Acs 400 Instruction Manual

Instruction Manual
ACS 400 with ACC 401

Emergency Acoustic BOP Control System
ACS 400
Emergency Acoustic BOP Control System Instruction Manual
ACS 400
Document history
Rev D Date 29 February 2012 Written by IJG Checked by JO Approved by 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: km.support@kongsberg.com HiPAP, HPR, Transponders, HAIN and ACS: Phone 24 hour: +47 992 03 808 E-mail: km.support.hpr@kongsberg.com
Kongsberg Maritime AS
Strandpromenaden 50 P.O.Box 111 N-3191 Horten, Norway Telephone: +47 33 03 41 00 Telefax: +47 33 04 47 53 www.kongsberg.com subsea@kongsberg.com
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Instruction Manual
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 shipyards 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 Maritimes maintenance philosophy: The onboard technical personnel shall, with the help of the documentation and the systems 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.
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ACS 400
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.
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Table of Contents
1 ABOUT THIS DOCUMENT ................................................................................11 Manual content .........................................................................................................11 Abbreviations ...........................................................................................................12 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 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
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ACS 400 BATTERY LIFE ....................................................................................28 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 CABLES ..................................................................................................................36 System cables ...........................................................................................................36 Test Cables ...............................................................................................................36 Cable specifications .................................................................................................37 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 ACC 401 UNIT FRONT PANEL..........................................................................41 LCD display.................................................................................................. 42 Cursor ........................................................................................................... 42 Pushbuttons................................................................................................... 42 Connectors................................................................................................................43 OPERATION AND TEST.....................................................................................44 How to switch power on and off ..............................................................................45
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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
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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
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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
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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
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20 CERTIFICATES ..................................................................................................174 21 INDEX ...................................................................................................................181
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About this document
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.
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ACS 400
Abbreviations
ACC ACS BOP CPU EDP LCD LED LF Max MC MIN MF MUNAV MUTRAN ROV RX S. no. SSIB SCU N/A TD TX Acoustic Control Command unit (topside) Acoustic Control System (complete system) Blow Out Preventor Central Processing Unit Emergency Disconnect Package Liquid Crystal Display Light emitting diode Low frequency Maximum Microcontroller Minimum Medium frequency Modular underwater navigation Modular underwater transponder Remotely operated vehicle Receive / reception Serial number Solenoid and Sensor Interface Board Subsea Control Unit Not Applicable TransDucer Transmit / transmission
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System description
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
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ACS 400
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
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System description
Available system units

The following units are available for Acoustic Control System (ACS) systems.
Note
Only the primary hardware items are listed.
Unit name Surface system
Units delivered for your system - see the Registration form (separate document). Unit P/N 125-217498 129-220871 301518 312844 332392 129-215265 129-216151 Order P/N ACC-219601 ACC-219600 023-220877 023-220878 023-220879 332392 AS4-215266 AS4-216150
Acoustic Control Command (ACC 401) unit - MF Acoustic Control Command (ACC 401) unit - LF Dunking transducer TDD 301-MF, with cable drum (3000 m) Dunking transducer TDD 303-MF, with cable drum (1500 m) Dunking transducer TDD 103-LF, with cable drum Hull mounted dunking 301 w/adapter plate Subsea system Subsea Control Unit (SCU) MF/LF, 8 Ch Subsea Control Unit (SCU) MF/LF, 10/16 Ch Interface cable DRY + S/N Interface cable PBOF + S/N (Oil filled) Subsea transducer TDA 324 MF (1500 m) Subsea transducer TDA 331 MF (3000 m) Subsea transducer TDA 133 - LF On deck test equipment
TD patch cable ACS 400 to portable Dunking TD Transducer test cable for Deck-test
Ref. Registration form Ref. Registration form 100-211373 100-210123 100-102841 334868 380-103277 313237 109-081009 100-211373 100-210123 TDL-103175 334868 380-103277 313237 TES-103183
BOP Simulator Unit 8 Channel BOP Simulator Unit 10 Channel (Obsolete) BOP Simulator Unit test cable
Ref. Registration form
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ACS 400
ACC 401 Control Unit
Cable 2, simulator Cable 1, transducer
Cable drum with 70 m cable
(CD34027a)
Dunking transducer
Figure 2 ACS 400 surface units

Subsea Control Unit (SCU)
To solenoid pack
(Cd34029)
Cable 5, interface
Cable 4, transducer
Cable 3, transducer
Subsea transducer 1
Subsea transducer 2
Figure 3 ACS 400 subsea units

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System description
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
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ACS 400
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 waterproof 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.
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System description
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 331 MF subsea transducer TDA 133 LF transducer Hull mounted dunking 301 w/adapter plate
TDA 324 MF subsea transducer
This transducer is designed for use in water depths down to 1500 m.
(Cd34032)
Figure 4 TDA 324 MF transducer with cable

This transducer is designed for use in water depths down to 3000 metres.
(Cd34061)
Figure 5 TDA 331 MF transducer with cable
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ACS 400
TDA 133 LF transducer
This transducer is designed for use in water depths down to 3000 m.
Figure 6 TDA 133 LF transducer

Hull mounted dunking 301 w/adapter plate
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
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System description
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 Registration Form (separate document).
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
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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
(CD34060)
Figure 10 BOP Simulator indicating test cable connector (A)

Note
The SCU must be at the surface when the simulator is used.
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System description
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.
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ACS 400
TECHNICAL SPECIFICATIONS
This chapter gives the technical specifications of the ACS system units.
Topics

Surface system
ACC 401 Portable surface system on page 24 ACS Subsea system on page 25

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: -40C to +70C Splash proof: IP64
Dunking Transducer Unit

Dimensions: on page 146 Length of cable: 70 m
TDD 303 MF Dunking transducer

Dimensions: on page 148 Beamwidth: (approx) 60 at -3dB Operating frequency: 25 kHz
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Technical specifications
TDD 301 MF Dunking transducer

Dimensions: on page 150 Beamwidth: (approx) 30 at -3dB Operating frequency: 25 kHz
TDD 103 LF Dunking transducer

