery with up to 1688

Wh capacity.

For normal ACS 400 system operations the standby operational

time does limit the system battery life more than the 48 V

battery part.

Example:

If operating for about 15 minutes each day using 10V battery

operation then the ACS 400 system has a lifetime of up to 1.7

years (620 days).

When we do transmit commands and operate solenoids then the

48V battery is the main power source.

Normally when operating a 24 V solenoid with 500 mA for 10

sec., a limited part of the 48 V power is used.

Example:

1Wh capacity (48 V) is approx. enough for 20 solenoid

operations alone.

2Wh capacity is used for 20 valve operations, using max

transmitter power for telemetry.

1 Wh With reduced Tx power down to High power setting

(20 Valve operations).

Summary: 20 valve operations may require 2-3 Wh totally form

the 48V battery supply.

As seen from the example above, a 48 V battery capacity of

almost 1700 Wh is sufficient for normal ACS 400 operations.

Note KM recommend to change the ACS 400 batteries "once a year"

due to the safety situation.

ACS 400 Battery life

301678/D 29

An operating procedure/test of the ACS 400 system should be

performed once a week in order to verify operation and

availability.

The built in battery monitoring system is designed to give a

battery warning when there is less than 10% battery capacity

left.

ACS 400

30 301678/D

5 INSTALLATION This chapter includes the basic information required to install

the ACS 400 units.

The ACS 400 system and its transducers and cables are normally

be strapped to a wooden pallet for transport.

Topics

Surface system installation on page 31

Subsea system installation on page 31

Pre-commissioning tests and checks on page 34

Related topics

Equipment handling on page 132

Drawings in the Drawing file chapter from page 146

Installation

301678/D 31

Installation guidelines

Unless otherwise stated, the installation yard is responsible for

the installation of the entire ACS system. In addition, the yard is

responsible for providing and connecting all cables. The actual

installation and cable laying must comply with the vessel’s

classification rules and the recommendations given in this

manual.

Assistance from Kongsberg Maritime

Kongsberg Maritime AS may assist during the installation if

specified in the contract or requested by the installation yard or

customer. Kongsberg Maritime AS may also assist with

installation drawings. All such assistance is charged to the

customer at the current rates.

If required during a contractual test period, the yard must

provide assistance necessary for the rapid and efficient

completion of the work even when the work is to be performed

outside normal working hours. This requirement includes

assistance from subcontractors when applicable. Excessive

waiting time resulting from delays caused by the yard will be

charged to the yard.

Surface system installation

The surface system consists of the ACC Control Unit and the

Dunking Transducer Unit. These units are interconnected by the

transducer cable.

The portable system requires no installation.

Subsea system installation

The subsea part of the ACS system comprises the Subsea

Control Unit, two transducers, two transducer cables (attached to

the transducers) and a solenoid interface cable.

The Subsea Control Unit and transducers must be installed onto

the BOP, and all cable connections must be made, before the

BOP is lowered to the sea bed. The ACS subsea system parts are

designed to be maintenance-free for long periods, only serviced

when the BOP is on the surface.

ACS 400

32 301678/D

SCU installation

The unit must be lowered into position in the BOP using suitable

lifting equipment.

Note The unit weighs approximately 300 kg in air.

The unit has two brackets welded to its casing, which are

designed to hook onto studs mounted on the BOP structure.

Once the unit is in position, four M12 bolts, nuts and spring

washers must be used to secure it.

Bracket dimensions and mounting holes on page 155

Note These bolts etc. are not provided with the unit as the types and

lengths will depend on the thickness and material of the

structure on which the unit is to be mounted. Tighten the bolts to

the torque recommended by the bolt manufacturers. If A4 or

similar high tensile-strength bolts are used, tighten the bolts to a

torque of 40 Nm.

Ensure that the bolts create a good electrical contact between the

Subsea Control Unit and the BOP structure so the cathodic

protection system will protect the unit.

Subsea transducer installation

The two transducers must be mounted on the BOP framework.

The transducers must be located at opposite sides of the BOP,

and must be positioned such that they have a clear line of sight

to the surface.

They should be located as far away from the BOP structure and

other reflective surfaces as possible to reduce the effects of

acoustic shadowing and echoes.

Each transducer is secured in position by five M8 bolts, nuts and

spring washers.

Installation

301678/D 33

Note These bolts etc. are not provided with the transducers as the

types and lengths of the bolts will depend on the thickness and

material of the structure onto which the transducers are to be

mounted. Tighten the bolts to the torque recommended by the

bolt manufacturers. If A4 or similar high tensile-strength bolts

are used, tighten the bolts to a torque of 12 Nm.

Transducer cables

Transducer cables for your system - see the System


Once the transducers have been mounted on the BOP, run the

cables to the Subsea Control Unit, and:

1 Secure the cables to the BOP structure so they do not

present a hazard to ROVs etc, and mount any protective

covers necessary to prevent the cables being damaged.

- Ensure enough slack is allowed to enable any

moving parts to move without stretching the cables.

- Ensure that any bends in the cables are no tighter

than the minimum radii given in the referenced

drawings.

2 When the cables are ready to be connected into the Subsea

Control Unit, proceed according to the instructions for the

specific type of connectors in use.

Solenoid interface cable

See the Solenoid Interface cables for your system - see the

System Registration Form (separate document).

Once the Subsea Control Unit has been mounted on the BOP:

1 Secure the cable to the BOP structure so it does not

present a hazard to ROVs etc.

2 Mount any protective covers necessary to prevent the

cable being damaged.

- Ensure enough slack is allowed to enable any

moving parts to move without stretching the cable.

When the cable is ready to be connected into the solenoid unit,

proceed according to the instructions for the specific type of

connector in use.

ACS 400

34 301678/D

Pre-commissioning tests and checks

Locations

Check that all the parts of the ACS 400 installation have been

mounted in the correct locations, and that all the units are

fastened securely using all the required bolts.

Transducer field of view

Check that the two communication transducers have an un-

impeded field of view throughout a cone of 30 (3000

m)/50 (1500 m) vertically upwards towards the surface.

Any obstructions within the field of view, and any reflective

surfaces nearby such as the BOP structure, may cause

communication problems.

Cables

Check that the transducer and solenoid interface cables are

run correctly according to the installation procedures.

Check that enough slack has been allowed to ensure the

cables will not be damaged where they cross joints etc.

Check that the cables are secured firmly to the BOP structure

so they will not present a danger to ROVs etc.

Ensure that all required protective coverings are secured

firmly in place.

Cable connections

Check that all the required electrical connections have been

made correctly according to the procedures for the particular

type of connector, and that the connections are tight. Ensure

that any pressure tests have been performed.

Welding procedures for the Subsea Control Unit

Procedure

1 Open the Subsea Control Unit

Refer to page 97.

2 Remove the two electronic units and batteries.

Refer to page 102 and 105.

Installation

301678/D 35

3 Replace the lid and fastened the bolts.

4 Cover and seal all three connectors.

5 Cover the gap between the barrel and the lid.

Execute the welding

1 Open the container again.

Refer to page 97.

2 Replace the electronic units and the batteries.

Refer to page 102 and 105.

3 Close the Subsea Control Unit.

Refer to page 108.

4 Execute function test of the complete assembled system.

ACS 400

36 301678/D

6 CABLES This chapter specifies the interconnection cables used by the

ACS system.

Note Kongsberg Maritime only specifies the physical cable

properties. We consider compliance with national standards to

be the responsibility of the end user.

Refer to ACS system figure 1 on page 16 and figure 2 on

page 16 for the cable plan.

System cables

Cable no. Cable type From/To Length Supplier

1 Transducer cable Control Command Unit

(ACC 401) → Dunking

transducer (on cable drum)

70 m Kongsberg

Maritime

3 Transducer cable Subsea Control Unit (SCU) →

Subsea transducer

15 m Kongsberg

Maritime

4 Transducer cable Subsea Control Unit (SCU) →

Subsea transducer

15 m Kongsberg

Maritime

5 Interface cable Subsea Control Unit (SCU) →

Customer BOP

Customer

specified

Kongsberg

Maritime

Test Cables

Cable no. Cable type From/To Length Supplier

1 Simulator cable BOP Simulator Unit →

Interface cable

15 m Kongsberg

Maritime

2 TD patch cable

ACS 400 to

portable Dunking

TD

Control Command Unit

(ACC 401) → Subsea Control

Unit (SCU)

30 m Kongsberg

Maritime

3 Transducer test

cable for Deck-test

Subsea Control Unit (SCU) →

Dunking transducer (on cable

drum)

30 m Kongsberg

Maritime

Cables

301678/D 37

Cable specifications

Cable specifications for your system - see the System


ACS 400

38 301678/D

7 SYSTEM SETUP This chapter describes the basic setup procedures.

Topics

Basic information on page 39

Surface system setup on page 40

Subsea system setup on page 40

Related topics

Charging the ACC battery on page 88

System setup

301678/D 39

Basic information

AD

F

BC

B

EG

(Cd34033)

Figure 11 Cable drum w/transducer

How to open the cable drum

1 Pull the locking clip (A) towards you to open the unit.

2 Fold out the handle (F).

3 Lift up the cover (D).

- The cable for ACC connection is placed inside the

drum - behind this cover.

4 Pull out the cable (E).

5 To unlock the transducer cable, unlock the locking-pin, by

turning the locking-knob (G) into vertical position.

How to close the cable drum

After use, wash the unit, cable and transducer before storage.

1 Use the handle to roll-up the transducer cable.

2 Place the transducer in the basket.

3 Push the cable locking-pin into position and lock the cable

by turning the locking-knob (G) into horizontal position.

4 Fold the handle (F) into position.

5 Press the two bars (B) together and push the locking clip

(C) into position.

6 Roll-up the ACC cable (E), and place it inside the drum.

7 Close the cover (D).

ACS 400

40 301678/D

Surface system setup

The system is now ready for use.

Procedure

1 Place the ACC Control Unit in a suitable location and

remove the container lid.

2 Place the cable drum close to the ACC Control Unit.

3 Prepare the cable drum for operation.

- See description above.

4 Pull the transducer cable and lower the dunking transducer

into the sea to a depth at least 10 m below the lowest part

of the platform's/vessel's keel or thrusters.

- If required - use the handle to roll-out the cable.

5 Connect the transducer cable into the connector marked

TD on the front of the ACC Control Unit.

4 Press the button to switch power on to the unit.

The surface system is now ready for operation!

Subsea system setup

No preparations.

ACC 401 unit front panel

301678/D 41

8 ACC 401 UNIT FRONT PANEL This chapter presents the mail functions of the ACC 401 front

panel.

Topics

LCD display on page 42

Cursor on page 42

Pushbuttons on page 42

Connectors for external connections on page 43

(Cd34043)

Figure 12 ACC 401 front panel

ACS 400

42 301678/D

LCD display

The LCD screen is used to display the system menu, and any

messages generated by the system. The screen is approximately

110 mm by 60 mm, and exists of 13 lines, each with maximum

30 characters.

The screen displays text as dark letters on a light background.

Backlighting is available to improve the contrast.

Cursor

The system uses a cursor to identify the selected command in

the menu. The cursor is formed of inverse video, with light

characters on a dark background.

Pushbuttons

Move the cursor upwards in the menu

Increase the required selection

Press the button: one step at a time

Press and hold the button: fast count

SELECT the required menu input

Move the cursor downwards in the menu

Decrease the required selection

Press the button: one step at a time

Press and hold the button: fast count

SELECT the required menu input

Select the highlighted command

Move the cursor to the right

Enter the selected value

ENTER, next menu level appears

CLOSE, go back one menu level

Aborts the command.

Two

EXECUTE

buttons

These buttons must be pressed simultaneously, and

held for a minimum of three seconds, to execute

critical commands.

POWER Switches ON the system (ACC 401)

There is no Power off button; the unit automatically

switches itself off if the arrow buttons have not been

pressed for ten minutes (or you can use the Exit

menu). When power is switched on, the unit's program

enters the main menu.

ACC 401 unit front panel

301678/D 43

LIGHT The button toggles the background lighting for the

display on and off. To save battery power, the light

will be switched off automatically two minutes after

the arrow buttons are last used.

HELP When you press and hold the button for a few

moments, the system will display help text appropriate

to the currently highlighted menu command.

Example:

By pressing the up/down arrow the operator selects the main

menu, and then pressing the right arrow the system will ENTER

the main menu's submenu.

A second level menu will appear on the display and the ACC

401 operator can SELECT the submenu. When pressing the

LEFT button the system will CLOSE or "Abort" the prepared

command.

Connectors

The following connections are implemented:

TD - Dunking transducer cable

110-230 VAC - Charging

COM - For test and diagnostic (KM -Internal)

ACS 400

44 301678/D

9 OPERATION AND TEST This chapter describes how to get started, the menu system,

operation examples and status messages. It also includes a

simulation procedure.

Topics

How to switch power on and off on page 45

Getting started on page 45

Main menu on page 46

Menu description on page 47

Menu system overview on page 48

Menu system on page 49

Operation example on page 61

Test in air on page 67

Simulation procedure on page 66

Related topics

Status information and messages on page 72

Operation and test

301678/D 45

How to switch power on and off

Power on

1 Press the button on the ACC 401 Control Unit

front panel.

2 Observe that the start-up page appears, and the Main menu

is displayed.

Power off

1 Select the Exit Program command and press .

- If the Exit menu is not used, the unit automatically

switches off after ten minutes, if no operation.

2 The system will shut down and the display will be

switched off.

How to get started

Before you start the operation:

1 Press the button on the ACC 401 Control Unit

front panel.

2 The system will then run a self-test to check internal

functions.

a In the event of a malfunction, a System malfunction

error message will be displayed.

b On successful completion of the test, the main menu is

displayed.

The system is now ready for operation!

Complete overview of the menu system, refer to page 26.

Operational procedures, refer to page 39.

ACS 400

46 301678/D

Main menu

The main menu window is displayed below. There are six sub-

menus (including Exit) in the main menu. Each sub-menu is

described in the following sections, and all accessible

commands are listed. The purpose of each command is then

explained, and screen layout examples and the various control

options available are given.

When system power is first switched on, the system will run a

self-test to check internal functions. In the event of a

malfunction, a System malfunction error message will be

displayed. On successful completion of the test, the system’s

main menu is displayed as shown below.

ACC 401 BAT% 75

---------------------------------------------

SYSTEM SETUP

BOP CONTROL

READ BOP STATUS

SELECTED: AUTO DETECT

ACC UNIT 1 UNIT 2

TX POWER: HIGH

LEAVE SELECT ENTER

Note ACC Control Unit battery status <BAT% xx> is displayed in the

upper right corner of the display by indicating remaining

battery capacity (0 to 100 %). When the battery capacity falls

below 50 % the “BAT” status starts flashing.

Operation and test

301678/D 47

Menu description

The menu system has two levels:

Top level (Main menu) - appears when the system is

switched ON.

Level of commands (submenu), for operator selection.

Menu presentation

Note Only three menu lines are presented in the window at a time!

This applies for both the main menu and the submenus. The

selected command is always presented at the same menu line

(the middle line) as indicated below. The example presents main

menu selections, but only part of the window is shown.

ACS 400

48 301678/D

Menu system overview

The standard menu system includes the following menu /

submenu. The submenus are described in details as follows:

SYSTEM SETUP on page 49

Includes the required system setup

functions.

SELECT BOP UNIT

SET TOPSIDE TX POWER

SET BOP UNIT 1 TX POWER


SHOW SYSTEM INFO

BOP CONTROL on page 52

These parameters are specified by

the customer. Each installation will

therefore be different.

The BOP CONTROL parameters

READ BOP STATUS on page 54

Includes required status functions.

READ ELECTRIC STATUS

READ VALVE STATUS

READ BATTERY STATUS

READ SHORT STATUS

GET SOLENOID CURRENT

GET ANALOGUE READBACK

(option)

READ ANALOGUE SENSORS (option)

SHOW BOP STATUS on page 60

Displays various status information.

No submenu.

The various status and information messages

are described in the Status information and

messages section on page

EXIT PROGRAM – on page 60 No submenu.

Operation and test

301678/D 49

Menu system

This section describes the ACC 401 Control Unit menu system

in detail.