Dimensions: on page 149 Beamwidth: (approx) 60 at -3dB 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
Dimensions: on page 154 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): 0C to 55C 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
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ACS 400
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. Dimensions: on page 155
Thickness: 10 m m Mounting holes: 3 holes 13 m m , one slotted

Beamw idth: (approx) 90 at -3dB Operating frequency: 25 kHz Dimensions: on page 157 Material: aluminium-bronze

Beamw idth: (approx) 30 at -3d B Operating frequency: 25 kH z
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Technical specifications
Dimensions: on page 156 Material: aluminium-bronze
TDA 133 LF subsea transducer

Beamwidth: approx. 60 at -3dB Operating frequency: 12.5 kHz Dimensions: on page 158 Material: aluminium-bronze
Test cable w/cable drum

Weight: 7.5 kg Cable length: 30 m
BOP Simulator Unit

Dimensions: on page 153 Weight: 1.5 kg
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ACS 400
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.
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ACS 400 Battery life
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.
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ACS 400
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
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Installation
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 vessels 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.
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ACS 400
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.
Note
Bracket dimensions and mounting holes on page 155
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.
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Installation
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 Registration Form (separate document). 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. 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). Secure the cable to the BOP structure so it does not present a hazard to ROVs etc. 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.
Once the Subsea Control Unit has been mounted on the BOP: 1 2
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.
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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 unimpeded 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. Remove the two electronic units and batteries. Refer to page 102 and 105.
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3 4 5
Replace the lid and fastened the bolts. Cover and seal all three connectors. Cover the gap between the barrel and the lid.
Execute the welding

1 Open the container again. Refer to page 97. Replace the electronic units and the batteries. Refer to page 102 and 105. Close the Subsea Control Unit. Refer to page 108. Execute function test of the complete assembled system.
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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.
System cables
Cable no. Cable type 1
Refer to ACS system figure 1 on page 16 and figure 2 on page 16 for the cable plan.
From/To
Length 70 m
Supplier Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime
Transducer cable Control Command Unit (ACC 401) Dunking transducer (on cable drum) Transducer cable Subsea Control Unit (SCU) Subsea transducer Transducer cable Subsea Control Unit (SCU) Subsea transducer Interface cable
3 4 5
15 m 15 m
Subsea Control Unit (SCU) Customer specified Customer BOP
Test Cables
Cable no. Cable type 1 2 Simulator cable
TD patch cable ACS 400 to portable Dunking TD
From/To BOP Simulator Unit Interface cable Control Command Unit (ACC 401) Subsea Control Unit (SCU)
Length 15 m 30 m
Supplier Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime
Subsea Control Unit (SCU) Transducer test cable for Deck-test Dunking transducer (on cable drum)
30 m
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Cable specifications
Cable specifications for your system - see the System Registration Form (separate document).
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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
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Basic information
F B A D B
(Cd34033)
C E
Figure 11 Cable drum w/transducer
How to open the cable drum

1 2 3 Pull the locking clip (A) towards you to open the unit. Fold out the handle (F). Lift up the cover (D). - The cable for ACC connection is placed inside the drum - behind this cover. Pull out the cable (E). To unlock the transducer cable, unlock the locking-pin, by turning the locking-knob (G) into vertical position.
4 5
How to close the cable drum

After use, wash the unit, cable and transducer before storage. 1 2 3 4 5 6 7 Use the handle to roll-up the transducer cable. Place the transducer in the basket. Push the cable locking-pin into position and lock the cable by turning the locking-knob (G) into horizontal position. Fold the handle (F) into position. Press the two bars (B) together and push the locking clip (C) into position. Roll-up the ACC cable (E), and place it inside the drum. Close the cover (D).
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Surface system setup

The system is now ready for use.
Procedure
1 2 3 4
Place the ACC Control Unit in a suitable location and remove the container lid. Place the cable drum close to the ACC Control Unit. Prepare the cable drum for operation. - See description above. 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. Connect the transducer cable into the connector marked TD on the front of the ACC Control Unit. Press the button to switch power on to the unit.
5 4
The surface system is now ready for operation!
Subsea system setup

No preparations.
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ACC 401 unit front panel
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
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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
POWER
These buttons must be pressed simultaneously, and held for a minimum of three seconds, to execute critical commands. 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.
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ACC 401 unit front panel
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. When you press and hold the button for a few moments, the system will display help text appropriate to the currently highlighted menu command.
HELP
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)
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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
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How to switch power on and off

Power on
1 2
Press the front panel.
button on the ACC 401 Control Unit
Observe that the start-up page appears, and the Main menu is displayed.
Power off
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. The system will shut down and the display will be switched off.
How to get started