Menu system overview, refer to page 48.

System setup

The acoustic link will be set up initially by Kongsberg Maritime

personnel, but some parameters can be changed offshore via the

System setup sub-menu. When this sub-menu is selected, the

display will read as follows:

SYSTEM SETUP BAT% 75

--------------------------------------------

SELECT BOP UNIT

SET TOPSIDE TX POWER



ACC UNIT 1 UNIT 2

TX POWER: HIGH

LEAVE SELECT ENTER

The following parameters are available for the System setup

command:

SELECT BOP UNIT on page 49

SET TOPSIDE TX POWER on page 50

SET BOP UNIT 1 TX POWER on page 51

SET BOP UNIT 2 TX POWER on page 51

SHOW SYSTEM INFO on page 52

Select BOP unit

The purpose of this command is to select the electronics unit in

the Subsea Control Unit to which the subsequent commands are

to be transmitted.

The following options are available:

BOP unit 1

BOP unit 2

Auto detect

The default setting is Auto detect.

ACS 400

50 301678/D

BOP unit 1 or 2 - Enables you to command the ACC Control

Unit to use a particular electronics unit in the Subsea Control

Unit.

Auto detect - When the ACC Control Unit is switched on, it

will initially attempt to communicate with Subsea Control Unit

electronic unit 1. If this is successful, the system will continue to

use unit 1 until either it stops answering, or you select unit 2

manually in this menu. If unit 1 does not answer however, the

ACC Control Unit will automatically switch to unit 2. If this is

successful then the system will go directly to unit 2 the next time

the system is used. If problems are also experienced with unit 2,

the ACC Control Unit will display a “No acknowledgment”

message and will not attempt to switch back to unit 1. The next

time the system is used, it will then start again with unit 1 and

repeat the procedure.

Set topside tx power

The purpose of this command is to set the power level to be used

when the ACC Control Unit transmits to the Subsea Control

Unit.


Min power

Low power

High power

Max power

The default setting is High power.

The differences in power levels for the various settings -

see page 139.

The power level required will depend on the water conditions at

the time of the transmission. If the level is set too low, the BOP

may not receive the transmission. If the level is set too high,

battery power will be wasted and reflections from subsea

structures may be registered as spurious signals resulting in

communication errors.

The power settings are stored in backup RAM such that the

system will use the same settings the next time it is used.

Operation and test

301678/D 51

Set BOP unit 1 tx power


when BOP unit 1 transmits to the ACC Control Unit.


Min power

Low power

High power

Max power

The default setting is High power.

The differences in power levels for the various settings -

see page139.

The power level required will depend on the water conditions at

the time of the transmission. If the level is set too low, the ACC

Control Unit may not receive the transmission. If the level is set

too high, battery power will be wasted and reflections from

subsea structures may be registered as spurious signals resulting

in communication errors.

The power settings are stored in backup RAM such that the

system will use the same settings the next time it is used.

Set BOP unit 2 tx power


when BOP unit 2 transmits to the ACC Control Unit.

BOP units 1 and 2 have identical power setting options and

default power setting.

ACS 400

52 301678/D

Show system info

This display shows information about the ACS system.

No operator-selectable options are available under this

command.

The system information is presented as shown below:

SYSTEM SETUP BAT% 75

--------------------------------------------

Rig/Ship name ACC 401 Vx.x

SERIAL NO: 1000 1001

CHANNELS: 76 86


ACC UNIT 1 UNIT 2

TX POWER: HIGH

PRESS LEFT TO CONTINUE

For SERIAL NO and CHANNELS for your system - see the


ACC 401 V.x.x - Version number of the program installed in

the ACC Control Unit.

SERIAL NO - Serial numbers of the two electronic units

installed in the Subsea Control Unit.

CHANNELS - Frequency channels used by the two Subsea

Control Unit electronic units. The frequency bands are set

manually using switches on the CPU card in the ACC Control

Unit, and these frequency bands dictate which channels are

used. These are set by the manufacturers and should not be

altered. Channels are wakeup channels used for the MF system.

Note If you are in the Auto detect mode, BOP unit 1 or 2 must be

selected prior to transmitting this command. Go to the Select

BOP unit menu to do this.

BOP control

The menu parameters listed under the BOP control command

are ordered specifically by the customer. Each installation will

therefore be different.

Parameters for your system - see the Registration Form


Operation and test

301678/D 53

When BOP control is selected, the menu will be displayed as

shown below (example):

BOP CONTROL BAT% 75

--------------------------------------------

ST LOCKS LOCK

RISER CONNECTOR UNLATCH

UNIT:x BOP STATUS:<status>

EL STATUS:<status>

LEAVE SELECT ENTER

General for all functions

Note The procedures, possibilities, status and display texts are similar

for all the functions - the only difference being the function

name in line three of the display. The full procedure, with all

possibilities and display layouts, is therefore described only for

the first command, ST locks LOCK. If you are in doubt about

the procedure for one of the other commands, select that

command then follow the procedure for ST locks LOCK.

Refer to the Operation example chapter starting on page

61.

The possible status messages are described in the BOP

control status messages chapter on page 77.

ACS 400

54 301678/D

Read BOP status

When the Read BOP status command is selected from the main

menu, the system will request a status report from the selected

BOP unit. When the status report is received, the following

display page will appear:

READ BOP STATUS BAT% 75

--------------------------------------------

READ ELECTRIC STATUS

READ VALVE STATUS

READ BATTERY VALUES


EL STATUS:<status>

LEAVE SELECT ENTER

The various status and information messages that may be

displayed are described in the Read BOP status messages

chapter on page 77.

If no reply telegram from the Subsea Control Unit is received

within the time limit, Unknown will be displayed in the

<status> fields in line six.

The following parameters are available for the Read BOP

status command:

READ ELECTRIC STATUS on page 55

READ VALVE STATUS on page 55

READ BATTERY STATUS on page 56

READ SHORT STATUS on page 57

GET SOLENOID CURRENT on page 57

GET ANALOGUE READBACK (option) on page 58

READ ANALOGUE SENSORS (option) on page 59

Operation and test

301678/D 55

Read electric/valve status

If you select Read electric status or Read valve status, the

following display page will appear while the system performs

the status check:


--------------------------------------------

READ VALVE STATUS

WAITING FOR REPLY XX


EL STATUS:<status>

LEAVE SELECT ENTER

Once the check has been completed, the display will present the

information as shown in the next diagram.

BOP STATUS BAT% 75

--------------------------------------------

UNIT: x EL. TEXTS: 1

ELECTRONIC: <status>

VALVE: <status>

1 2 3 4 5 6 7 8


EL STATUS:<status>

LEAVE PREV. LAST

The UNIT fields indicate which Subsea Control Unit electronic

unit is selected.

The EL. TEXTS (Option) field indicates the EL. TEXTS page

no. 1 (Normally removed).

VALVE: <status> will display a line of characters, one for each

valve in the system. Each character will be either an 0, an 1 or a

U depending on the current status of the corresponding valve.

An 0 indicates that the valve is closed, an 1 indicates it is active,

and a U indicates that the valve status is unknown.

The possible status messages are described in the Status

information and messages section starting on page 66.

ACS 400

56 301678/D

Read battery status

This command requests a status report from the battery in the

Subsea Control Unit on the BOP.

If you select Read battery status, the system will make a

transmission and the “Waiting for reply” message will be

displayed. On completion, the following display page will

appear:


----------------------------------------

CONSUMED 10V: xx%

CONSUMED 48V: xx%


EL STATUS:<status>


The battery consumption to date will be given as a percentage of

the total battery capacity.

The Subsea Control Unit keeps a continuous record of the total

time it has been switched on, the power used during each

transmission it has made, and all other power expenditures. The

total power used is compared with the total capacity of a new

battery, and the result is calculated as a percentage. The values

will be reset automatically when the battery is changed or the

power is switched off.

Pressing the key will return you to the Read BOP status

menu.

Read short status

This command requests a status report from the selected Subsea

Control Unit electronic unit. The information received is used to

update the status information displayed in the BOP

STATUS:<status> and EL STATUS:<status> lines.

If you select Read short status, the system will make a


displayed. On completion, the Read BOP status menu will

reappear.



Operation and test

301678/D 57

Get solenoid current

When a stack function has been executed, the solenoid current

value is stored by the subsea system software.

If you select Get solenoid current, the ACC Control Unit will

display the latest value stored.

Analogue inputs 8 and 16 are set up to read the solenoid current.

These inputs can sense a full range of 0 to 4 A. The solenoid

current will be read after 70 % of the pulse duration.

If you select Get solenoid current, the system will make a


displayed. On completion, the following display page will

appear:

ANALOG STATUS BAT% 75

--------------------------------------------

-

CHANNEL: <channel no.>

VALUE: <value> MA


EL STATUS:<status>


The <channel no.> field will display the sensor channel selected

and the <value> field gives the current value (in mA) detected

by the sensor.


menu.

ACS 400

58 301678/D

Get analogue readback (option)

The analogue current values for all executed stack functions are

stored by the subsea system software. The Get analogue

readback command gets the values of each channel. The

displayed value will be in range of 4 to 20 mA.

If you select Get analogue readback, the following information

will be received from the subsea system:

GET ANALOG READBACK BAT% 75

--------------------------------------------

ANALOGUE CHANNEL READBACK CHANNEL (1-8/16)


EL STATUS:<status>

LEAVE SELECT ENTER

Press or to select the required channel number (1 to

8/16) and then press to enter the number into the system.

The system will then request a status report from the selected

BOP.

When the status report is received, the following display page

will appear:

ANALOG STATUS BAT% 75

----------------------------------------------

CHANNEL: <channel no.>

VALUE: <value> MA


EL STATUS:<status>


The <channel no.> field will display the sensor channel selected

and the <value> field gives the current value (in mA) detected

by the sensor.


menu.

Operation and test

301678/D 59

Read analogue sensors (option)

The BOP can be fitted with a number of different sensors, such

as hydraulic pressure sensors, voltage or current sensors,

counters etc. The ACC Control Unit can read the analogue

values of these sensor channels and convert the values into

specific readings with units as required (e.g. xx psi, xx volts

etc).

The command Read analogue sensors transmits the sensor

control telegram to the Subsea Control Unit. The sensors are

pre-programmed in the ACC Control Unit parameter file with

name, engineering units and limits.

If you select Read analogue sensors, the system will make a


displayed. On completion, the following information will be

received from the subsea system:


--------------------------------------------

READ ANALOG SENSORS

<SENSOR NO. 1>: <value>

<SENSOR NO. 2>: <value>


EL STATUS:<status>


The <sensor no.> field displays which sensor is selected and the

<value> field gives the analogue value (in its corresponding

engineering unit) detected by the sensor.


menu.

ACS 400

60 301678/D

Show BOP status

Entering this menu command opens the status information page.

The following display page will be presented:

BOP STATUS BAT% 75

--------------------------------------------



VALVE: <status>

1 2 3 4 5 6 7 8


ACC UNIT 1 UNIT 2

TX POWER: HIGH

LEAVE SELECT ENTER

The UNIT fields indicate which Subsea Control Unit electronic

unit is selected.

The EL. TEXTS (Option) field indicates the EL. TEXTS page

no. 1 (Normally removed).

VALVE: <status> will display a line of letters, one for each

valve in the system. Each letter will be (depending on the

current status of the corresponding valve) either:

O - indicates that the valve is closed

I - indicates it is active

U - indicates that the valve status is unknown.

See Status information and messages section on page 66.

Exit program

When you wish to leave the program, highlight the Exit

program command, then press to enter the command. The

system will shut down and the display will be switched off.

To switch the system on again, press the button.

Operation and test

301678/D 61

Operation example

The operational procedure, display layouts and messages are

virtually identical for all stack functions. The only visible

difference between them is the name of the function displayed in

line 3. The first stack function in the BOP control list has been

explained in detail here. If you have any doubts while operating

one of the other functions in the list, the procedure is identical to

that described here.

Normal procedure for: Pipe Ram CLOSE

Select Pipe Ram CLOSE. The following text is displayed:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

PRESS EXEC BUTTONS FOR 3 SEC.

TO EXECUTE STACK FUNCTION


EL STATUS:<status>

EXECUTE ABORT EXECUTE

Press the buttons for three seconds to transmit the

command. The display then reads as shown below while the

message is transmitted and the ACC Control Unit waits for the

Acknowledge message. The XX field will display the time

elapsed since the transmission was started.

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

WAITING FOR ACKNOWLEDGE XX


EL STATUS:<status>

PRESS LEFT TO ABORT

You can abort the command by pressing the button.

ACS 400

62 301678/D

If the procedure is allowed to run and the ACC Control Unit

receives the Acknowledge message from the Subsea Control

Unit, the Execute message will be transmitted automatically and

the display will change to that shown below to inform you of the

current status of the BOP system:

Once the function has been executed by the Subsea Control

Unit, the result of the operation is displayed:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

STATUS: OK VERIFICATION


EL STATUS:<status>


The possible messages are listed in the Status information

and messages section on page 66.

Forcing transmission of the “Execute” command

If the Acknowledge message from the Subsea Control Unit is

not received within the time limit, a time-out message will be

displayed in the Status line:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

STATUS: TIMEOUT

FORCE ERROR, PRESS EXECUTE


EL STATUS:<status>


The possible messages are listed in the Status information

and messages section on page 66.

You can then force the transmission of the Execute command

by pressing the two buttons again. The display will

then read:

Operation and test

301678/D 63

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

EXECUTING STACK CMD XX


EL STATUS:<status>


Caution As the Acknowledge message has not been received by

the ACC Control Unit you have no way of knowing the

status of the Subsea Control Unit or whether the Subsea Control Unit has received the command, and

afterwards only events will indicate whether the BOP has performed the command.

On completion of the transmission, the display will read:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

STATUS: NO VERIFICATION


EL STATUS:<status>


Forcing “Execute” without arm status

A situation could occur when the Subsea Control Unit cannot

verify that the BOP has armed its hydraulics. This could be

caused by the Pipe Ram CLOSE command not being transmitted

first, by a lack of sufficient hydraulic pressure in the system or

by a damaged pressure sensor. In this event, the display shows

as follows (note that line 3 will show the requested stack

function):

ACS 400

64 301678/D

BOP CONTROL BAT% 75

--------------------------------------------

RISER CONNECTOR UNLATCH

STATUS: SYSTEM IS DISARMED

FORCE ERROR, PRESS EXECUTE


EL STATUS:<status>


You must now decide whether to abort or force the Execute. See

the Caution above.

Aborting the command

In the event of communication problems while a stack function

is being performed, the ACC Control Unit will display the

Timeout message. The system will not transfer automatically to

the other Subsea Control Unit electronic unit and continue - you

must press the button and abort the command. You must

then change manually to the other electronic unit (via the

System setup menu) and restart the procedure from the

beginning. Problems arising, after communication has been

established, may be caused by acoustic shadowing or echoes.

If there is still a problem, try changing the transmission powers

via the System Setup menu (note that too much power could

also create problems), and consider moving the dunking

transducer to a different location.

You can also abort a command at any point in the command

sequence by pressing . The display will then read:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

ABORTING


EL STATUS:<status>


Operation and test

301678/D 65

And on completion, the following page will be presented:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE


TO EXECUTE STACK FUNCTION


EL STATUS:<status>


Press the two buttons over again if you want to re-

transmit the command or press to return to the BOP

Control menu.

Caution An erroneous command should be aborted at the earliest possible moment - in any case within 10

seconds of the function being initiated if the BOP is to continue to function normally. When the “Execute” message is sent (after about 10 seconds depending on

conditions, depth, etc.) the BOP hydraulic equipment will start to function, and even if you abort then, a half-

closed shear ram is as catastrophic for the BOP as one that is fully closed.

Errors

If an error situation occurs, the following page will be displayed:

BOP CONTROL BAT% 75

--------------------------------------------

PIPE RAM CLOSE

STATUS: <status>

BOP INF: <status>


EL STATUS:<status>




Press to return to the BOP Control menu

ACS 400

66 301678/D

Valve operation failed/error

If a real valve operation fails, the initial fault-finding step would

be to connect the BOP Simulator Unit and operate the system

with the simulator connected. If the simulator system appears to

work correctly, look for the fault in the hydraulic package.