Before you start the operation:
1 2
Press the front panel.
button on the ACC 401 Control Unit
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.
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Main menu
The main menu window is displayed below. There are six submenus (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 systems main menu is displayed as shown below.
ACC 401 BAT% 75
--------------------------------------------SYSTEM SETUP BOP CONTROL READ BOP STATUS SELECTED: ACC TX POWER: LEAVE AUTO DETECT UNIT 1 HIGH SELECT
UNIT 2
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.
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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.
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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 SET BOP UNIT 2 TX POWER SHOW SYSTEM INFO The BOP CONTROL parameters
BOP CONTROL on page 52 These parameters are specified by the customer. Each installation will therefore be different. 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) No submenu. The various status and information messages are described in the Status information and messages section on page No submenu.
SHOW BOP STATUS on page 60 Displays various status information.
EXIT PROGRAM on page 60
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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 SET BOP UNIT 1 TX POWER SELECTED: ACC TX POWER: LEAVE AUTO DETECT UNIT 1 HIGH SELECT
UNIT 2
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.
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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. The following options are available: 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.
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Set BOP unit 1 tx power
The purpose of this command is to set the power level to be used when BOP unit 1 transmits to the ACC Control Unit. The following options are available: 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
The purpose of this command is to set the power level to be used when BOP unit 2 transmits to the ACC Control Unit. BOP units 1 and 2 have identical power setting options and default power setting.
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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 SELECTED: ACC TX POWER: PRESS LEFT AUTO DETECT UNIT 1 HIGH TO CONTINUE UNIT 2
For SERIAL NO and CHANNELS for your system - see the Registration Form (separate document).
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 (separate document).
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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> SELECT ENTER
LEAVE
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.
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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
UNIT:x
BOP STATUS:<status> EL STATUS:<status> SELECT ENTER
LEAVE
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
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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 BOP STATUS BAT% 75 -------------------------------------------READ VALVE STATUS WAITING FOR REPLY XX
UNIT:x
LEAVE
Once the check has been completed, the display will present the information as shown in the next diagram.
BOP STATUS BAT% 75 -------------------------------------------UNIT: x ELECTRONIC: VALVE: UNIT:x EL. TEXTS: 1
<status> <status>
1 2 3 4 5 6 7 8 BOP STATUS:<status> EL STATUS:<status> PREV. LAST
LEAVE
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.
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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:
READ BOP STATUS BAT% 75
---------------------------------------CONSUMED 10V: xx% CONSUMED 48V: xx%
UNIT:x
BOP STATUS:<status> EL STATUS:<status> TO CONTINUE
PRESS LEFT
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 menu. key will return you to the Read BOP status
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 transmission and the Waiting for reply message will be displayed. On completion, the Read BOP status menu will reappear.
The possible status messages are described in the Status information and messages section starting on page 66.
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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 transmission and the Waiting for reply message will be displayed. On completion, the following display page will appear:
ANALOG STATUS BAT% 75
-------------------------------------------CHANNEL: <channel no.> VALUE: <value> MA UNIT:x BOP STATUS:<status> EL STATUS:<status> PRESS LEFT TO CONTINUE
The <channel no.> field will display the sensor channel selected and the <value> field gives the current value (in mA) detected by the sensor. Pressing the menu. key will return you to the Read BOP status
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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)
UNIT:x
LEAVE
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: VALUE: UNIT:x

<channel no.> <value> MA
PRESS LEFT
The <channel no.> field will display the sensor channel selected and the <value> field gives the current value (in mA) detected by the sensor. Pressing the menu. key will return you to the Read BOP status
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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 transmission and the Waiting for reply message will be displayed. On completion, the following information will be received from the subsea system:
READ BOP STATUS BAT% 75
-------------------------------------------READ ANALOG SENSORS

<SENSOR NO. 1>: <SENSOR NO. 2>: <value> <value>
UNIT:x
PRESS LEFT
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. Pressing the menu. key will return you to the Read BOP status
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Show BOP status

Entering this menu command opens the status information page. The following display page will be presented:
BOP STATUS BAT% 75
-------------------------------------------UNIT: x EL. TEXTS: 1 ELECTRONIC: <status> VALVE: <status> 1 2 3 4 5 6 7 8 SELECTED: ACC TX POWER: LEAVE AUTO DETECT UNIT 1 UNIT 2 HIGH 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.
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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 UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
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
UNIT:x
BOP STATUS:<status> EL STATUS:<status> TO ABORT
PRESS LEFT
You can abort the command by pressing the
button.
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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: UNIT:x OK VERIFICATION BOP STATUS:<status> EL STATUS:<status> TO CONTINUE
PRESS LEFT
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 UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
EXECUTE
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:
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BOP CONTROL
BAT% 75
-------------------------------------------PIPE RAM CLOSE EXECUTING STACK CMD XX
UNIT:x
BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
EXECUTE
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
UNIT:x
PRESS LEFT
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):
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BOP CONTROL
BAT% 75
-------------------------------------------RISER CONNECTOR UNLATCH STATUS: SYSTEM IS DISARMED FORCE ERROR, PRESS EXECUTE UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
EXECUTE
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
UNIT:x
PRESS LEFT
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And on completion, the following page will be presented:

BOP CONTROL BAT% 75
-------------------------------------------PIPE RAM CLOSE PRESS EXEC BUTTONS FOR 3 SEC. TO EXECUTE STACK FUNCTION UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
EXECUTE
Press the two
buttons over again if you want to reto return to the BOP
transmit the command or press 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 halfclosed 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> UNIT:x BOP STATUS:<status> EL STATUS:<status> TO CONTINUE
PRESS LEFT
Press
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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.
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Auto shutdown (option)
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.
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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 UNIT:x BOP STATUS:<status> EL STATUS:<status> SELECT ENTER
LEAVE
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.
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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:
AUTO SHUTDOWN BAT% 75 --------------------------------------------UNIT: x SHD CONTROL :<status> SHD IRQ :<status> SHD READ:<status> SOL. CURR :<status> STACK E: <status,0/E> SEQUENCE:12345678 UNIT:x BOP STATUS:<status> 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:
AUTO SHUTDOWN BAT% 75 ----------------------------------------------READ TIME OF LAST SHUTDOWN TIME SINCE LAST ACT.: <status> UNIT:x BOP STATUS:<status> EL STATUS:<status>
Note
The read time of last shutdown status represents the number of minutes since last activation.
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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:
AUTO SHUTDOWN BAT% 75 ----------------------------------------------DISABLE SHUTDOWN PRESS EXEC BUTTONS FOR 3 SEC. UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
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 topside unit waits for the Acknowledge message. The XX field will display the time elapsed since the transmission was started. You can abort the command by pressing the button. 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:
AUTO SHUTDOWN BAT% 75 ---------------------------------------------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.
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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:
AUTO SHUTDOWN BAT% 75 ---------------------------------------------ENABLE SHUTDOWN (Select: ALL)
PRESS EXEC BUTTONS FOR 3 SEC. UNIT:x BOP STATUS:<status> EL STATUS:<status> ABORT EXECUTE
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 topside unit waits for the Acknowledge message. The XX field will display the time elapsed since the transmission was started. You can abort the command by pressing the button. 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:
AUTO SHUTDOWN BAT% 75 ---------------------------------------------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
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The various status and information messages that may be displayed are described in the Read BOP status messages chapter on page72.
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11 STATUS INFORMATION AND MESSAGES