Auto shutdown (option)

301678/D 67

10 AUTO SHUTDOWN (OPTION) This chapter gives a short introduction to the Auto Shut Down

(ASHD) system.

Auto shutdown specification for your system - see the

System Registration Form.

Valves used in the sequence

Ordinary defined BOP single valve operations may be put

together to a predefined sequence of valve operations in order to

perform a controlled shut down of a BOP system.

This specific sequence must be defined by the BOP

manufacturer and predefined in the ACU/SCU system parameter

set.

Sequence operation and timing

The BOP ASHD sensors (minimum 1 - maximum 3 sensors) are

connected to the two available SCUs. It is possible to define

different criteria for ASHD triggering from the BOP sensors

(single sensor trig. - two of 3 possible sensors etc...).

Both the SCU units will receive the same triggering signal

simultaneously. In order to control the BOP operation, by

sending current to a specific solenoid only from one SCU at a

time, then the programmed sequence operation may be

performed. The sequence in the example with 4 single valve

operations will be executed directly after triggering from the

BOP sensors from SCU 1. The SCU 2 will perform a defined

delay before starting the ASHD valve sequence, trying to avoid

that the SCUs are sending current to one solenoid at the same

time.

When an ASHD operation is performed, the main priority is

subsea at the SCUs in order to control the BOP.

If an ACU operator tries to control and communicate with

the SCU in ASHD time slot, a possible status reply from a

SCU will only inform the operator that an ASHD sequence

is performing or has occurred.

It will be possible to read a specific ASHD status info telegram

when the ASHD sequence is finished. An ASHD sequence will

be executed once, and then it is required to enable the function

from the ACU if it is to be run a second time.

ACS 400

68 301678/D

Figure 13 Example of sequence operation and timing

Auto shutdown

The menu parameters listed under the AUTO SHUTDOWN

command are used to enable/disable the Auto shutdown

function, option settings and to read status from the Auto

shutdown system.

When one of the commands from the Auto shutdown menu is

activated, it will operate on the selected BOP unit.

Entering this menu command has the same effect as pressing the

STATUS button. The following display page will be presented:

AUTO SHUTDOWN BAT% 75

-------------------------------------------

READ AUTO SHUTDOWN STATUS

READ TIME OF LAST SHUTDOWN

DISABLE AUTO SHUTDOWN


EL STATUS:<status>

LEAVE SELECT ENTER

The following parameters are available for the Auto shut down

command:

Read auto shutdown status

Read time of last shutdown

Disable auto shutdown

Enable auto shutdown

Read auto shutdown

This command requests Auto shutdown status from the selected

ACS 401 electronic unit.


301678/D 69

If you select READ AUTO SHUTDOWN STATUS, the

system will make a transmission and the “Waiting for reply”

message will be displayed.

On completion, the following display page will appear:


---------------------------------------------

UNIT: x

SHD CONTROL :<status>

SHD IRQ :<status> SHD READ:<status>

SOL. CURR :<status> STACK E: <status,0/E>

SEQUENCE:12345678


EL STATUS:<status>

PRESS LEFT ← TO CONTINUE

The various status and information messages are

described in the Status information and messages chapter on

page 72.

Read time of last shutdown

This command gives the time elapsed since the last Auto

shutdown sequence was activated. If you select READ TIME

OF LAST SHUTDOWN, the system will make a transmission

and the “Waiting for reply” message will be displayed.

On completion, the following display page will appear:


-----------------------------------------------

READ TIME OF LAST SHUTDOWN

TIME SINCE LAST ACT.: <status>


EL STATUS:<status>


Note The read time of last shutdown status represents the number of

minutes since last activation.

ACS 400

70 301678/D

Disable auto shutdown

This command is used to disable the Auto shutdown function on

the selected BOP unit. When this function has been carried out,

you will get full status information on the Auto shutdown state.

If you select DISABLE SHUTDOWN, the following text is

displayed:


-----------------------------------------------

DISABLE SHUTDOWN



EL STATUS:<status>

EXECUTE ABORT ← EXECUTE



message is transmitted and the topside unit waits for the




If the procedure is allowed to run and the ACC 401 unit

receives the Acknowledge message from the SCU 400, the

display will change to that shown below to inform you of the

current status of the Auto shutdown, example:


----------------------------------------------

UNIT: 1

SHD CONTROL : <status>

SHD IRQ : <status> SHD READ: <status>

SOL. CURR : <status> STACK E: 00000000

SEQUENCE:12345678

UNIT:x BOP STATUS: RESET

EL STATUS: OK


The various status and information messages are

described in the Status information and messages chapter

on page 72.


301678/D 71

Enable auto shutdown

This command is used to enable the Auto shutdown function on

the selected BOP unit. When this function has been carried out,

you will get full status information on the Auto shutdown state.

If you select ENABLE SHUTDOWN, the following text is

displayed:

If you select ALL (Default), SENSOR 1 or SENSOR 2, the

following display page will appear:


----------------------------------------------

ENABLE SHUTDOWN (Select: ALL)



EL STATUS:<status>

EXECUTE ABORT ← EXECUTE



message is transmitted and the topside unit waits for the




If the procedure is allowed to run and the ACC 401 unit receives

the Acknowledge message from the SCU, the display will

change to that shown below to inform you of the current status

of the Auto shutdown:


----------------------------------------------

UNIT: 1



SOL. CURR : <status> STACK E:00000000

SEQUENCE:12345678


EL STATUS: OK


The various status and information messages that may be

displayed are described in the Read BOP status messages

chapter on page72.

ACS 400

72 301678/D

11 STATUS INFORMATION AND MESSAGES

“Status page” information

The standard status page is laid out as shown below:

BOP STATUS BAT% 75

--------------------------------------------



VALVE: <status>

1 2 3 4 5 6 7 8


EL STATUS:<status>

LEAVE PREV. LAST

The information displayed is as follows:

UNIT: x This is the currently selected Subsea Control Unit’s electronic

unit. It will indicate unit 1 or 2.

EL. TEXTS: <x> The EL. TEXTS (Option) field indicates the EL. TEXTS page no. 1

(Normally removed).

ELECTRONIC: This can be one of the following messages <errors> (assume both unit 1 and 2 are tested):

ANALOGUE SENS ERR

Description One of the analogue sensors has d eveloped a

fault.

Action Analogue sense on solenoid package has to be

repaired / replaced next time BOP is on deck.

BATTERY WARNING 10V

Description The 10 V section of the selected electronic

unit’s battery will soon fail.

Action Battery must be replaced next time BOP is on

deck. Read the power consumption of the

Subsea Control Unit. The warning will be

executed when reaching approx. 90% of

power consumption.

Status information and messages

301678/D 73

BATTERY WARNING 48V

Description The 48 V section of the selected electronic

unit’s battery will soon fail.





power consumption.

BATTERY WARNING 48V PING

Description The ping counter for the 48 V battery has

exceeded the limit.


deck. Theoretical calculations say that the 48 V

battery is empty.

ELECTRIC STAT UNKNOWN

Description No acoustic reply received .

Action Lower the Dunking transducer further down.

Increase power, both from the surface and

subsea units if possible.

If not ok, call Kongsberg Maritime.

NO ELECTRIC ERROR

Description No electrical error is detected in the Subsea

Control Unit.

Action None.

STATUS UNKNOWN

Description The electrical status is not known.

Action Check power settings, battery status etc.

Increase power settings for the subsea and

surface units.

SW WATCHDOG

Description Program error detected .

Action Reset the system. (Self power off after one (1)

minute).

VALVE: This can be one of the following messages: <status>

XXX

Description This indicates which of the valves is active,

closed or status unknown.

For systems with dynamic switches, the

valves will be displayed as 0 (= closed), 1 (=

active) or U (= unknown).

Action None.

ACS 400

74 301678/D

STATUS UNKNOWN

Description The valve status has not been read from the

Subsea Control Unit, so is therefore not

known.

Action None.

BOP STATUS: This can be one of the following messages:

<status>

Blank field

Description For systems without Arm/ Reset functions, a

blank, dark rectangle will be d isplayed for the

BOP S status.

Action None.

ARM

Description The BOP hydraulic system is armed and ready

to accept stack function orders.

Action None.

PRES. E

Description Pressure error. The BOP is armed but the

hydraulic pressure is not satisfactory.

Action Check hydraulic pressure. Read BOP status

again.

If not ok, call Kongsberg Maritime.

RESET

Description The BOP hydraulic system is d isarmed (reset).

It must be armed before is can carry out stack

function orders.

Action None.

UNKNOWN

Description The BOP status is not known.

Action Read the BOP status. Operate ARM or

DISARM function.

VALVE E

Description Valve error. One or more of the read backs

from the stack valves are open after a

DISARM function is executed . (This message

is only possible just after a DISARM function

is executed).

Action Take care - do not execute the ARM function.

The faulty valve will be operated .

V + P E

Description Valve error and pressure error.


301678/D 75

Action Check solenoid package. If the BOP is on

deck, test against the simulator box.

V + R E

Description Valve error and reset error.

Action Check solenoid package. If the BOP is on

deck, test against the Simulator box.

ABORTED

Description The stack command has been aborted .

Action None.

EL STATUS: This can be one of the following messages: <status>

BATT W.

Description Battery warning. The battery is beginning to

run down.





power consumption.

ERROR

Description The operator must execute the Read Electr

Status command to receive a detailed error

message.

Action None.

OK

Description All functions and results are correct.

Action None.

UNKNOWN

Description The electrical status is unknown due to faulty

communications etc.

Action Try again. Adjust power both on surface and

subsea units.

If not ok, contact Kongsberg Maritime.

Note Unknown will be displayed in the BOP S: and EL S: <status>

fields if the ACC Unit does not receive a status message from

the Subsea Control Unit.

ACS 400

76 301678/D

Stack operation result messages

The following display page may be presented as a result of a

stack operation:

BOP STATUS BAT% 75

--------------------------------------------

STATUS : <status>

INTF ERROR : <status>


EL STATUS:<status>

LEAVE PREV. LAST

STATUS: This can be one of the following messages: <status>

FAULTY VERIFICATION

Description Incorrect readback signal from the sensors. In

systems without readback the system checks

the current, and this message then indicates

that the current is not within the specified

limits.

Action Check the solenoid current. If ok, the fault is

in the solenoid package.

Check the readback switches.

NO VERIFICATION

Description The current stack operation has not been

verified .

Action Try again. Adjust power. The signal from the

Subsea Control Unit has not been detected .

OK VERIFICATION

Description Successful operation of current stack function.

Action None.

INTF ERROR : This can be one of the following messages: <status>

LOW SOLENOID CURRENT

Description The solenoid current is below the lower

current limit.

Action Read solenoid current. Check internal battery

in the Subsea Control Unit, and solenoid in

solenoid package.


301678/D 77

HIGH SOLENOID CURRENT

Description The solenoid current is above the upper

current limit.

Action Check solenoid package. Test against the BOP

simulator if possible.

CURRENT OVERFLOW

Description A short circuit has been detected in the subsea

system. The selected Subsea Control Unit’s

electronic unit will not perform any further

operations - abort the command and select the

other electronic unit.



UNCONTROLLED CURRENT

Description A current is sensed when no current should be

flowing. The selected Subsea Control Unit’s

electronic unit will not perform any further

operations - abort the command and select the

other electronic unit.



Check SCU battery (10/ 48V package).

“BOP Control” status messages

“BOP Control” can include the same error messages as the

Status page.

Refer to page 66.

“Read BOP status” messages

The “Read BOP Status” page can include the same error

messages as the Status page.

Refer to page 66.

ACS 400

78 301678/D

BOP acknowledge messages

The various acknowledge messages that the system can display

in the Status field while performing stack functions in the BOP

Control menu, are as follows:

OK ACKNOWLEDGE

Description The ACC Unit has received the appropriate

acknowledgement message.

Action None.

SYSTEM IS DISARMED

Description The Subsea Control Unit cannot confirm that

the BOP hydraulic system is armed. This may

be due to a damaged pressure sensor or a lack

of hydraulic pressure in the BOP.

Action Check solenoid package, hydraulic pressure.

SUBSEA ELECTRONIC ERROR

Description The Subsea Control Unit has developed an

electronic fault.

Action Abort the command and switch to the other

Subsea Control Unit’s electronic unit. As

described .


TELEGRAM ERROR

Description A check-sum error or an unexpected telegram

has been received .

Action Reset the system. Try again.


TIMEOUT

Description The ACC Unit has not received an

acknowledgement message within the time

limit. The message may have been transmitted

by the Subsea Control Unit but a valid

message has not been received .

Action Increase/ decrease power on both surface and

subsea units. Try again.



301678/D 79

Auto Shutdown status messages


----------------------------------------------

UNIT: <x>



SOL. CURR : <status> STACK E: 00000000

SEQUENCE: 12345678


EL STATUS: OK


STATUS: This can be one of the following messages: <status>

UNIT: x This is the currently selected Subsea Control Unit’s electronic

unit. It will indicate unit 1 or 2.

SHD CONTROL: This can be one of the following messages: <status>

ENABLE ALL

Description Indicates that the Subsea system is Enabled

for making an Auto Shutdown sequence

DISABLE ALL

Description Indicates that the Subsea system is Disabled .

None Auto Shutdown sequence will start

while IRQ/ Switches activates.

SHD IRQ : This can be one of the following messages: <status>

NONE / SHD 1 / SHD 2 / ALL

Description Indicates that the Subsea system is Enabled

for making an Auto Shutdown sequence with

ex. ALL (Both switches).

SHD READ : This can be one of the following messages: <status>

SW 1 / SW 2 / ALL

Description Indicates that the Subsea system has

performed an Auto Shutdown sequence with

ex. ALL (Both switches).

ACS 400

80 301678/D

SOL CURRENT: This can be one of the following messages: <status>

N/A / OK / LOW / HIGH

Description Indicates that the Subsea system has

performed an Auto Shutdown sequence with

OK solenoid drive current.

STACK E: This can be one of the following messages: <status>

0 / E /

Description 0 = OK and E = Error in the auto sequence.

SEQUENCE: This can be one of the following messages: <status>

Description 1, 2, 3 – 8 indicates the function number in the

sequence.

On deck test/Test in air

301678/D 81

12 ON DECK TEST/TEST IN AIR This chapter describes how to test the ACS 400 system in air/on

deck testing, BOP simulation and also how to test the system

with HiPAP.

Topics

Acoustic communication on page 81

BOP simulation and test procedure on page 82

On deck test of ACS 400 with HiPAP on page 84

Acoustic communication

Cable drumwith 70 m cable


Subsea transducer 1

Subsea transducer 2

(Cd

340

27

g)

Dunkingtransducer

Test cable

Interface cable

Alternative 2

Altern

ative 2

Alternative 1

Altern

ative 1

TD Test cablewith 30 m cable


Figure 14 Test in air

ACS 400

82 301678/D

Figure 14 shows a complete setup of the system test in air. For

test of the acoustic communication either alternative 1 or 2 can

be used, but use of alternative 2 is the preferred option for heavy

testing of BOP stack functions.

Alternative 1

Alternative 1 can be used for test in air, but Alternative 2 is the

preferred procedure. Acoustic communication in air is not an

easy way to communicate as the transducers is made for

communication in water. Use Low or Min Tx-Power to avoid

destruction of transducers when communicating in air.

Alternative 2 (Preferred option)

1 Disconnected the SCU subsea transducer 1 (TDA331)

from the SCU.

2 Connect one end of the transducer test cable to the SCU.

3 Connect the other end of the cable to the ACC transducer

connector.

- It is not needed to use more than LOW POWER

when testing with the Trandsducer test cable!

4 If the SCU is power up and down during testing, please

make sure that either the subsea transducer or the test

cable is connected to the SCU prior to battery power on!

- This in order to start transmitting at power up with a

load connected to the transmitter.

5 Check that either the dunking transducer or the test cable

is connected to the ACC before activating/transmitting any

acoustical commands!

This in order to start transmitting with a load connected to the

transmitter.

BOP Simulation and test procedure

To simulate a valve operation with feedback, proceed as

follows:

1 Replace the valve controller package with the BOP

Simulator Unit. Connect the simulator test cable to the

interface cable. The other end of the interface cable must

be connected to the Subsea Control Unit.

2 Establish contact with Subsea Control Unit’s electronic

unit no. 1 using the ACC Control Unit and the Dunking

transducer. Manually select unit no. 1 in the menu.

3 Execute a BOP stack function from the ACC Control Unit.


301678/D 83

Note Check if the systems have readback; if not toggle the switch.

Some time will elapse before the solenoid current is switched on.

4 When the LED for the valve operation lights, wait for a

second or two and toggle the valve switch.

- The switch simulates that the hydraulic pilot

pressure has opened the slide valve. This should

result in a correctly confirmed valve operation.

Note For some systems, the sequence of the menu items displayed on

the ACC Control Unit will not correspond with the operable

solenoid valve functions. Refer to the front label on the BOP

Simulator Unit to relate readback values with executed valve

operations.

5 When the LED is switched off, check on the ACC Control

Unit front panel that the correct status message is

displayed.

Note For systems with dynamic switches, valve status can only be

read when the solenoid function has been carried out. For

systems with static switches, valve status can be read at any

time.

6 Repeat points 3 to 5 for the other stack functions.

7 Move the Dunking transducer in order to establish contact

with Subsea Control Unit’s electronic unit no. 2.

8 Manually select unit no. 2 in the menu.

9 Repeat points 3 to 5 for the all stack functions.

10 Some deliveries have a feature for reading an analogue

sensor. This option can also be tested by using the BOP

Simulator Unit. The toggle switch, located in lower right

corner of the simulator, will simulate 6 or 16 mA readings

on the analogue sensor.

Note The system has a command called “Read BOP valve status”. If

this command is executed, the Subsea Control Unit will read the

positions of the switches on the simulator and transmit the

information to the ACC Control Unit as “Operated valves”.

During this operation no solenoid currents will be switched on,

so no green LEDs will light.

ACS 400

84 301678/D

On deck test of ACS 400 with HiPAP

It is possible to test the ACS system on deck by using HiPAP.

Connect the “TD patch cable” as shown in Figure 15.

1 Lower the dunking TD into the water.

2 Operate the subsea ACS from APOS via the HiPAP

transducer.

Note If there is no acoustic communication it is due to the transducer

not pointing towards the HiPAP so therefore make up an

arrangement for this.

Figure 15 shows a complete setup for the on deck test with

HiPAP and BOP simulator.


301678/D 85

Portable dunking TD- Cable drum with 70 m cable


Subsea transducer 2

(Cd

340

87a

)

Dunkingtransducer

TD Patch cable ACS 400 to portable dunking TD

Test cable

Interface cable

Operator StationAPOS

HiPAP 500/350transducer

Subsea

Surface

HiP

AP

co

nn

ecte

d t

o A

PO

S

Figure 15 Test in air of ACS 400 with HiPAP

ACS 400

86 301678/D

13 MAINTENANCE This chapter includes the maintenance procedures for the

complete BOP emergency control system. The maintenance

routines are described in detail for the various parts of the

system.

Topics

ACC 401 Control Unit (surface system) on page 87

Dunking Transducer Unit (surface system) on page 92

Subsea Control Unit (subsea system) on page 94

Inter-seal test port (subsea system) on page 110

Subsea transducers (subsea system) on page 112

During maintenance, remember the following:

1 Whenever power to the electronic units is switched off, the

battery usage counters are reset. If you do not intend to

change the batteries, log the current battery usage before

switching off the units and add these figures onto any

subsequent readings

2 Before switching power on to the units always connect the

transducers. You can then use the three pulses sent from

the system after system initialization as a verification of

system operation.

3 If the CPU or the SSIB boards are changed, remember to

set the switches on the new board to the same settings as

those on the old board so the correct frequencies and board

locations are used. Refer to the board description

paragraphs for details of switch positions.

Maintenance

301678/D 87

Surface system

ACC Control Unit electronics rack

The ACC Control Unit has been designed such that only a

limited amount of maintenance is required. This consists

primarily of charging the battery and changing circuit boards or

the battery if a fault develops.

The surface rack is constructed of extruded aluminium strips and

plates.

Figure 16 ACC Control Unit front panel

Front panel

The front panel holds:

Liquid crystal display (LCD) screen

Three splash-proof connectors located below the display

screen. These are:

Power connector (230 VAC)

Transducer connector (TD)

Interface/communication connector (COM)

ACS 400

88 301678/D

Two LEDs located above the Power and Transducer

connectors respectively. These are:

“Charge” LED

“Transmission” LED

nine control buttons.

The control buttons are of the soft membrane type and the

connection sockets are sealed, ensuring the panel is splash-

proof.

Charging the ACC Control Unit battery

The ACC Control Unit is designed to remain on charge at all

times while not in use.

To start charging:

1 Connect the cable to the 230 VAC connector on the front

of the unit.

Note Use only the mains cable supplied with the system.

Figure 17 Mains cable

2 Connect the other end of the cable into a 230 Vac mains

supply.

- The green LED above the 230 VAC connector will

changes colour from yellow to green when the

battery capacity is higher than 90 percent of full

capacity.

If the battery is completely discharged, a complete recharge will

take approximately 15 hours.

If the ACC Control Unit is stored, it is important that the battery

is fully charged. It must be recharged at least every 12 months.

Maintenance

301678/D 89

Opening the ACC Control Unit

In the event of a fault in the ACC Control Unit, one or more

circuit boards may need to be replaced. To gain access to the

circuit boards, the electronic rack must first be removed from

the housing.

Removing the rack

1 Place the ACC Control Unit on a stable work bench.

2 Remove the four phillips screws.

Refer to figure 11 on page 87.

3 Gently pull up the rack and place it on the work bench.

- Disconnect the grounding wire if necessary.

Replacing the rack

1 To replace the rack into the housing, follow the procedure

above in reverse order.

Battery replacement

The battery is not a field replaceable part.

How to replace the ACC Control Unit

circuit boards

In the event of a fault developing in the ACC Control Unit, one

or more of the circuit boards may have to be replaced.

The ACC Control Unit holds the following circuit boards and

modules:

Front panel unit

Transmitter board (Tx)

Receiver board (Rx)

Microcontroller board (CPU)

Battery charger board

AC power supply

Battery pack

Motherboard

Internal layout of the electronics rack – see the figures on

pages 90 and 91.

Refer to the Internal Units chapter starting on page 114

for detailed information on these units.

ACS 400

90 301678/D

Figure 18 ACC Control Unit electronics rack - internal layout (front panel removed)

- The SSIB board is connected to the rack by two

terminal blocks J1 and J2 (held in position by two

screws each) and a ribbon-cable connector J3, in

addition to P1 (the 96-pin angle connector to the

motherboard).

c Ease the SSIB gently towards the bottom of the rack till

it separates from the motherboard, and then manoeuvre

it out to one side of the rack.

Once the terminal blocks and ribbon-cable connector

are accessible, use a small screwdriver to release the

two screws holding each terminal block in position, and

unclip the ribbon cable connector by folding out the

lugs.

Figure 40 on page 128 shows the locations of the

connectors P1, J1, J2 and J3 on the SSIB board.

Maintenance

301678/D 91

Figure 19 ACC Control Unit electronics rack - internal layout

(view without rear panel)

General replacement procedure

Proceed as follows to remove one of the circuit boards:

1 Remove the rack unit from the housing.

Refer to page 89 for this procedure.

2 Remove the rear panel from the rack.

3 Switch Off the Power switch on the Charger board.

Refer to figure 2 for the Power switch location.

4 Carefully ease the faulty board out of the rack.

- If the faulty board is connected to another board

(Receiver board/Microcontroller board), remove the

cable from the faulty board.

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Proceed as follows to replace the board:

5 Find the appropriate slot for the board, and locate the

board carefully into the rails.

6 Slide the board into the rack till the edge connector on the

back of the board begins to mate with the connector on the

backplane. Gently press the board home.

Note The edge connectors on the backs of the boards are keyed so the

boards will only go into the rack one way. If the edge connectors

will not mate correctly, do not attempt to force the board into

the rack as you will seriously damage the board and/or the

backplane. Remove the board and check to ensure it is

orientated and located correctly in the rack before trying again

to install it.

7 Switch On the Power switch on the Charger board.

8 Fix the rear panel to the rack.

9 Replace the rack unit into the housing.

Refer to page 89 for this procedure.

Dunking Transducer Unit

When the Dunking Transducer Unit has been used, a simple

maintenance routine will ensure it is available for use next time

it is required.

Wash the cable drum and cable with fresh water to remove any

salt and dirt.

Caution Do not use high-pressure hose for this operation - the

transducer could be damaged.

1 Check the transducer.

- Ensure the face is clean and free from defects.

2 Check that the retaining strap is in good condition and will

prevent the transducer falling out of its holder during

transportation

3 Check the connector on the “surface end” of the cable.

- Ensure the rubber seal is fitted and is in good

condition.

Maintenance

301678/D 93

4 Ensure the protective cap is attached to the drum, and is

fitted to the surface connector when the unit is not in use.

- This will prevent the ingress of water into the

connector, and will prevent damage to the connector

pins.

5 A few drops of oil on the drum and roller bearings, around

the winding handle and on the break screw thread will

help to prevent corrosion and ensure trouble-free operation

when the unit is required.

6 Check the lifting strop and look for cuts, frays and other

damage.

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Subsea system

Subsea Control Unit

The Subsea Control Unit and subsea transducers are intended to

remain secured to the BOP during the BOP’s operational life

and only serviced when the BOP is on the surface.

Maintenance will primarily include change of battery when it is

exhausted. If the battery is changed and the unit is still not

working, contact Kongsberg Maritime for assistance.

.

Figure 20 Subsea Control Unit - side view

Maintenance

301678/D 95

The Subsea Control Unit housing comprises a cylindrical steel

container sealed by a domed lid. The lid is bolted on, the seal

being ensured by two O-rings. The unit is protected from the

environment by special paint.

The housing is divided internally into four vertical cylindrical

compartments. Two compartments contain the batteries, two

contain the electronics racks.

Figure 21 Subsea Control Unit - internal layout

The two racks sit in vertical tubes within the container, and

comprise two identical electronic units.

Each rack contains:

A set of four circuit boards

A motherboard into which the other circuit boards are

connected.

An extra board can be fitted as an option to increase the

number of solenoid drivers from a maximum of eight to a

maximum of 16.

The two electronic units function independently, and are

separate except for their common connections to the solenoids

and sensors.

Each battery pack sits vertically in a cylindrical tube in the

container and is secured in position by two bolts. The cables

from the batteries plug into connectors on the electronic racks.

The batteries can be replaced without disturbing the electronics.

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The rack units can be withdrawn from the container for

maintenance.

The container is secured to the BOP using two mounting

brackets. The brackets hook onto studs welded onto the BOP,

and are then bolted into position.

Zinc anodes

Three sacrificial zinc anodes are welded to the base of the

container to reduce corrosion. When these need to be replaced,

the welds must be cut away and new anodes can then be welded

on.

External connectors

Three cables are connected into the base of the unit. Two cables

carry signals to and from the transducers, while the third carries

the signals to and from the hydraulic control solenoids and

sensors. Several different types of connectors are available.

BOP

A: Sacrificial anodes

A

A A

(Cd34066)

Figure 22 Subsea Control Unit base - connectors and anodes

Refer to page 160 for transducer cable pin configurations.

Refer to page 128 for the solenoid interface.

Maintenance

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Opening the Subsea Control Unit

1 Clean the Subsea Control Unit thoroughly using a stiff

brush (not wire), wooden or plastic scrapers and lots of

fresh water.

- Ensure all dirt, slime and growth are removed. Use a

wooden or plastic scraper to remove shells etc. Be

careful not to damage the paint as this will lead to

corrosion.

2 Dry the unit thoroughly.

3 If the Subsea Control Unit is not to be dismounted from

the BOP before maintenance commences, erect a

protective cover above the unit to prevent the ingress of

water and dirt when the lid is removed.

4 Remove the eight bolts, nuts and washers from around the

flange. Use an 8 mm hexagonal key and a suitable

spanner,

Figure 23 Subsea Control Unit lid

5 Carefully lift the lid free from the housing.

Note The lid weighs approximately 70 kg. You are strongly

recommended to use a suitable lifting apparatus. When setting

the lid down, be very careful not to damage the sealing surface

of the flange.

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Subsea Control Unit electronics rack

The Subsea Control Unit holds two identical rack units. Each

rack unit drives one transducer. Each rack unit contains the

following items:

Top plate

Motherboard

Two storage capacitors

DC/DC converter

Cables and connectors

Figure 24 Electronics rack - circuit board locations

Top plate

The top plate holds the following items:

On/Off switch

Sensor/solenoid connector P1

Transducer connector P2

Battery connector P3

Unit serial number

Maintenance

301678/D 99

Figure 25 Electronics rack - top plate

Motherboard

The board holds the connectors into which the other circuit

boards are plugged. Circuit boards:

Control processor unit circuit board (CPU)

Transmission circuit board (Tx)

Receiver circuit board (Rx)

Sensor and solenoid interface board (SSIB)

(a second board is optional)

Storage capacitors

The two large capacitors located in the upper part of the rack are

charged up between transmissions, and discharged during

transmissions to supplement the power output to the transducer.

DC/DC converter

A 48 V to 48/24 V DC/DC converter is mounted in the bottom

of the rack. This unit converts the voltage output by the battery

to those required by the SSIB. Power to the converter is

switched on via a relay on the SSIB.

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Cables and connectors

The cables connecting the external units to the circuit boards are

drawn along the electronics rack chassis.

The electronics rack contains the following connectors:

External connectors

Sensor and solenoid connector P1


Battery interface cable connector P3

Internal connectors

Terminal block J1

Terminal block J2

Ribbon-cable connector J3

Figure 26 Electronics rack chassis

A fault in the Subsea Control Unit may be caused by defects in

the interfaces between the external units and the electronics

rack. This section displays pin configurations and wire colour

codes for all relevant cables and connectors, allowing you to

carry out necessary signal measurements and to make minor

replacements.

Sensor and solenoid connector P1

This plug connects the electronics rack to the customer’s

solenoid pack.


The transducer is connected to the motherboard through the

transducer connector P2.

Refer to on page 96 for transducer connections to the

subsea control unit.

Maintenance

301678/D 101

Battery interface cable connector P3

This plug connects the battery to the motherboard through the

On/Off switch.

Terminal block J1

This plug connects the SSIB circuit board to the motherboard

through the DC/DC converter.

Terminal block J2 and ribbon-cable connector J3

These plugs connect the SSIB circuit board to the customer’s

solenoid pack through the sensor and solenoid connector P1.

Subsea Control Unit battery packs

The unit holds two identical non-rechargeable battery packs.

Each supplies power to one electronic rack.

Each battery is divided into groups of 42 and 12 cells. The

battery outputs are 49 Vdc and 10.5 Vdc respectively. Each

group of cells may be tested separately at the battery plug via a

pin. This pin is isolated by a diode from the rest of the groups.

Refer to page124 for the battery plugs and cells.

The batteries may be stored for up to 10 years with little loss of

capacity. The total capacity lost over 10 years will is

approximately 15%.

Note The battery usage counters are reset whenever power to the

electronic units is switched off. This means that if maintenance

must be performed on the electronic units, either the batteries

should be changed or the battery usage prior to switching off

should be recorded and added “manually” to the subsequent

usage.

Caution The batteries must be stored upright.

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How to replace the Subsea Control Unit

circuit boards

Caution Static electricity will damage sensitive electronic

components. Ensure the work bench has a conductive surface and is connected to the vessel/platform ground.

Wear an earthing bracelet while working on the electronic racks.

1 Open the unit.

This procedure is described on page 97.

2 Ensure the electronics racks are switched off, and then

disconnect the battery interface cable.

3 Remove the two bolts securing the faulty electronic unit,

and then lift the unit out of the Subsea Control Unit.

- Use a 6 mm hexagonal key.

4 Place the unit on a clean, stable workbench, and support

the unit so it cannot roll off.

5 Remove the grey plastic covers from the appropriate rack

section.

- Use a 4 mm hexagonal key and a flat-blade

screwdriver.

6 Locate and remove the defective circuit board.

7 To remove the Tx board, pull it carefully towards the top

of the rack till the angle-connector disconnects from the

motherboard, then manoeuvre it out to one side of the

rack.