Status page information
The standard status page is laid out as shown below:
BOP STATUS BAT% 75
--------------------------------------------
UNIT: x ELECTRONIC: VALVE:
EL. TEXTS: 1
<status> <status>
1 2 3 4 5 6 7 8 UNIT:x BOP STATUS:<status> EL STATUS:<status> PREV. LAST
LEAVE
The information displayed is as follows:

UNIT: x
This is the currently selected Subsea Control Units electronic unit. It will indicate unit 1 or 2.
The EL. TEXTS (Option) field indicates the EL. TEXTS page no. 1 (Normally removed).
EL. TEXTS: <x>
ELECTRONIC:
<errors>
This can be one of the following messages (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 tim e BOP is on d eck.
BATTERY WARNING 10V Description The 10 V section of the selected electronic units battery w ill soon fail. Action Battery m ust be replaced n ext tim e BOP is on d eck. Read the pow er consum ption of the Subsea Control Unit. The w arning w ill be executed w hen reaching approx. 90% of pow er consum ption.
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Status information and messages
BATTERY WARNING 48V Description Action The 48 V section of the selected electronic units battery w ill soon fail. Battery m ust be replaced next tim e BOP is on d eck. Read the pow er consum ption of the Subsea Control Unit. The w arning w ill be executed w hen reaching approx. 90% of pow er consum ption.
BATTERY WARNING 48V PING Description The ping counter for the 48 V battery has exceed ed the lim it. Action Battery m ust be replaced next tim e BOP is on d eck. Theoretical calculations say that the 48 V battery is em pty.
ELECTRIC STAT UNKNOWN Description N o acoustic reply received . Action Low er the Dunking transd ucer further d ow n. Increase pow er, both from the surface and subsea units if possible. If not ok, call Kongsberg Maritim e.
NO ELECTRIC ERROR Description N o electrical error is d etected in the Subsea Control Unit. Action Description Action N one. The electrical status is not know n. Check pow er settings, battery status etc. Increase pow er settings for the subsea and surface units.
STATUS UNKNOWN
SW WATCHDOG Description Program error d etected . Action VALVE:

<status>
Reset the system . (Self pow er off after one (1) m inute).
This can be one of the following messages: XXX Description
This ind icates w hich of the valves is active, closed or status unknow n. For system s w ith d ynamic sw itches, the valves w ill be displayed as 0 (= closed), 1 (= active) or U (= unknow n). N one.
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STATUS UNKNOWN Description The valve status has not been read from the Subsea Control Unit, so is therefore not know n. N one.
Action BOP STATUS:

<status>
This can be one of the following messages: Blank field Description
For system s w ithout Arm / Reset functions, a blank, d ark rectangle w ill be d isplayed for the BOP S status. N one. The BOP hyd raulic system is arm ed and read y to accept stack function ord ers. N one. Pressure error. The BOP is arm ed but the hyd raulic pressure is not satisfactory. Check hyd raulic pressure. Read BOP status again. If not ok, call Kongsberg Maritim e. The BOP hyd raulic system is d isarm ed (reset). It m ust be arm ed before is can carry out stack function ord ers. N one. The BOP status is not know n. Read the BOP status. Operate ARM or DISARM function. Valve error. One or m ore of the read backs from the stack valves are open after a DISARM function is executed . (This m essage is only possible just after a DISARM function is executed ). Take care - do not execute the ARM function. The faulty valve w ill be operated . Valve error and pressure error.
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Action ARM Description Action PRES. E Description Action
RESET Description
Action UNKNOWN Description Action VALVE E Description
Action V+PE Description

74
Action V+RE Description Action ABORTED Description Action EL STATUS:

<status>
Check solenoid package. If the BOP is on d eck, test against the simulator box. Valve error and reset error. Check solenoid package. If the BOP is on d eck, test against the Simulator box. The stack com m and has been aborted . N one.
This can be one of the following messages: BATT W. Description Action
Battery w arning. The battery is beginning to run d ow n. Battery m ust be replaced next tim e BOP is on d eck. Read the pow er consum ption of the Subsea Control Unit. The w arning w ill be executed w hen reaching approx. 90% of pow er consum ption . The operator m ust execute the Read Electr Status com m and to receive a d etailed error m essage. N one. All functions and results are correct. N one. The electrical status is unknow n d ue to faulty com m unications etc. Try again. Ad just pow er both on surface and subsea units. If not ok, contact Kongsberg Maritim e.
ERROR Description
Action OK Description Action UNKNOWN Description Action
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.
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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>
UNIT:x
BOP STATUS:<status> EL STATUS:<status> PREV. LAST
LEAVE
STATUS:
<status>
This can be one of the following messages: FAULTY VERIFICATION Description Incorrect read back signal from the sensors. In system s w ithout readback the system checks the current, and this m essage then ind icates that the current is not w ithin the specified lim its. Action Check the solenoid current. If ok, the fault is in the solenoid package. Check the read back sw itches.
NO VERIFICATION Description The current stack operation has not been verified . Action Try again. Ad just pow er. The signal from the Subsea Control Unit has not been d etected . Successful operation of current stack function. N one.
OK VERIFICATION Description Action INTF ERROR :

<status>
This can be one of the following messages: LOW SOLENOID CURRENT Description Action The solenoid current is below the low er current limit. Read solenoid current. Check internal battery in the Subsea Control Unit, and solenoid in solenoid package.
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HIGH SOLENOID CURRENT Description Action The solenoid current is above the upper current limit. Check solenoid package. Test against the BOP sim ulator if possible. A short circuit has been d etected in the subsea system . The selected Subsea Control Units electronic unit w ill not perform any further operations - abort the com m and and select the other electronic unit. Check solenoid package. Test against the BOP sim ulator if possible. A current is sensed w hen no current should be flow ing. The selected Subsea Control Units electronic unit w ill not perform any further operations - abort the com m and and select the other electronic unit. Check solenoid package. Test against the BOP sim ulator if possible. Check SCU battery (10/ 48V package).
CURRENT OVERFLOW Description
Action
UNCONTROLLED CURRENT Description
Action
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.
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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 acknow led gem ent m essage. Action Description N one. The Subsea Control Unit cannot confirm that the BOP hyd raulic system is arm ed . This m ay be d ue to a d am aged pressure sensor or a lack of hyd raulic pressure in the BOP. Check solenoid package, hyd raulic pressure. SYSTEM IS DISARMED
Action
SUBSEA ELECTRONIC ERROR Description The Subsea Control Unit has d eveloped an electronic fault. Action Abort the com m and and sw itch to the other Subsea Control Units electronic unit. As d escribed . If not ok, contact Kongsberg Maritim e.
TELEGRAM ERROR Description A check-sum error or an unexpected telegram has been received . Action TIMEOUT Description The ACC Unit has not received an acknow led gem ent m essage w ithin the tim e lim it. The m essage m ay have been transmitted by the Subsea Control Unit but a valid m essage has not been received . Increase/ d ecrease pow er on both surface and subsea u nits. Try again. If not ok, contact Kongsberg Maritim e. Reset the system . Try again. If not ok, contact Kongsberg Maritim e.
Action
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Auto Shutdown status messages

AUTO SHUTDOWN BAT% 75 ---------------------------------------------UNIT: <x> 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
STATUS:
<status>
This can be one of the following messages:
UNIT: x
This is the currently selected Subsea Control Units electronic unit. It will indicate unit 1 or 2.
This can be one of the following messages: ENABLE ALL Description DISABLE ALL Description
SHD CONTROL:
<status>
Ind icates that the Subsea system is Enabled for m aking an Auto Shutd ow n sequence Ind icates that the Subsea system is Disabled . N one Auto Shutd ow n sequence w ill start w hile IRQ/ Sw itches activates.
SHD IRQ :
<status>
This can be one of the following messages: NONE / SHD 1 / SHD 2 / ALL Description Ind icates that the Subsea system is Enabled for m aking an Auto Shutd ow n sequence w ith ex. ALL (Both sw itches).
SHD READ :
<status>
This can be one of the following messages: SW 1 / SW 2 / ALL Description Ind icates that the Subsea system has perform ed an Auto Shutd ow n sequence w ith ex. ALL (Both sw itches).
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SOL CURRENT:
<status>
This can be one of the following messages: N/A / OK / LOW / HIGH Description Ind icates that the Subsea system has perform ed an Auto Shutd ow n sequence w ith OK solenoid d rive current.
STACK E:
<status>
This can be one of the following messages: 0/E/ Description
0 = OK and E = Error in the auto sequence.
SEQUENCE:
<status>
This can be one of the following messages: Description 1, 2, 3 8 indicates the function num ber in the sequence.
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On deck test/Test in air
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
TD Test cable with 30 m cable ACC 401 Control Unit
Altern ative
Alter nativ
e1
Cable drum with 70 m cable

(Cd34027g)
Dunking transducer
Al te rn at ive
Test cable
Interface cable
Subsea transducer 1
Alternative 2
Subsea transducer 2
Figure 14 Test in air
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ACS 400
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 2 3 Disconnected the SCU subsea transducer 1 (TDA331) from the SCU. Connect one end of the transducer test cable to the SCU. 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! 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. 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. Establish contact with Subsea Control Units electronic unit no. 1 using the ACC Control Unit and the Dunking transducer. Manually select unit no. 1 in the menu. Execute a BOP stack function from the ACC Control Unit.
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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 7 8 9 10 Repeat points 3 to 5 for the other stack functions. Move the Dunking transducer in order to establish contact with Subsea Control Units electronic unit no. 2. Manually select unit no. 2 in the menu. Repeat points 3 to 5 for the all stack functions. 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.
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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 2 Lower the dunking TD into the water. 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.
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Operator Station APOS

Portable dunking TD - Cable drum with 70 m cable
Test cable
(Cd34087a)
HiPAP connected to APOS
Interface cable
Surface
TD Patch cable ACS 400 to portable dunking TD Subsea transducer 2
Subsea
Dunking transducer
HiPAP 500/350 transducer
Figure 15 Test in air of ACS 400 with HiPAP
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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:
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 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. 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.
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Maintenance
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)
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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 splashproof.
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.
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Maintenance
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 2
Place the ACC Control Unit on a stable work bench. Remove the four phillips screws. Refer to figure 11 on page 87. Gently pull up the rack and place it on the work bench. - Disconnect the grounding wire if necessary.
Replacing the rack
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.
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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.
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Maintenance
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. Remove the rear panel from the rack. Switch Off the Power switch on the Charger board. Refer to figure 2 for the Power switch location. 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 6 Find the appropriate slot for the board, and locate the board carefully into the rails. 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 8 9 Switch On the Power switch on the Charger board. Fix the rear panel to the rack. 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 2
Check the transducer. - Ensure the face is clean and free from defects. Check that the retaining strap is in good condition and will prevent the transducer falling out of its holder during transportation Check the connector on the surface end of the cable. - Ensure the rubber seal is fitted and is in good condition.
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Maintenance
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. 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. 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 BOPs 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

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Maintenance
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.
A:
Sacrificial anodes
BOP
(Cd34066)
Figure 22 Subsea Control Unit base - connectors and anodes

96
Refer to page 160 for transducer cable pin configurations. Refer to page 128 for the solenoid interface.
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Maintenance
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. Dry the unit thoroughly. 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. Remove the eight bolts, nuts and washers from around the flange. Use an 8 mm hexagonal key and a suitable spanner,
2 3
Figure 23 Subsea Control Unit lid 5