- The CPU and Rx boards are connected together by

ribbon cable, and must be removed from the rack

together.

a First remove the TX board to give yourself some room,

then carefully pull the CPU and Rx boards towards the

top of the rack and out to one side. Once they are out of

the rack, place them on the work bench.

Maintenance

301678/D 103

b To separate the boards, insert the blade of a small

screwdriver into the slot in the centre of the cable

connector and carefully ease the connector apart. The

slots on each end of the connector block can also be

used.

Figure 27 Separating the CPU and Rx boards

- The SSIB board is connected to the rack by two

terminal blocks J1 and J2 (held in position by two

screws each) and a ribbon-cable connector J3, in

addition to P1 (the 96-pin angle connector to the

motherboard).

c Ease the SSIB gently towards the bottom of the rack till

it separates from the motherboard, and then manoeuvre

it out to one side of the rack.

Once the terminal blocks and ribbon-cable connector

are accessible, use a small screwdriver to release the

two screws holding each terminal block in position, and

unclip the ribbon cable connector by folding out the

lugs.

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Locations of the connectors P1, J1, J2 and J3 on the

SSIB board:

Figure 28 SSIB board - terminal blocks and connectors / wire colour codes

8 Removed the faulty board.

9 Open the protective bag containing the new board, remove

the board from the bag, and mount it into the rack in the

correct location.

Note If either the CPU or the SSIB board is being replaced, reconnect

the ribbon cable connector before fitting the boards into the

rack.

If the SSIB board is being replaced, first connect the ribbon-

cable connector, then connect J1 and J2, then fit the board into

the rack. Wire colour codes for J1 and J2 – see figure above.

Note Key slots and lugs on the 96-pin angle connectors ensure you

cannot fit the boards into the rack the wrong way round. If the

connector does not fit together easily, check the orientation of

the board.

10 Once you have re-fitted the circuit boards into the rack and

mounted the plastic side covers, lower the rack unit

carefully into its tube and secure it into position using the

two bolts and washers.

Maintenance

301678/D 105

11 Reconnect the battery cable.

12 Switch on both electronics units

Note the “Power on” sequence on page 108.

13 Close the unit.


How to replace the Subsea Control Unit

batteries

Under normal operating conditions the batteries should last for

approximately one year.

When the batteries need to be changed, the BOP will have to be

raised to the surface. Therefore - if the BOP is on the surface for

other reasons, use the opportunity to change the batteries and

inspect the Subsea Control Unit.

A new battery pack is delivered ready for immediate

replacement.

Note The Subsea Control Unit need not be removed from the BOP.

However, care must be taken to ensure no water or dirt gets into

the container.

Procedure

1 Open the unit.


2 Switched off the SCU electronics units power (A) before

proceeding.

3 Disconnect the battery interface cable.

AA

(Cd34048)

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4 Remove the two bolts securing the battery into position.

- Use a 13 mm hexagonal key.

5 Lift the battery out of the unit, using the lifting handle.

Maintenance

301678/D 107

6 Place the old battery “standing up” beside the new battery.

A

B

C

C

(Cd34049)

7 Move the top tie plate (B) from the old battery, to the new

one.

- The top tie plate is cecured by the four bolts.

8 Move the two retaining rings (C) from the old battery to

the new one.

9 Install the new battery, and secure it into position.

10 Reconnect the battery cable.

11 Cut open the plastic bag protecting the desiccator bag in

the new battery pack.

12 Switch on the electronics units.

- OPTION: Select SYSTEM SETUP in the ACC 401

Control Unit’s main menu. Run the BATTERY

RESET function. – When preforming this option, use

the Dunking cable or a test cable.

Note This must be done for both electronics units.

13 Close the unit.


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Closing the Subsea Control Unit

“Power-on” sequence

The last thing you do before closing the Subsea Control Unit is

to switch power on to the electronic units using the power

switches on the tops of the racks.

When you switch power on to the racks, the system is initialized

and an internal system test is performed. At the end of the

initialization sequence, the electronic units transmit a sequence

of two pulses to the transducers. The click sound produced by

the transducers indicates that the system electronics is operating,

and the sound should be used as an initial system check after

power on. If the sound is not heard from one or both of the

transducers, switch the appropriate unit off, wait for at least

three minutes, then switch it on again.

On completion of the power-on sequence, power is maintained

on the electronics for approximately one minute. After this, the

electronic units switch into a “sleep” mode where the processor

clock speed is reduced and power is switched off to parts of the

system.

Note To reduce the risk of erroneous valve operations, power is not

switched on to the SSIB board during the power-on sequence.

Closing the unit

Once maintenance is completed and the racks are switched on,

the Subsea Control Unit must be closed. The procedure must be

performed correctly to ensure a good seal between the container

and the lid.

1 Remove the old O-rings and support ring from the grooves

in the container flange.

2 Clean the container and lid flanges carefully, ensuring all

traces of dirt, old grease etc. are removed.

Note Do not use metal tools to clean the surfaces. Use only plastic or

wooden scrapers, solvents and soft cloths.

3 Once the flanges are clean, inspect them for damage.

4 Ensure all tools, cloths, debris etc are removed from the

top of the unit.

5 Apply a thin film of silicone grease to the new O-rings and

support ring and then fit them into the grooves in the

container flange.

Maintenance

301678/D 109

Note The support ring has a triangular cross-section. The ring must

be orientated such that the wide “base” of the triangle is

uppermost.

Figure 29 O-rings and support ring fitted into the container flange

6 Manoeuvre the lid over the container, ensure it is

orientated correctly (see note below), then lower it

carefully into position.

Note The unit serial number is stamped into the container and lid

flanges. These serial numbers must be aligned.

7 Fit the M8 bolts, nuts and spring-washers, and tighten

them to a torque of 24 Nm.

8 Inspect the unit externally for damage to paintwork.

9 Prepare and paint as necessary to prevent corrosion.

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Inter-seal test port (option)

An inter-seal test port, closed by a screw plug, is located in the

container lid flange. The port is used to connect in a hydraulic

pump enabling the volume between the O-ring seals to be

pressurised and the security of the seals between the container

body and lid to be tested.

Figure 30 Test port location

Note Under normal conditions the external water pressure will force

the lid onto the container, while this procedure pressurises the

seals from the inside forcing the lid away from the container

body.

Warning Never increase the pressure above the maximum

stated in the procedure as this will stretch the bolts and may cause serious damage.

The procedure is as follows:

1 Close the unit.


Maintenance

301678/D 111

2 Remove the plug from the test port. Use an 8 mm

hexagonal key.

3 Connect in a suitable hydraulic pump (fitted with an

accurate manometer), and slowly build up the pressure in

the volume between the O-rings to a maximum of 10 bar.

4 Close off the inlet pipe and note the exact pressure, then

leave the unit to stand for a minimum of 1 hour.

5 If the pressure has reduced during the period, one or both

of the O-ring seals may be leaking.

- Check the flange joint for signs of a leak.

Note The pressure reduction may be due to a leak in the valve,

manometer, pipe-work, or connection into the test port. Check

all connections etc.

6 If the container fails the test, vent the pressure, open the

container, replace the O-rings and support ring (ensure the

support ring is fitted correctly, thick edge up as shown in

the figure above), then close the container. Repeat the

pressure test.

Figure 24 indicates how the O-rings and the support ring

are to be fitted into the container flange.

7 If the container is correctly sealed, vent the pressure and

disconnect the pump apparatus.

8 Clean the test port and the plug carefully, ensuring all

traces of dirt and old grease are removed.

- If the plug or seal appears to be damaged in any

way, replace them.

Part numbers and other information are provided in the

Spare parts chapter starting on page 37.

9 Wipe a thin film of silicone grease onto the plug thread

and sealing ring, then screw the plug into the port. Tighten

the plug to a torque of 35 Nm.

Note The seals formed by the two O-rings between the container and

the lid have been tested, but the seal provided by the test port

plug cannot be tested. The container seal will therefore depend

on the seal provided by the inner O-ring and the seal on the test

port plug. Ensure the plug is undamaged and is fitted correctly.

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Subsea (BOP) transducers

Cleaning the transducers

Any marine growth on the transducers will degrade the system’s

operational capabilities. The transducers should therefore be

cleaned at every opportunity.

The transducers must be handled with care. If the black rubber

coating on a transducer is damaged, the transducer must be

replaced.

Note Use only a stiff, plastic-bristled brush, rounded wooden or

plastic scrapers, and fresh water to clean the transducers. Do

not use metal tools, solvents, or high-pressure water/steam.

1 Remove all mud and weed from the transducer. Use a

plastic-bristled brush, cloths and fresh water.

2 Remove stubborn crustacean growth using a rounded

wooden or plastic scraper. Be careful not to damage the

rubber coating on the transducer.

3 Dry the unit and inspect it for damage.

Replacing a subsea transducer

1 Clean the base of the unit, ensuring all mud and marine

growth is removed.

2 Dry the area around the transducer cable connector.

3 Remove all cable clips and bindings securing the

transducer cable to the BOP, and disconnect the cable

connector from the Subsea Control Unit.

4 Support the transducer such that it cannot fall when the

securing bolts are removed.

5 Remove the five M8 bolts securing the transducer to the

BOP.

6 Lift the transducer clear of the BOP.

Note Each transducer weighs approximately 10 kg.

7 Lift a new transducer onto the mounting position on the

BOP.

8 Fit five new M8 bolts of the same type and length as the

old ones.

Maintenance

301678/D 113

Note The bolts etc. are not listed in the spare parts chapter as they

will depend on the thickness and material of the structure on

which the transducers are mounted.

9 Tighten the bolts to the torque recommended by the bolt

manufacturers.

10 Run the transducer cable to the Subsea Control Unit

following the same route as the original cable. Secure the

cable to the BOP frame at the appropriate positions.

11 Follow the procedure below and make the connection to

the container:

a If necessary, clean the insulators and casing using a

stiff brush and water or ethyl-alcohol.

Caution Do not use products of the hydro-carbon or acetone

families, e.g. trichloroethylene, methylethyl-ketone, benzine etc.

b Fill the tapered recesses in the front of the insulator

with silicone grease.

c Make the connection and tighten the coupling nut.

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14 INTERNAL UNITS This chapter provides information on the circuit boards and

modules used in the surface and subsea units.

Signal processing with relevant I/O’s are explained using block

diagrams. Switch settings and links are described where

necessary.

Layout of the main component in the electronics racks is given

in the Maintenance chapter. The Maintenance chapter also

contains procedures for replacements of the circuit boards.


Topics

The following circuit boards and modules are used:

Front panel unit - description on page 115.

Transmitter board (Tx) on page 117.

Receiver board (Rx) on page 117.

Microcontroller board (CPU) on page 118.

Battery charger board on page 121.

AC power supply on page 123 .

Battery pack on page 124.

Motherboard on page 125.

Subsea Control Unit

Topics

The following circuit boards and modules are used:

Transmitter board (Tx) on page 117.

Receiver board (Rx) on page 117.

Microcontroller board (CPU) on page 118.

Solenoid and sensor interface board (SSIB) on page 127

Internal units

301678/D 115

Front panel unit

Location


The Front panel unit holds:

A front plate containing all function switches and indicator

LEDs.

All switches are membrane-type switches, which will

ensure reliable functionality in all type of weather. All

connectors used are equipped with protection caps which

will prohibit water ingression.

A LCD display with an integrated display driver / controller.

The display unit is a 240 x 128 dots transflective LCD

graphic display with a LED04 back-light and a Toshiba

T6963C controller.

Panel connectors for ac power input, transducer signals and

responder trig signals.

Connectors for Motherboard interconnection.

Front panel connectors

The front panel holds three splash-proof connectors located

below the display screen. These are as follows:

Power connector (230 VAC) - This is a male 4-pin

Amphenol socket for the mains cable. This cable is used to

connect the surface unit to a standard 230 Vac mains supply

to recharge the internal battery.

The battery should last for approximately 24 hours of normal

use, and will take approximately 15 hours to recharge from

fully discharged.

Transducer connector (TD) - This is a female 3-pin

Amphenol socket for connecting in the transducer cable. 70

m of cable is held on a separate winch unit, with the

transducer permanently connected.

Interface/communication connector (COM) - This is a

male 9-pin D-sub serial line connector. It is used by the

manufacturers for testing and debugging the unit.

Front panel LEDs

The front panel holds two LEDs located above the Power and

Transducer connectors respectively. These are as follows:

“Charge” LED - This LED indicates that mains power is

connected and gives the charging status of the internal

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battery. Green light indicates that the battery is charged up

and yellow light indicates that the battery is being charging.

“Transmission” LED - This LED will flash with a yellow

light during transmissions from the ACC Control Unit.

The front panel connectors and LEDs are displayed in

figure 11 on page 87.

Front panel connectors

Front panel unit - front side, refer to page 87.

Flylead connectors

LCD display plug (P1)

Front panel plug (P2)

Transducer plug (P3)

Display back-light plug (P5)

230 Vac power plug (P6)

Responder trig plug (P9)

P9

P1

P2

P6

P3

Figure 31 Front panel board - rear side

Internal units

301678/D 117


Location


Subsea Control Unit

Purpose and description

The Transmitter board is a general purpose transmitter,

containing its own frequency generator, power control and

power supply circuits, (the board feeds both the receiver and

microcontroller circuit boards.

Figure 32 Transmitter circuit board (MF version)

Receiver board (Rx)

Location


Subsea Control Unit


The receiver board is designed to receive transponder

interrogation signals and telemetry signals. It contains nine

narrow-band channel receivers, and a WIDE-detector and phase-

locked loops for generating the right modulation frequencies to

the channel receivers.

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Figure 33 Receiver circuit board (MF version)

Microcontroller board

Location


Subsea Control Unit


The Microcontroller board is a general purpose single

microcontroller board, with the main task of performing

calculations and digital signal control. It uses the 87C196KC/KD

Microcontroller manufactured by Intel.

Internal units

301678/D 119

Figure 34 Microcontroller circuit board - ACC 401 Control Unit

Figure 35 Microcontroller circuit board - Subsea Control Unit

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Switches

The board carries one 4-way Dip-switch block and two 10-

position rotary switches:

The Dip-switch block is used to set the system’s operating

frequency band.

For the subsea electronic units, the two rotary switches

define which electronic unit the board is located in (define

which wake-up signal frequencies the board will respond to).

The two rotary switches on the board that is mounted in the

surface control unit have no effect.

The 4-way Dip-switch block (S1) switches are to be set as

follows:

Band S1-1 S1-2 S1-3 S1-4

LF Off Off Off On

MF On Off Off On

Rotary switches S2 and S3:

LF (unit 1) LF (unit 2)

S2 4 4

S3 5 6

Note The boards used in the surface and subsea units are not

identical and cannot be exchanged without modifications. The

correct software for each board must be installed. Ensure that

the correct board is fitted in each unit.

Links

The microcontroller board used in the surface unit must have

PROM U19 mounted and link Lk6 must be closed.

The microcontroller board used in the subsea unit must not

have PROM U19 mounted, and link Lk6 must be open.

Refer to figures 31 and 32 for the locations of the

switches, links and PROMs on the microcontroller board.

Internal units

301678/D 121

Battery charger board (Charger-2)

Location


Description

The charger is a Constant-Current / Constant-Voltage type

charger with a temperature compensated output voltage.

The charger board consists of:

A constant current source (U8) with a current sense (U7)

which is used to control the charge indicator LED’s.

An adjustable constant voltage source (U5) with a shut-down

transistor (Q1).

External temperature sense input (BAT_PTC).

Figure 36 Battery charger board

The charger board should be supplied with 48 Vdc power.

Initially the output voltage will be adjusted to 41.5 volt (in room

temperature) with the adjustable resistor R1. The temperature

correction will be approximately -40 mV/°C. The charger shut-

down is activated from an external temperature sensor via an

amplifier (U1) and a comparator (U3).

The shut-down will also be activated if a pos. signal is applied to

the CHARGE_OFF input line. The verification of a shut-down

status is that both charger LED’s are switched off.

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Note When a shut-down has occurred, the input supply power must be

removed in order to reset the shut-down mode.