Note
Carefully lift the lid free from the housing.
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
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Maintenance
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 Transducer connector P2 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 customers solenoid pack.
Transducer connector P2
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.
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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 customers 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.
The batteries must be stored upright.
Caution
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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.
Open the unit. This procedure is described on page 97. Ensure the electronics racks are switched off, and then disconnect the battery interface cable. 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. Place the unit on a clean, stable workbench, and support the unit so it cannot roll off. Remove the grey plastic covers from the appropriate rack section. - Use a 4 mm hexagonal key and a flat-blade screwdriver. Locate and remove the defective circuit board. 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.
2 3
4 5
6 7
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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 9 Removed the faulty board. 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 ribboncable connector, then connect J1 and J2, then fit the board into the rack. Wire colour codes for J1 and J2 see figure above. 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.
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Note
104
Maintenance
11 12
Reconnect the battery cable. Switch on both electronics units Note the Power on sequence on page 108. Close the unit. This procedure is described on page 108.
13
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. This procedure is described on page 97. Switched off the SCU electronics units power (A) before proceeding. Disconnect the battery interface cable.
2 3
(Cd34048)
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Remove the two bolts securing the battery into position. - Use a 13 mm hexagonal key.
Lift the battery out of the unit, using the lifting handle.
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Place the old battery standing up beside the new battery.
B C
C
(Cd34049)
Move the top tie plate (B) from the old battery, to the new one. - The top tie plate is cecured by the four bolts. Move the two retaining rings (C) from the old battery to the new one. Install the new battery, and secure it into position. Reconnect the battery cable. Cut open the plastic bag protecting the desiccator bag in the new battery pack. Switch on the electronics units. - OPTION: Select SYSTEM SETUP in the ACC 401 Control Units main menu. Run the BATTERY RESET function. When preforming this option, use the Dunking cable or a test cable.
8 9 10 11 12
Note
This must be done for both electronics units. 13 Close the unit. This procedure is described on page 108.
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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 2
Note
Remove the old O-rings and support ring from the grooves in the container flange. Clean the container and lid flanges carefully, ensuring all traces of dirt, old grease etc. are removed.
Do not use metal tools to clean the surfaces. Use only plastic or wooden scrapers, solvents and soft cloths. 3 4 5 Once the flanges are clean, inspect them for damage. Ensure all tools, cloths, debris etc are removed from the top of the unit. 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.
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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 8 9 Fit the M8 bolts, nuts and spring-washers, and tighten them to a torque of 24 Nm. Inspect the unit externally for damage to paintwork. 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. This procedure is described on page 108.
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2 3
Remove the plug from the test port. Use an 8 mm hexagonal key. 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. Close off the inlet pipe and note the exact pressure, then leave the unit to stand for a minimum of 1 hour. 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.
4 5
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. If the container is correctly sealed, vent the pressure and disconnect the pump apparatus. 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. 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.
7 8
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 systems 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 2 Remove all mud and weed from the transducer. Use a plastic-bristled brush, cloths and fresh water. Remove stubborn crustacean growth using a rounded wooden or plastic scraper. Be careful not to damage the rubber coating on the transducer. Dry the unit and inspect it for damage.
Replacing a subsea transducer

1 2 3 Clean the base of the unit, ensuring all mud and marine growth is removed. Dry the area around the transducer cable connector. Remove all cable clips and bindings securing the transducer cable to the BOP, and disconnect the cable connector from the Subsea Control Unit. Support the transducer such that it cannot fall when the securing bolts are removed. Remove the five M8 bolts securing the transducer to the BOP. Lift the transducer clear of the BOP.
4 5 6
Note
Each transducer weighs approximately 10 kg. 7 8 Lift a new transducer onto the mounting position on the BOP. Fit five new M8 bolts of the same type and length as the old ones.
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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 10 Tighten the bolts to the torque recommended by the bolt manufacturers. 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. 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.
11
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/Os 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. ACC 401 Control Unit
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
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Front panel unit

Location
ACC 401 Control Unit 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)
P1
P2 P9
P3
P6
Figure 31 Front panel board - rear side
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Transmitter board (Tx)

Location
ACC 401 Control Unit 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

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 phaselocked 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

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.
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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 10position rotary switches: The Dip-switch block is used to set the systems 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 LF MF S1-1 Off On S1-2 Off Off S1-3 Off Off S1-4 On On
Rotary switches S2 and S3: LF (unit 1) LF (unit 2) S2 S3

Note
4 5
4 6
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.
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Internal units
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 LEDs. 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 shutdown 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 LEDs 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 backlight 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 25C)
Power control
To power up the board: 1 2 Switch on SW1. 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.
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Internal units
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
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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.
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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
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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)
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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).
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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.
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Spare parts
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.: Item name: No. in sys.: Kongsberg Maritimes part number. The name of the item. 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 125-217498 Ite m n a m e ACC 401 Con t r ol Un it com plet e Re c o m m e n d e d s p a re s 1
Example of listed spare part items
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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 125-217498 500-098580 380-219476 382-219335 380-101422 599-217882 382-219052 382-098602 659-087572 MF (30 k Hz) 129-220871 301518 332392 382-219490 382-083602 LF (12 k Hz) 312844 382-089502 382-101205 Du n kin g Tr a n sdu cer TDD103 LF (+/-30) Receiver boa r d (Rx) LF Tr a n sm it t er boa r d (Tx) LF 1 1 1 Du n kin g Tr a n sdu cer TDD301 MF (+/-15) Du n kin g t r a n sdu cer TDD 303 MF (+/-30) H u ll m ou n t ed du n kin g 301 w/ a da pt er pla t e (+/-15) Tr a n sm it t er boa r d (Tx) MF Receiver boa r d (Rx) MF 1 1 1 1 1 Ite m n a m e ACC 401 Con t r ol Un it com plet e ACC 401 spla sh -pr oof con t a in er Ma in s ca ble Micr ocon t r oller boa r d (CP U) 16 MH z F la t ca ble, Rx boa r d t o CP U boa r d Su ppor t ba r Ba t t er y ch a r ger boa r d AC power su pply 48 Vdc/1 A 45 W Desicca n t 10 g Re c o m m e n d e d s p a re s 1 0 1 1 0 0 1 1 3
BOP Simulator Unit

KM P /N TES-103183 313237 380-103221 Item name BOP Simulator Unit (Old 10channel) BOP Simulator Unit 8 channel BOP simulator cable Custom spec refer Registration form Re c o m m e n d e d s p a re s 0 0 0 -
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Spare parts
Subsea system
The list only contains the main components and units. Other components may be available on request.
KM P /N 290-089592 540-084885 540-063488 549-082344 629-086818 560-087294 562-087297 577-087298 Item name Battery pack L10/50 O-ring 355.0 x 6.99 MIL413B O-ring 380.3 x 6.99 MIL413B Support ring, F/O ring 355 x 7.0 Aluminium anode, AL-1F Bolt, M8X60 SYLH. W/INV6 DIN912 SUPER DUPLEX Nut, 6K-Nut M8 DIN934 SUPER DUPLEX Spring washer F/M8 DIN127B SUPER DUPLEX F/M8 DIN127B acid-resistant 659-087572 304407 Desiccant bag Interseal test port, 3/8" SAE x 10 mm Seal Screw (NOTE! For systems delivered later than 2003) 540-099521 139-087300 540-099521 382-083551 382-102974 380-103168 Oil-F illed 380-103384 Dr y MF (30 k Hz) 100-211373 100-210123 Surface system Surface system LF (12 k Hz) 100-102841 Subsea Transducers TDA133 LF (+/-15) 1 Subsea Transducers TDA324 MF (+/- 30) 1500 m Subsea Transducers TDA331 MF (+/-15) 3000 m Tr a n sm it t er boa r d (Tx) MF Receiver boa r d (Rx) MF 1 1 0 0 O-ring Interseal for plug 304407 Interseal test port, Sea lin g P lu g VSTI R3/8" -E D/71 (NOTE! For systems older than 2003) O-ring Interseal plug 139-087207 Control Processor Unit circuit board Sensor & Solenoid Interface Board (SSIB) BOP Interface Cable, Customer Specification (PBOF) Refer to Reg. form/Instruction manual BOP Interface Cable, Customer Specification (Dry) Refer to Registration form/Instruction manual 2 1 2 1 1 1 1 Re c o m m e n d e d s p a re s 2 2 2 1 3 8 8 16 4 1
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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
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Equipment handling
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.
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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.
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Equipment handling
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.
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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
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Principles of operation
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 units 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.
3 4 5
Refer to figure 6 for the procedure. The surface unit wakes up the subsea unit using a twofrequency channel code. The surface unit transmits the selected stack function command. 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. 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. On receipt of the Execute command, the subsea unit performs the stack function command, and then transmits a status report to surface.
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8
Note
The surface system displays the final status of the BOP.
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) 1 Transmits wake-up pulses followed by BOP command
Acoustic Telegram Type Wake up pulses and Stack function --------------> Long address
Subsea Control Unit (SCU) (slave)
Wakes up, makes ready for signal reception Receives, decodes & checks address and command
Receives decodes & checks
Acknowledge <--------------
2 Confirms received telegram. Waits for Execute command
3 If OK, transmits Execute command
Execute -------------->
Receives, decodes & checks
5 Receives decodes & checks. Displays system status.
4 Carries out order BOP status <-------------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.
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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 Low power Minimum power approx. -4 dB rel. max. power approx. -8 dB rel. max. 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 units 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 High power Low power Minimum power pulse length pulse length pulse length pulse length = 16 ms = 14 ms = 12 ms = 10 ms
Note
Refer to the System setup menu description on page 49 for details about changing the transmission power.
The selected power setting, and therefore pulse length, is used for all frequency pulses transmitted by both the surface and subsea units.
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Wake up telegram timing

The systems 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 42Wake 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.
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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. F0 F1 F2 F3 F4 F5 F6 MF (Hz) 25000 25250 25500 25750 26000 26250 26500
Wake-up frequencies
The wake-up frequencies are as follows: Unit No. 1 No. 2 F1 (Hz) 24000 24500 F2 (Hz) 23500 23500
Channel
yy yy
Channel for your system - see the Registration Form (separate document).
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Acoustical address
Unit No. 1 Address xxxx Unit No. 2 Address 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. 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.
10
Note
This second type of data coding is commonly termed Multi Frequency Shift Keying (MFSK).
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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.
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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.
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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.
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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.
301714 -1 301714 -2 302020 Cd34034 332392 322167 322171
Rev.
B B A N/A A A A
Description
Dunking Transducer (TD) Unit - outline dimensions TDD 303 MF dunking TD - outline dimensions TDD 301 MF dunking TD- outline dimensions TDD 103 LF dunking TD - outline dimensions Hull mounted dunking 301 w/adapter plate ACC 401 Unit - outline dimensions BOP Simulator Unit - outline dimensions
Ref.
on page 147 on page 148 on page 149 on page 150 on page 151 on page 152 on page 153
Surface system
Subsea system
320613 Cd34067 Cd4160a 860-211372 Cd3767 Cd4487 103141 103233 A N/A N/A D N/A N/A D D Subsea Control Unit (SCU) - outline dimensions SCU mounting brackets - outline dimensions TDA 331 MF subsea BOP TD - outline dimensions TDA 324 MF subsea (BOP) TD - outline dimensions TDA 133 LF subsea (BOP) TD- outline dimensions BOP transducer cable, pin connections SCU rack wiring 8 channel system SCU rack wiring 16 channel system on page 154 on page 155 on page 156 on page 157 on page 158 on page 159 on page 160 on page 161
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Drawing file
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.
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TDD 303 MF dunking TD - outline dimensions
Weight: 5 kg
Note: All measurements are in mm. The drawing is not in scale.
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Drawing file
TDD 301 MF dunking TD - outline dimensions
Weight: 10 kg
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TDD 103 LF dunking TD - outline dimensions
355
Weight: 10 kg
128
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Drawing file
Note: The drawing is not in scale.
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ACC 401 outline dimensions
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Drawing file
BOP Simulator Unit outline dimensions
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Subsea Control Unit (SCU) - outline dimensions
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Drawing file
SCU mounting brackets - outline dimensions
50
125
3 holes, 13
125
50
30 10
50
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TDA 331 MF subsea (BOP) Transducer - outline dimensions
178
12
5 mounting holes
Weight (w/cable): 9.6 kg
156
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Drawing file
TDA 324 MF subsea (BOP) Transducer - outline dimensions
185
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1 27
157
ACS 400
TDA 133 LF subsea (BOP) Transducer - outline dimensions