Display power

Logic power, 5V_LCD is generated with a linear voltage

regulator (U12). This supply is also used to supply the back-

light diodes (BL) and different circuits on the board, when the

board is powered only from the battery terminals.

Display power (-15 V) is generated from a dc/dc converter built

up around U10. This power supply have a 50 msec. start-up

delay. The output voltage is temperature corrected with 50 mV/

°C (nominal output is -15 V at 25°C)

Power control

To power up the board:

1 Switch on SW1.

2 An external POWER_SWITCH must be switched on

or

link ST8 must be connected.

An external 5 V signal applied to the POWER_HOLD input line

will also switch the power on.

If power-on should be inhibited while charging is in progress,

link ST7 must be installed.

Internal units

301678/D 123

AC power supply

Location


Description

The AC power is a 45 watts single Euro-size switching power

supply. It is connected to the Motherboard via a 15 pin (DIN

41612) connector.

This power supply is a sealed unit. In the event of malfunction,

replace the unit.

Figure 37 AC power supply

Specifications

Input voltage: 100 - 240 Vac

Input frequency: 47 - 63 Hz

Inrush current: 25 - 30 A / 230 Vac

Output voltage: 48 Vdc

Switching frequency: 45 kHz

ACS 400

124 301678/D

Internal battery

Location


Description

The battery is a rechargeable Lead / Acid battery. It is mounted

at the right side of the rack.

Figure 38 ACC 401 internal battery

Battery

Eighteen (18) rechargeable sealed lead/acid cells. These cells

are connected in one serial string, giving an operation

voltage of 35 to 40 volt.

A silicone fuse of 1.6 amps to prevent fire hazards.

A temperature transducer that will generate a current output

of 1 mA per Kelvin. This is used by the battery charger

board (Charger-2) to interrupt the charging due to high

temperature.

A cable that leads from the battery to the battery connector

(P7) on the left side to the Motherboard.

Internal units

301678/D 125

Battery lifetime

The battery may be stored for up to two years (if fully charged),

though it will require charging before use.

A fully charged battery will last for approximately 24 hours

operation.

A discharged battery will require approximately 15 hours

charging to be fully charged.

Option

The Microcontroller board can monitor the temperature

inside the battery.

Motherboard

Location


Description

The Motherboard contains all the interconnections between the:

Microcontroller board

Transmitter board

Receiver board

Battery charger board (Charger-2)

AC power supply

ACS 400

126 301678/D

Figure 39 Motherboard (solder side) fitted in the cabinet

All signals and power to and from the Front panel unit and

battery unit are also being connected to the Motherboard. This

applies to the following connectors:

LCD display plug (P1)

Front panel plug (P2)

Transducer plug (P3)

Display back-light plug (P5)

230 Vac power plug (P6)

Battery plug (P7)

COM plug RS-232 (P9)

COM plug RS-422 (P10)

Battery termistor (P12)

Internal units

301678/D 127

LCD termistor (P13)

The TX - CAP board is mounted piggy-back to the

Motherboard.

Fuses

The Motherboard holds two mains fuses, F1 and F2. The fuses

are located on the solder side.

Switches

The Motherboard holds one switch, SW1. The switch is located

on the solder side.

Caution Make sure that the switch SW1 is switched off before

the battery plug is disconnected, and then switched on again when the battery plug is connected.

Solenoid and sensor interface board (SSIB)

Location

Subsea Control Unit


All interfacing between the CPU and the solenoids and sensors

on the BOP is performed via the Solenoid and Sensor Interface

Board (SSIB). The solenoids open and close hydraulic valves on

the BOP, and the sensors indicate the status of the valves

(whether they are open or closed).

ACS 400

128 301678/D

Figure 40 Solenoid and sensor interface board (SSIB)

Power to the SSIB is switched on by a relay controlled by the

processor on the CPU board. The SSIB board also contains

safety logic to prevent uncontrolled switching of current to the

various solenoids.

The board can drive up to eight solenoid valves, and a second

board can be added to the system if additional solenoid drivers

are required. If two boards are used, a link setting defines which

is board A and which is board B.

Links

The link settings are as follows:

8-channel system: Links PCB2 and ST2 must be mounted.

Spare parts

301678/D 129

15 SPARE PARTS This chapter includes the listed spare parts and modules defined

by Kongsberg Maritime for the ACS 400 system.

The required mounting components (such as nuts, bolts, washers

etc.) included in this list shall always be used.

Codes used

The following codes are used in the parts lists:

Part no.: Kongsberg Maritime’s part number.

Item name: The name of the item.

No. in sys.: The quantity of the item used in the system.

An example of spare part definition is shown in the table below.

There is one item with this P/N in the system, but this P/N is not

recommended as spare.

KM P /N Ite m nam e Re com m e nde d

spare s

125-217498 ACC 401 Control Unit complete 1

Example of listed spare part item’s

ACS 400

130 301678/D

Surface system

The list only contains the main components and units that are

most likely to be required. Other components may be available

on request.

KM P /N Ite m nam e Re com m e nde d

spare s

125-217498 ACC 401 Control Unit complete 1

500-098580 ACC 401 splash -proof conta iner 0

380-219476 Mains cable 1

382-219335 Microcont roller board (CPU) 16 MHz 1

380-101422 Fla t cable, Rx board to CPU board 0

599-217882 Suppor t ba r 0

382-219052 Ba t tery charger board 1

382-098602 AC power supply 48 Vdc/1 A 45 W 1

659-087572 Desiccan t 10 g 3

MF (30 kHz)

129-220871 Dunking Transducer TDD301 MF (+/-15) 1

301518 Dunking t ransducer TDD 303 MF (+/-30) 1

332392 Hull mounted dunking 301 w/ adapter pla te (+/-15) 1

382-219490 Transmit ter board (Tx) MF 1

382-083602 Receiver board (Rx) MF 1

LF (12 kHz)

312844 Dunking Transducer TDD103 LF (+/-30) 1

382-089502 Receiver board (Rx) LF 1

382-101205 Transmit ter board (Tx) LF 1

BOP Simulator Unit

KM P /N Item name Re com m e nde d

spare s

TES-103183 BOP Simulator Unit (Old 10channel) 0

313237 BOP Simulator Unit 8 channel 0

380-103221 BOP simulator cable 0

Custom spec refer Registration form -

Spare parts

301678/D 131

Subsea system

The list only contains the main components and units. Other

components may be available on request.

KM P /N Item name Re com m e nde d

spare s

290-089592 Battery pack L10/50 2

540-084885 O-ring 355.0 x 6.99 MIL413B 2

540-063488 O-ring 380.3 x 6.99 MIL413B 2

549-082344 Support ring, F/O ring 355 x 7.0 1

629-086818 Aluminium anode, AL-1F 3

560-087294 Bolt, M8X60 SYLH. W/INV6 DIN912 SUPER DUPLEX 8

562-087297 Nut, 6K-Nut M8 DIN934 SUPER DUPLEX 8

577-087298 Spring washer F/M8 DIN127B SUPER DUPLEX 16

F/M8 DIN127B acid-resistant -

659-087572 Desiccant bag 4

304407 Interseal test port, 3/8" SAE x 10 mm Seal Screw

(NOTE! For systems delivered later than 2003)

1

540-099521 O-ring Interseal for plug 304407 2

139-087300

Interseal test port, Sea ling P lug VSTI R3/8" -ED/71

(NOTE! For systems older than 2003)

1

540-099521 O-ring Interseal plug 139-087207 2

382-083551 Control Processor Unit circuit board 1

382-102974 Sensor & Solenoid Interface Board (SSIB) 1

380-103168 BOP Interface Cable, Customer Specification (PBOF) 1

Oil-F illed Refer to Reg. form/Instruction manual -

380-103384 BOP Interface Cable, Customer Specification (Dry) 1

Dry Refer to Registration form/Instruction manual -

MF (30 kHz)

100-211373 Subsea Transducers TDA324 MF (+/- 30) 1500 m 1

100-210123 Subsea Transducers TDA331 MF (+/-15) 3000 m 1

Surface system Transmit ter board (Tx) MF 0

Surface system Receiver board (Rx) MF 0

LF (12 kHz)

100-102841 Subsea Transducers TDA133 LF (+/-15) 1

ACS 400

132 301678/D

16 EQUIPMENT HANDLING This chapter describes how to transport, pack and unpack, clean,

preserve and store electronic, electro-mechanical and

mechanical units supplied by Kongsberg Maritime.

The units may be supplied as spare parts, or as parts of a

delivery.

Topics

Equipment responsibility on page 133

Transportation on page 133

Storage on page 133

Inspection on page 134

Unpacking, lifting and handling on page 134

Equipment handling

301678/D 133

Equipment responsibility

Upon receipt of the equipment, the installation shipyard

automatically becomes fully responsible for the equipment

unless otherwise stated in the contract. This responsibility

covers the storage period before installation, the actual

installation, commissioning, and the period between the

completion of the commissioning and the acceptance of the

equipment by the end user (normally the owner of the vessel

into which the equipment is to be installed).

Transportation

The ACS units can be transported by all methods approved for

delicate electronic equipment, subject to local transport

regulations. Special regulations concerning the transport of units

containing lithium batteries may apply. The existence and

content of such regulations must be checked before the units are

dispatched.

The pallet holding the equipment must not be subjected to

shocks, excessive vibration or other rough handling.

Unpacking, lifting and handling

No special precautions need to be taken when receiving the

equipment. Normal precautions for handling, transportation and

storage of fragile electronic equipment must be undertaken. The

transducers and cabling must not be exposed to any mechanical

stress. The transducer heads are fragile and must be handled

with extreme care.

ACS 400

134 301678/D

Inspection

On receiving the equipment, the receiving personnel must

ensure that the delivery is complete. Check that all units have

been received by comparing the tag numbers, registration

numbers and serial numbers with the packing lists.

Inspect each unit for physical damage. If the inspection on

receipt reveals indications of crushing, dropping, immersion in

water or any other form of damage, the receiving personnel

should request a representative from the carrier to be present at

the shipyard during unpacking.

During unpacking, the equipment should be inspected for

physical damage, i.e. broken parts, dents, scratches, damaged

cables etc.

If damage to the equipment is discovered, the receiving

personnel should notify the carrier and Kongsberg Maritime so

that Kongsberg Maritime can arrange for replacement or repair

of the damaged item(s).

Storage

Pre-installation

The equipment should be stored on its original transportation

pallet until ready for installation. It must be kept in an

atmosphere free from corrosive agents, and isolated from

sources of vibration. The equipment must not be used for any

purpose for which it was not intended (e.g. work platforms etc.).

After use

If the SCU is brought up to the surface to be placed into storage,

it must be properly cleaned and prepared before packing.

Cleaning

As the unit will have been exposed to sea-water for an extended

period, it must be thoroughly cleaned. All traces of marine

growth, mud, crustaceans etc. must be removed, and it must be

washed with copious amounts of fresh water. On completion,

dry the unit thoroughly.

All surfaces must be inspected for signs of corrosion, e.g.

flaking/bubbling paint, stain etc. Damaged or suspect areas must

be cleaned, prepared and preserved using the correct

preservation mediums.

Equipment handling

301678/D 135

Cables

Thoroughly clean all exposed cables, and check for damage. If a

cable shows signs of wear or ageing, contact Kongsberg

Maritime for advice.

Batteries

The system batteries will slowly discharge. If the unit is to be

stored for an extended period, batteries must be disconnected.

Coating

Spray the entire unit with a corrosion inhibitor (e.g. a light oil)

before placing it into storage.

Storage and transport

The units should be stored and transported on suitable pallets.

Coil the transducer cables loosely and strap them to prevent

them uncoiling.

Place the transducers and their cables on a pallet and strap

them in position to prevent them falling off when the pallet

is moved.

Cover the transducer faces with a protective cover to prevent

damage.

Cover the units with a plastic sheet to keep them clean.

Strap it into position to prevent it falling off when the pallet

is moved.

Cover the unit with a plastic sheet to keep it clean.

ACS 400

136 301678/D

17 PRINCIPLES OF OPERATION This chapter describes telemetry communication is transmitted

acoustically between the ACC 401 Control Unit (the master) and

the Subsea Control Unit (the slave). It also describes the

telemetry communication format used to convey information

between the surface and subsea units.

Note The ACS system can be delivered as either an MF or an LF

system. This document describes the LF frequencies and timing.

Telemetry communication

Acoustic coding principle

The telemetry command link uses bursts of seven pulses, each

pulse having a different frequency, transmitted in a particular

sequence to make up a message unit. The system is called

“Factorial coding”, and has a total of 5040 combinations. 4096

of these are used to define 12-bit messages, while the remainder,

4097 to 5040, are spare. The spare combinations can be used for

special messages.

A complete telegram is constructed by sending several message

units in sequence.

A special set of pulse timing parameters is employed in the

system to ensure the Subsea Control Unit will not detect

acoustic signals from other systems and interpret them as

telemetry messages.

Refer to “Wake up” telegram timing on page 136 and the

message telegram on page 140.

Standard telemetry telegram

A standard telemetry telegram is constructed as follows:

Header byte

Address

Telegram type

Data

Principles of operation

301678/D 137

All telegrams transmitted by both the surface and subsea

units contain the header byte. This byte comprises telemetry

setup and checksum information.

After the header comes the telegram address. A “long

address” is included in all telegrams transmitted by the

surface unit down to the subsea unit. The “long address” will

be the subsea unit’s production serial number (a number

between 100 and 32767). Telegrams transmitted by the

subsea unit to the surface unit do not include an address.

The address is followed by the telegram type code. This

code can be any number from 0 to 255, and defines the type

of telegram being transmitted.

The remainder of the telegram is made up of the data or

command bytes. These contain the actual information to be

transmitted. The last byte in the data block will be an XOR

byte containing the XOR function of the data block

information (including the address and/or telegram type).

Note “Wake up” pulses are always transmitted before the surface

unit transmits a telegram down to the subsea unit, except when

the “Execute” command is transmitted.

In all cases, the subsea unit will reply only with the header, type

and data information. No address will be transmitted.

Acoustic telegram transmission sequence

The procedure for a normal stack function operation is

illustrated in the figure below.

Refer to figure 6 for the procedure.

3 The surface unit wakes up the subsea unit using a two-

frequency “channel code”.

4 The surface unit transmits the selected stack function

command.

5 The subsea unit replies with an “Acknowledgement”

telegram to say that it has received a certain message and

decoded it to be a valid command.

6 If the command that the subsea unit has received is the

correct one, the surface unit automatically transmits an

“Execute” telegram to tell the subsea unit to perform the

given BOP function.

7 On receipt of the “Execute” command, the subsea unit

performs the stack function command, and then transmits

a status report to surface.

ACS 400

138 301678/D

8 The surface system displays the final status of the BOP.

Note Exceptions to this routine may occur if a slave unit detects

internal errors which should be reported immediately to the

master in a status telegram. This function is optional.

An “Abort” command can be transmitted at any time to stop the

valve operation. If the stack function is performed correctly, the

subsea unit will transmit a BOP status telegram to verify the

operation has been completed.

Wake up and Perform BOP Stack function

Acoustic Control Unit (ACC)

(master) Acoustic

Telegram Type Subsea Control Unit (SCU)

(slave)

1 Transmits wake-up pulses

followed by BOP command

Receives decodes & checks

3 If OK, transmits “Execute”

command

5 Receives decodes & checks.

Displays system status.

“Wake up” pulses and

Stack function

-------------->

Long address

Acknowledge

<--------------

Execute

-------------->

BOP status

<--------------

Wakes up, makes ready for

signal reception

Receives, decodes & checks

address and command

2 Confirms received

telegram.

Waits for “Execute” command

Receives, decodes & checks

4 Carries out order

Confirms stack function

executed

Figure 41 Normal stack function procedure

If no new command is received or expected, the slave unit will

be powered down after a time-out period of 30 seconds after

the status message is transmitted. When a solenoid operation is

performed, the time-out delay before power down is 30 seconds.


301678/D 139

Power settings

You can select the desired transmission power for the system via

the system menu. The power in the transmitted pulses is

changed by adjusting the duty cycles of the pulses. The

differences in power levels for the various settings are:

Maximum power

High power - approx. -4 dB rel. max. power

Low power - approx. -8 dB rel. max. power

Minimum power - approx. -12 dB rel. max. power

At longer ranges, the signal pulses transmitted by the surface

and subsea units have a tendency to spread out due to refraction

in the water. The part of the pulse above the receiving unit’s

detection threshold therefore reduces in length. The receivers in

the surface and subsea units expect to receive pulses with a

duration of approximately 10 ms, so they may ignore pulses of a

shorter duration. The lengths of the pulses transmitted are

therefore increased to compensate for the effects caused by

longer ranges. The pulse lengths are:

Maximum power - pulse length = 16 ms

High power - pulse length = 14 ms

Low power - pulse length = 12 ms

Minimum power - pulse length = 10 ms

Refer to the System setup menu description on page 49 for

details about changing the transmission power.

Note The selected power setting, and therefore pulse length, is used

for all frequency pulses transmitted by both the surface and

subsea units.

ACS 400

140 301678/D

“Wake up” telegram timing

The system’s frequency channel is normally used as the “wake

up” telegram. This telegram comprises two pulses; Fx and Fy.

The pulses have a duration of 10 ms, and are separated by 20 ms

from the start of the first pulse to the start of the second.

The “wake up” pulses and the message telegram are separated

by a minimum of 1000 ms.

Figure 42“Wake up” to message pulse timing

Note The same two wake-up frequencies are used for all ACS systems,

and these frequencies can also be used by transponders for

general communication. To avoid excessive battery use within

the Subsea Control Unit due to it being constantly “awake”, do

not locate transponders that use these frequencies in the vicinity

of the Subsea Control Unit.

The first pulse (Fx) will wake up the subsea unit, then the

software will wait for the second pulse (Fy). If the second pulse

is not received within 100 ms, the subsea unit will enter “sleep

mode”.

After reception of the second pulse, the subsea unit will wait for

the acoustic telegram. If the telegram is not received within 3 s,

the subsea unit will enter “sleep mode”.


301678/D 141

Message telegram

The message telegram comprises a series of seven pulses, each

pulse being at one of the frequencies listed. Each pulse has a

duration of 10 to 16 ms depending on the power setting.

Refer to Power settings on page 139.

The pulses are separated by a delay of 70 ms from the start of

one pulse to the start of the next.

The message telegrams are separated by a delay of 1 s from the

start of one telegram to the start of the next.

Figure 43 “Message” pulse timing

Frequencies for the telemetry messages

The MF system uses the MUNAV telemetry band 1, sub-band 1

frequencies for the telemetry messages. These frequencies are:

Freq. no. MF (Hz)

F0

F1

F2

F3

F4

F5

F6

25000

25250

25500

25750

26000

26250

26500

Wake-up frequencies

The wake-up frequencies are as follows:

Unit F1 (Hz) F2 (Hz) Channel

No. 1

No. 2

24000

24500

23500

23500

yy

yy

Channel for your system - see the Registration Form


ACS 400

142 301678/D

Acoustical address

Unit Address Unit Address

No. 1 xxxx No. 2 xxxx+1

Acoustic address for your system - see the Registration

form (separate document).

Surface/subsea communication

Principles

Each electronic unit communicates with the surface system via

its own transducer. This interface enables the electronic unit to

respond to the following commands:

Switch the ACS system from standby to fully operational

status or vice versa.

Read general internal status (checking batteries, etc.) and

transmit the status to the surface system.

Activate any one of the operating solenoids.

Signal types

All signals transmitted between the surface and subsea units

consist of bursts of acoustic waves. These are generated at

specific frequencies with specific intervals, but at fixed

amplitudes. Each burst presents a binary digit, but not coded in

normal binary notation. The signals transmitted from the surface

system to the transducer are of two basic types:

9 Two-frequency wake-up: Serial bits, transmitted at two

fixed frequencies, specially coded by spacing to represent

a power-on command.

10 Groups of five serial bits, each bit being separately

identified by being at one of seven frequencies (not the

same frequencies as the wake-up signals), and each group

of five bits being coded by bit-sequence to form different

operational commands for the Subsea Control Unit.

Note This second type of data coding is commonly termed Multi

Frequency Shift Keying (MFSK).


301678/D 143

Note The same two wake-up frequencies are used for all ACS systems,

and these frequencies can also be used by transponders for

general communication. To avoid excessive battery use due to

the Subsea Control Unit being constantly “awake”, do not

locate transponders that use these frequencies in the vicinity of

the Subsea Control Unit.

Message processing

After power is switched on to the electronic units (using the

power switches on the tops of the racks) the system is initialized

and an internal system test is performed. At the end of the

initializing sequence the electronic units transmit a sequence of

three pulses on the transducers. The “click” sound from the

transducers indicates that the system electronics is working, and

should be used as an initial system check after power on. If the

sound is not heard, switch off the units, wait for at least three

minutes, and then switch them on again.

On completion of the power on sequence, power is maintained

on the electronics for approximately one minute. After this

delay, the electronics enter into a “sleep mode” where the

processor clock speed is reduced and power is switched off to

parts of the system.

Note Power is switched on to the solenoid interface board only if a

status or solenoid function command is executed. Power is not

switched on to the solenoid interface board during the

initialization period.

Two channels on the receiver board are dedicated to receiving

the wake-up pulses. When the first wake-up pulse is detected, an

interrupt is sent to the processor which switches power on. The

unit then comes out of the sleep mode, and listens for the second

wake-up pulse. If the second wake-up pulse is not detected

within a preset time interval, the unit returns to the sleep mode

again. If the correct second pulse is detected within the time

limit, the processor stays awake and waits for further

commands.

When a command is received and decoded correctly with its 7

MFSK, the command is executed and the Tx board sends a

confirmation message back to the surface.

ACS 400

144 301678/D

Automatic switchover

If the surface unit cannot make contact with the BOP electronic

unit 1 on the first attempt and if the system is set to change

automatically, it will repeat the procedure using the other BOP

channel. If the system still has problems making contact, you

must move the transducer to another location and order the

surface unit to repeat the procedure starting with BOP electronic

unit 1.

Refer to the Select BOP unit chapter on page 49 for the

procedure.

Solenoid operation

Before operating a solenoid the computer checks to see if there

is a leakage current in the control circuit. It does this by

switching on the return transistor and sensing the current

through a resistor connected in series with that transistor.

Any current through the resistor will indicate a fault in one of

the solenoids or control circuits (not necessarily the selected

one). If in this situation full operating power is applied to the

solenoid, this could result in the wrong solenoid being operated,

so the operation is halted. You will then have to switch to the

other electronic unit and restart the operation.

If no current is sensed, the solenoid is operated by switching the

positive voltage to the solenoid and simultaneously switching

the return line to 0 V. The computer then senses the current

through the solenoid by reading the voltage across a series

resistor in the return line. The current value is checked against

preset nominal upper and lower limit values programmed for

each delivery.

If the current exceeds a preset maximum (uncontrolled current,

2-3 times the nominal value), it will be switched off as this

would indicate the existence of a short circuit in the solenoid or

cables.

If the current remains within the limits, it is maintained for a

preset interval. The processor monitors the solenoid current, and

if no specific feedback sensor is provided it uses the current

information to verify the operation of the solenoid via sensor

channel 7. (It assumes that if the correct current has passed

through the solenoid for the correct time, the solenoid is in

working order and will have operated correctly.) On completion

of the operation, the appropriate information is transmitted to the

surface unit and displayed.


301678/D 145

Interfaces

The electronic units can read up to eight digital and three

analogue sensors (in addition to channel 8) located on the subsea

structure, and can transmit the information to the surface system.

The interfacing between the sensors and the electronic units is

performed by the SSIB. Additional digital and analogue sensor

channels can be provided if specifically ordered by the

customer.

Since only one electronic unit is operational at any one time (the

other is used as the back-up unit), both units are connected in

parallel to all the sensors.

Analogue interfaces

Analogue interface is performed via an 8-channel serial output

A/D converter. Channel 8 of is dedicated to reading solenoid

current values; the remaining channels can be used for other

analogue feedback functions. The analogue sensors are powered

from the SSIB board during a valve operation and whenever

required for status readings.

Digital interfaces

Digital feed back is read from static or dynamic switches by the

SSIB. The digital sensors are powered from the SSIB board

during a valve operation and whenever required for status

readings.

The feedback signal is defined as “dynamic” if the status

information is only available while the appropriate solenoid is in

operation (e.g. the status of a solenoid is read from the current

flowing through it). In this case the status will be unknown

while the solenoid current is switched off.

The feedback signal is defined as “static” if the status

information is available at all times (i.e. the status information is

taken from, for example, a pressure switch in a hydraulic line).

Note “Dynamic” sensor information will be displayed as “unknown”

when you enter the “Read BOP status” command.

Refer to the Read BOP status on page 54 for further

information.

ACS 400

146 301678/D

18 DRAWING FILE This chapter holds illustrations referred to in various sections in

this manual. The illustrations are based on the original system

drawings and wiring diagrams.

The original drawings are available in electronic format on

request.

Drawings

Part No. Rev. Description Ref.

Surface system

301714 -1 B Dunking Transducer (TD) Unit - outline dimensions on page 147

301714 -2 B TDD 303 MF dunking TD - outline dimensions on page 148

302020 A TDD 301 MF dunking TD- outline dimensions on page 149

Cd34034 N/A TDD 103 LF dunking TD - outline dimensions on page 150

332392 A Hull mounted dunking 301 w/adapter plate on page 151

322167 A ACC 401 Unit - outline dimensions on page 152

322171 A BOP Simulator Unit - outline dimensions on page 153

Subsea system

320613 A Subsea Control Unit (SCU) - outline dimensions on page 154

Cd34067 N/A SCU mounting brackets - outline dimensions on page 155

Cd4160a N/A TDA 331 MF subsea BOP TD - outline dimensions on page 156

860-211372 D TDA 324 MF subsea (BOP) TD - outline dimensions on page 157

Cd3767 N/A TDA 133 LF subsea (BOP) TD- outline dimensions on page 158

Cd4487 N/A BOP transducer cable, pin connections on page 159

103141 D SCU rack wiring 8 channel system on page 160

103233 D SCU rack wiring 16 channel system on page 161

Drawing file

301678/D 147

Dunking Transducer (TD) Unit - outline dimensions

Weight: Approx 25 kg depnding on type of TD

Note:All measurements are in mm.The drawing is not in scale.

ACS 400

148 301678/D

TDD 303 MF dunking TD - outline dimensions

Weight: 5 kg


Drawing file

301678/D 149

TDD 301 MF dunking TD - outline dimensions

Weight: 10 kg


ACS 400

150 301678/D

TDD 103 LF dunking TD - outline dimensions

Ø 128

Ø 3

55

Weight: 10 kg


Drawing file

301678/D 151


Note:The drawing is not in scale.

ACS 400

152 301678/D

ACC 401 – outline dimensions


Drawing file

301678/D 153

BOP Simulator Unit – outline dimensions


ACS 400

154 301678/D

Subsea Control Unit (SCU) - outline dimensions


Drawing file

301678/D 155

SCU mounting brackets - outline dimensions

50

10

30

50

125

125

50

3 holes, ø13


ACS 400

156 301678/D

TDA 331 MF subsea (BOP) Transducer - outline dimensions

Ø 127

5 mounting holes

Ø 1

78

210

Weight (w/cable): 9.6 kg


Drawing file

301678/D 157

TDA 324 MF subsea (BOP) Transducer - outline dimensions


Ø1

85

Ø142

Ø127

ACS 400

158 301678/D

TDA 133 LF subsea (BOP) Transducer - outline dimensions

System ACS400 Unit TRANSDUCERPart no. 100-102841 Ser. no.Compass safe dist. Stand: m Steer: m

IP class Power: VA V Hz

CE conformity Made in Norway

Ø155

6 holesM10

Ø40

120

Ø194

335

15

Ø173

M10

Base oftransducer

Weight (w/cable): 35 kg


Drawing file

301678/D 159

BOP transducer cable, pin connections

Vector plugcontainer end

Moulded couplingtransducer end

PenetratorTransformator

R R R

YEYEYE

1

2

1

2

1

3

12

11

10

1

4

7

5

9

6

8

2

3


ACS 400

160 301678/D

SCU rack wiring 8 channel system

Drawing file

301678/D 161

SCU rack wiring 16 channel system

ACS 400

162 301678/D

19 LITHIUM BATTERIES SAFETY PROCEDURES

This chapter includes transponder safety information for the

Kongsberg Maritime units with lithium battery, and separate

Kongsberg Maritime lithium batteries. It also includes

emergency procedures.

____________________________________________________________

Warning This chapter must be read before handling units with lithium battery and separate lithium batteries.

____________________________________________________________

Topics

Identification of the products and company on page 163

Composition and information on ingredients on page 163

Hazards identification on page 165

First-aid measures on page 166

Fire-fighting measures on page 167

Accidental release measures on page 167

Handling and storage on page 167

Exposure controls and personals protection on page 171

Physical and chemical properties on page 171

Stability and reactivity on page 171

Toxiclogical information on page 171

Ecological information on page 172

Disposal considerations on page 172

Transport information on page 172

Regulatory information on page 173

Other information on page 173

Lithium batteries safety procedures

301678/D 163

Identification of the products and company

Product name

All Kongsberg Maritime units (Transponder/SCU – named

transponder in this chapter) with a lithium battery, and separate

Kongsberg Maritime lithium batteries.

Range of products

Company address

Kongsberg Maritime AS

P.O.Box 111

N-3190 Horten

Norway

Emergency contact

Duty phone 24 hour: +47 992 03 808

PART NUMBER BATTERY TYPE

290-089501 L10/36 (15/20)

290-101665 L10/36 (18/30)

290-103053 L10/36 (15/40)

290-089505 L10/36 (36/60)

290-102726 L10/40 (3/11)

290-210845 L10/40 (3/11)

290-089010 L10/21 (6/12)

290-082380 L10/21 (6/48)

290-089592 L10/50 (12/42)

290-222071 L10/50 (27/28)

290-083530 L50/10/24

290-219492 L24 (98)

290-062447 L50

290-080718 L80

325902 L14.4 (48)

319554 D48-Li

ACS 400

164 301678/D

Composition and information on ingredients

Battery chemistry

A transponder lithium battery consists of Lithium Metal cells

with chemistry:

Lithium Thionyl Chloride - Li/SOCl2

Negative electrode: Lithium metal (Li)

Positive electrode: Carbon

Electrolyte: Solution of lithium tetrachloroaluminate

(LiAlCl4) in thionyl chloride

Battery weight and lithium content

PART

NUMBER

BATTERY

TYPE

BATTERY

WEIGHT (kg)

LITHIUM

CONTENT (g)

290-089501 L10/36 (15/20) 4,3 175

290-101665 L10/36 (18/30) 5,6 240

290-103053 L10/36 (15/40) 6,6 235

290-089505 L10/36 (36/60) 11,7 480

290-102726 L10/40 (3/11) 1,7 70

290-210845 L10/40 (3/11) 1,7 70

290-089010 L10/21 (6/12) 2,2 90

290-082380 L10/21 (6/48) 6,7 270

290-089592 L10/50 (12/42) 6,5 228

290-222071 L10/50 (27/28) 6,6 247

290-083530 L50/10/24 10 438

290-219492 L24 (98) 11 490

290-062447 L50 4,3 175

290-080718 L80 6,8 280

325902 L14.4 (48) 5,9 183

319554 D48-Li 5,9 183

Battery cell manufacturers/types

A transponder lithium battery consists of cells from one or two

of the following manufacturers and types:

Tadiran TL-2300

Sonnenschein SL-780

Saft LS 33600

Saft LSH 20

Sonnenschein SL-760


301678/D 165

Battery design

A transponder lithium battery consists of several battery cells

that are electrical connected, both in serial and parallel.

There are transponder batteries with different number of cells,

voltages and capacity.

All transponder batteries include protection against short-circuits

(re-settable fuses) and reverse current (diodes).

Hazards identification

Short-circuits, overheating, mechanical damage and exposure to

water can start chemical reactions and high currents inside the

transponder lithium battery. This can generate noxious gases

and/or danger of explosions. The chemical reactions will

continue without additional supply of oxygen, as the battery

cells contain the necessary ingredients for maintaining the

chemical reactions.

During operation, the battery is placed inside the transponder.

Water ingression into the transponder can cause dangerous

situations.

Danger of explosions

If the cells that form the battery exceed the critical

temperature of 180 C, they may explode.

External fire - The temperature can reach the critical point

of 180 C.

Water ingression - The battery temperature will increase,

caused by the high internal currents. The temperature can

reach the critical point of 180 C.

Water ingression - Electrolysis gives hydrogen. Together

with oxygen, hydrogen can create oxyhydrogen gas inside the

transponder (depends on the concentration). This gas is very

inflammable/explosive.

Water ingression - Chemical reactions in the battery will

cause a pressure build-up inside the transponder. The

transponder can explode if the inside pressure is high enough.

If the transponder explodes, either the transducer or the

bottom end cap will blow out, or the transponder becomes

fragmented. This can cause serious damages on personnel

and/or equipment.

Some transponders have a relief valve that will prevent over-

pressure. Noxious gases will then leak out of the transponder

until the chemical reactions have stopped.

ACS 400

166 301678/D

____________________________________________

Note The relief valve can be plugged, caused by products from the

chemical reactions during an emergency as described above.

____________________________________________

Noxious gases

Thionyl chloride (SOCl2)

Sulphur dioxide (SO2)

Hydrogen chloride (HCl)

Chlorine (Cl2)

First-aid measures

All personnel that have been exposed to the noxious gases

should immediately be seen by a doctor.

Inhalation: Remove from exposure, rest and keep warm.

Skin contact:

Wash off skin thoroughly with water. Remove

contaminated clothing and wash it before

reuse.

Eye contact:

Irrigate thoroughly with water for at least 15

minutes.

Ingestion:

Wash out mouth thoroughly with water and

give plenty of water to drink.

Fire-fighting measures

Cool down the battery with copious amounts of cold

water.

Transponder with lithium battery:

* Immerse the transponder in the sea for 24 hours or

permanent.

* If this method is impossible, the transponder can be

cooled down by use of a fire hose.

Separate transponder lithium battery:

* Immerse the battery in the sea for 24 hours or

permanent.

* If this method is impossible, the battery can be cooled

down by use of a fire hose.


301678/D 167

Cooling down the battery with copious amount of cold water is

the only way to reduce/stop the internal chemical reactions, or to

limit the fire/explosions to as few battery cells as possible. The

chemical reactions/fire will continue without additional supply

of oxygen, so extinguisher like Lith-X will not work properly.

Applying water directly onto a battery may develop hydrogen

gas, due to the possible electrolysis if the battery terminals are

exposed to water. Mixed with air, this gas is very

inflammable/explosive. However, if the water cooling takes

place out on deck, or in a storeroom with good ventilation, there

will never be enough hydrogen gas to exceed the lower

explosive limit of hydrogen in air (ca 4%).

Remove transponders with lithium battery and separate

transponder lithium batteries in case of an external fire if

possible.

Accidental release measures

Refer to Chapter 0, Handling and Storage on page 167.

Handling and storage

All personnel that handle transponders must know the

transponder’s status:

’Functioning’ - ’Failing’ - ’Unknown’

A Transponder with unknown status, must be handled as a

transponder that is failing.

Recovering a ”functioning” transponder

All transponders recovered from the sea, should be placed in

a safe place out on deck and controlled for minimum 2 hours:

Look for outer damages that could involve a water

leakage.

The transponder housing temperature must be checked to

verify a possible temperature increase in the lithium

battery.

If everything is OK refer to Kongsberg Maritime transponder

instruction manuals for normal procedures.

Recovering a ”failing” transponder

Handle as possible water ingression.

Evacuate all unnecessary people.

Recover the transponder with great precaution. Use a crane.

ACS 400

168 301678/D

No people should be near the transponder when it is lifted up

on deck.

Place the transponder in a safe place out on deck, shielded

from people and vital equipment.

Fasten the transponder in a crane, ready to lower it into the

sea again.

Control the transponder for minimum 2 hours:

Look for outer damages that could involve a water

leakage.

The transponder housing temperature must be checked to

verify a possible temperature increase in the lithium

battery.

Failing and normal temperature:

Take out the battery - see Opening a transponder with

defect/possible defect battery.

Failing and increasing temperature:

See Handling a heated or self-heated transponder.

Handling a heated or self-heated

transponder


Fasten the transponder to a rope and immerse it in the sea for

24 hours or permanent.

If this method is impossible, the transponder can be cooled

down with copious amount of cold water. Use a fire hose.

Recover the transponder and control the temperature.

Repeat this until the temperature is low and stable.

The transponder can now be opened - see Opening a

transponder with defect/possible defect battery.

Handling a transponder if relief valve

opens


Use necessary protection equipment.

Fasten the transponder to a rope and immerse it in the sea for

24 hours or permanent.

If this method is impossible, the transponder can be cooled

down with copious amount of cold water.

Use a fire hose.


301678/D 169

Repeat this until no gases come out the check valve and the

temperature is low and stable.

The transponder can now be opened - see Opening a

transponder with defect/possible defect battery.

Wash out chemical reaction products with water.

Opening a transponder with defect/possible defect battery

The transponder is reported failing. There could have been

water ingression in the transponder.

Open the transponder in a safe place out on deck, shielded


Use necessary protection equipment.

____________________________________________

Caution Do not stand in front of transducer or bottom end cap, when opening the transponder.

____________________________________________

If there has been water ingression, and the battery is still

warm:

Disconnect the battery from the transponder electronics,

and then - see Handling heated or warm separate battery.


Opening a “functioning” transponder

The transponder is reported functioning.

Open the transponder in a safe place out on deck, shielded


____________________________________________

Caution Do not stand in front of transducer or bottom end cap, when opening the transponder.

____________________________________________

Handling heated or warm separate battery


Fasten the battery to a rope and immerse it in the sea for 24

hours or permanent.

If this method is impossible, the battery can be cooled

down with copious amount of cold water.

Use a fire hose.


ACS 400

170 301678/D

Handling transponders and separate

transponder batteries in case of an external fire

Remove transponders with lithium battery and separate

transponder lithium batteries in case of an external fire if

possible

Cool down transponders and separate transponder batteries

with copious amounts of cold water - see Chapter 0,

Fire-fighting measures on page 166.

Storage ____________________________________________

Caution A transponder that is failing must be stored in a safe place out on deck, shielded from people and vital equipment.

____________________________________________

A transponder that is functioning, and separate batteries can be

stored indoors. The battery must be removed from the

transponder when stored indoors.

Storage temperature:

Recommended storage temperature lies between 0º C and

+25º C (max +50º C, min -55º C).

Storage relative air humidity:

Recommended relative air humidity is 40 to 70%.

A transponder/separate battery must not be stored directly in

the sunlight.

A battery must not be exposed to water.

Storeroom:

A solid room with study racks for transponders/separate

batteries.

A room where no people are staying, or no vital equipment

is placed.

Good ventilation.

Clearly identified.

Easy to remove transponders and batteries in case of an

external fire.

____________________________________________


301678/D 171

Caution The storeroom must have a sprinkler system or a fire station, with fire hose (water), must be placed outside

the storeroom.

____________________________________________

Exposure controls and personals protection

Fire/explosion:

Use self contained breathing apparatus.

Relief valve opens and noxious gasses come out:

Use a full face mask with minimum BE-filter, and protective

equipment of rubber or plastic.

Opening transponder with defect/possible defect battery:

Use a full face mask with minimum BE-filter, and protective

equipment of rubber or plastic.

Opening a functioning transponder:

Use protective goggles.

Physical and chemical properties

Not applicable unless individual components exposed.

Stability and reactivity

The products are stable under normal conditions - see Chapter 0,

Hazards identifications on page 165.

Toxiclogical information

Signs and symptoms:

None, unless battery ruptures. In the event of exposure to

internal contents, corrosive fumes with pungent odour will be

very irritating to skin, eyes and mucous membranes. Over-

exposure can cause symptoms of non-fibrotic lung injury and

membrane irritation.

Inhalation: Lung irritant.

Skin contact: Skin irritant.

Eye contact: Eye irritant.

Ingestion: Tissue damage to throat and gastro/respiratory

tact if swallowed.

Medical

conditions:

Eczema, skin allergies, lung injuries, asthma

and other respiratory disorders may occur.

ACS 400

172 301678/D

Ecological information

None known if used/disposed of correctly.

Disposal considerations

A lithium thionyl chloride battery does not contain any heavy

metals, and is therefore not regarded as special waste

(contains only biodegradable parts).

A used transponder lithium battery often contains a

significant amount of residual energy. It is the danger of

explosion that presents a problem when disposing a battery.

Used batteries must therefore be handled with the same

care as new ones.

____________________________________________

Caution For safe disposal, contact the nearest local company that has been approved to collect and dispose lithium batteries.

____________________________________________

Transport information

All transponders with a lithium battery and separate transponder

lithium batteries must be shipped in accordance with the

prevailing national regulations.

Transponder with lithium battery:

UN no. 3091, Class 9 Miscellaneous

(Lithium batteries contained in equipment).

Separate transponder lithium battery:

UN no. 3090, Class 9 Miscellaneous (Lithium batteries)

Transport:

Aircraft: IATA DGR

Sea Transport: IMDG Code

Railway: RID

Road transport: ADR

Aircraft - Only new separate transponder lithium batteries

can be transported by air.

Aircraft - Transport of all transponders with new lithium

battery and new separate transponder lithium batteries by air

is only permitted onboard cargo aircraft. The goods must be


301678/D 173

clearly labelled:

CARGO AIRCRAFT ONLY

____________________________________________

Caution Transponder with lithium battery - During transport the lithium battery must always be disconnected from the electronics.

____________________________________________

Original transponder/battery cages must be used.

Regulatory information

Not applicable.

Other information

The battery cell manufacturers’ safety data sheets are available

on the following internet addresses:

Saft: www.saftbatteries.com

Tadiran / Sonnenschein: www.tadiranbatteries.de

ACS 400

174 301678/D

20 CERTIFICATES This chapter contains the type approval certificates for the

Kongsberg Maritime Emergency Acoustic BOP Control System.

Certificates

301678/D 175

ACS 400

176 301678/D

Certificates

301678/D 177

ACS 400

178 301678/D

Certificates

301678/D 179

ACS 400

180 301678/D

Index

301678/D 181

21 INDEX

A

Abbreviations, 12

AC power supply, 123

ACC, 12

ACC 401 Control Unit, 114

Acoustic Control Subsea units, 18

Acoustic Control System, 14, 15

ACS, 12

ACS 400, 13

ACS Subsea system, 25

ACU, 18

B

Battery, 124

Battery charger board, 121

Replacing, 89

Battery lifetime, 125

Battery replacement, 89

BOP, 12

BOP Simulator, 22

C

Certificates, 174

Charger-2, 121

Charging the ACU battery, 38

Close the cable drum, 39

CPU, 12

E

EDP, 12

Electronics rack

Subsea system

Contents, 98

Maintenance, 97

Replacing the battery, 105

Topside system

Charging the battery, 88

Contents, 87

Maintenance, 88

Equipment handling, 132

Equipment responsibility, 133

F

Frequencies for the telemetry messages,

141

Front panel connector, 115, 116

Front panel LED, 115

Front panel unit, 102, 115

H

Handling, 133

High voltage safety warning, 2

How to use the test cable, 81

I

Illustrations:

AC power supply, 123

ACC 401 internal battery, 124

ACC Control Unit front panel, 87

Acoustic Control System for BOP

operation, 14

Battery charger board, 121

BOP Simulator indicating test cable

connector, 22

ACS 400

182 301678/D

Electronics rack - circuit board

locations, 98

Electronics rack - top plate, 99

Electronics rack chassis, 100

Mains cable, 88

Message pulse timing, 141

Microcontroller circuit board - ACC

401 Control Unit, 119

Microcontroller circuit board -

Subsea Control Unit, 119

Motherboard, 126

O-rings and support ring fitted into

the container flange, 109

Receiver circuit board (MF version),

118

Separating the CPU and Rx boards,

90, 103

Solenoid and sensor interface board

(SSIB), 128

SSIB board - terminal blocks and

connectors / wire colour codes,

104

Subsea Control Unit - internal layout,

95

Subsea Control Unit - side view, 94

Subsea Control Unit base -

connectors and anodes, 96

Subsea Control Unit lid, 97

Transmitter circuit board (MF

version), 117

Wake up to message pulse timing,

140

Inspection, 134

Installation guidelines, 31

Installation procedures

Tests and checks, 34

Topside system, 31

Interfaces

Analogue interfaces, 145

Digital interfaces, 145

Internal units, 114

L

LCD, 12

LED, 12

LF, 12

Lifting, 133

Lithium batteries safety procedures, 162

Lithium Battery, 11

M

Maintenance

Dunking Transducer Unit, 92

Subsea system

Battery pin configurations, 100

Closing the container, 108

Inter-seal test port, 110

Opening the container, 97

Replacing circuit boards, 102

Replacing the battery, 105

Topside system

Charging the battery, 88

Contents, 87

Removing the rack, 89

Replacing circuit boards, 89

Transducers

Cleaning, 112

Replacing, 112

Manual content, 11

Max, 12

MC, 12

Menu system

Exit program, 60

Initial start-up, 46

Read BOP status, 54

Show BOP status, 60

System setup, 49

Index

301678/D 183

MF, 12

Microcontroller board (CPU)

Purpose, 118

Replacing, 89, 102

MIN, 12

Motherboard, 125

Mounting brackets, 26

MUNAV, 12

MUTRAN, 12

N

N/A, 12

O

Open the cable drum, 39

Operation

Operation example, 61

Status information and messages, 72

Operation example

Aborting the command, 64

Errors, 65

Operation method

Communication principles, 142

Interfaces, 145

Solenoid operation, 144

Operation principles

Message telegram, 141

Power settings, 139

Telemetry communication, 136

Wake up telegram timing, 140

R

Read BOP status

Get analog readback, 58

Get solenoid current, 57

Parameters, 54

Read analog sensors, 59

Read battery status, 56

Read electric valve status, 55

Read short status, 56

Receiver board (Rx)

Purpose, 117

Replacing, 89, 102

Remove the rack, 89

Replace the rack, 89

ROV, 12

RX, 12

S

S. no., 12

SCU, 12, 18

SCU installation, 32

Simulator, 22

Solenoid and sensor interface board

(SSIB)

Purpose, 127

Replacing, 102

Spare parts, 129

SSIB, 12


BOP ackowledge messages, 78

BOP status messages, 74

Electronic status messages, 75

Error messages, 72

Stack operation result messages, 76

Status page, 72

Valve status messages, 73

Storage, 134

Subsea system

Battery description, 101

Battery life, 101

Container description, 95

Electronics rack, 98

External connectors, 96

ACS 400

184 301678/D

Maintenance, 94

Overview, 18

Spare parts, 131

Subsea transducer installation, 32

System overview, 15

System setup

Parameters, 49

Select BOP tx power, 51

Select BOP unit, 49

Select topside tx power, 50

Show system information, 52

T

TD, 12

TDA 133 LF subsea transducer, 27

TDA 324 MF subsea transducer, 26

TDA 331 MF subsea transducer, 26

TDA 331 MF transducer, 19


Surface system

AC power supply unit, 24

Battery, 24

Topside system

Battery, 26

Environmental conditions, 24

Topside system

Electronics rack, 87

Installation, 31

Maintenance, 87

Spare parts, 130

Topside unit front panel

Connectors, 115

LCD screen, 42

LEDs, 88, 115

Transducer test cable, 21

Transducers (subsea)

Maintenance, 112

Replacing, 112


Purpose, 117

Replacing, 89, 102

Transportation, 133

TX, 12

U

Unpacking, 133

W

Wake-up frequencies, 141

Welding procedures, 34

Z

Zinc anodes, 96

AC

S 400 Instruction M

anual

AC

S 400 Instruction M

anual

AC

S 400 Instruction M

anual

AC

S 400 Instruction M

anual

AC

S 400 Instruction M

anual

AC

S 400 Instruction M

anual

acs 400 instruction manual

Documents

auto shutd

call kongsberg

st locks lock

spurious signals

hyd raulic

contact kongsberg

portable dunking

auto shutdown