155
120 Base of transducer
40 6 holes M10
194
335
System ACS400 Unit TRANSDUCER Part no. 100-102841 Ser. no. Compass safe dist. Stand: m Steer: IP class Power: CE conformity VA m V Hz Made in Norway
Weight (w/cable): 35 kg
M10 173
15
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Drawing file
BOP transducer cable, pin connections
Moulded coupling transducer end
Transformator
12 11 10 1 2 3
Penetrator
Vector plug container end
1 2
R YE
R YE
1 2
R YE
1 3
9 8 7
4 5 6
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SCU rack wiring 8 channel system
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Drawing file
SCU rack wiring 16 channel system
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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
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Lithium batteries safety procedures
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
PART NUMBER 290-089501 290-101665 290-103053 290-089505 290-102726 290-210845 290-089010 290-082380 290-089592 290-222071 290-083530 290-219492 290-062447 290-080718 325902 319554 BATTERY TYPE L10/36 (15/20) L10/36 (18/30) L10/36 (15/40) L10/36 (36/60) L10/40 (3/11) L10/40 (3/11) L10/21 (6/12) L10/21 (6/48) L10/50 (12/42) L10/50 (27/28) L50/10/24 L24 (98) L50 L80 L14.4 (48) D48-Li
Company address
Kongsberg Maritime AS P.O.Box 111 N-3190 Horten Norway
Emergency contact
Duty phone 24 hour: +47 992 03 808
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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 290-089501 290-101665 290-103053 290-089505 290-102726 290-210845 290-089010 290-082380 290-089592 290-222071 290-083530 290-219492 290-062447 290-080718 325902 319554
BATTERY TYPE L10/36 (15/20) L10/36 (18/30) L10/36 (15/40) L10/36 (36/60) L10/40 (3/11) L10/40 (3/11) L10/21 (6/12) L10/21 (6/48) L10/50 (12/42) L10/50 (27/28) L50/10/24 L24 (98) L50 L80 L14.4 (48) D48-Li
BATTERY WEIGHT (kg) 4,3 5,6 6,6 11,7 1,7 1,7 2,2 6,7 6,5 6,6 10 11 4,3 6,8 5,9 5,9
LITHIUM CONTENT (g) 175 240 235 480 70 70 90 270 228 247 438 490 175 280 183 183
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
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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 overpressure. Noxious gases will then leak out of the transponder until the chemical reactions have stopped.
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____________________________________________ 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: Skin contact: Remove from exposure, rest and keep warm. Wash off skin thoroughly with water. Remove contaminated clothing and wash it before reuse. Irrigate thoroughly with water for at least 15 minutes. Wash out mouth thoroughly with water and give plenty of water to drink.
Eye contact: Ingestion:
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.
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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 transponders 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.
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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

Evacuate all unnecessary people. 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

Evacuate all unnecessary people. 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.
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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 from people and vital equipment. 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. Wash out chemical reaction products with water.
Opening a functioning transponder

The transponder is reported functioning. Open the transponder in a safe place out on deck, shielded from people and vital equipment.
____________________________________________ Caution Do not stand in front of transducer or bottom end cap, when opening the transponder. ____________________________________________
Handling heated or warm separate battery

Evacuate all unnecessary people. 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. Wash out chemical reaction products with water.
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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 0 C and +25 C (max +50 C, min -55 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.
____________________________________________
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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. Overexposure can cause symptoms of non-fibrotic lung injury and membrane irritation. Inhalation: Skin contact: Eye contact: Ingestion: Medical conditions:
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Lung irritant. Skin irritant. Eye irritant. Tissue damage to throat and gastro/respiratory tact if swallowed. Eczema, skin allergies, lung injuries, asthma and other respiratory disorders may occur.
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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: Sea Transport: Railway: Road transport: IATA DGR IMDG Code RID 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
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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
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20 CERTIFICATES
This chapter contains the type approval certificates for the Kongsberg Maritime Emergency Acoustic BOP Control System.
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Certificates
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ACS 400
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Certificates
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177
ACS 400
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Certificates
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ACS 400
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Index
21 INDEX
Subsea system 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
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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
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
182
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
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Index
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
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
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
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SCU, 12, 18 SCU installation, 32 Simulator, 22 Solenoid and sensor interface board (SSIB) Purpose, 127 Replacing, 102 Spare parts, 129 SSIB, 12 Status information and messages 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
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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 Technical specifications Surface system AC pow er 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 Transmitter board (Tx) Purpose, 117 Replacing, 89, 102 Transportation, 133 TX, 12 U Unpacking, 133 W Wake-up frequencies, 141 Welding procedures, 34 Z Zinc anodes, 96
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ACS 400 Instruction Manual

Acs 400 Instruction Manual

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Acs 400 Instruction Manual

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Instruction Manual

ACS 400 with ACC 401

Update manual with new DNV Type Approval certificate.

HIGH VOLTAGE SAFETY WARNING

20 CERTIFICATES ..................................................................................................174 21 INDEX ...................................................................................................................181

About this document

ABOUT THIS DOCUMENT

ACS 400 system - short overview

Figure 1 Acoustic Control System for BOP operation

Available system units

Only the primary hardware items are listed.

Unit name Surface system

Ref. Registration form

ACC 401 Control Unit

Cable 2, simulator Cable 1, transducer

Cable drum with 70 m cable

Figure 2 ACS 400 surface units

Figure 3 ACS 400 subsea units

ACC 401 Control Unit

Dunking transducer unit

Short subsea system description

This transducer is designed for use in water depths down to 1500 m.

Figure 4 TDA 324 MF transducer with cable

Figure 5 TDA 331 MF transducer with cable

TDA 133 LF transducer

This transducer is designed for use in water depths down to 3000 m.

Figure 6 TDA 133 LF transducer

Figure 7 Hull mounted dunking 301 w/adapter plate

On deck test equipment

TD Patch cable ACS 400 to portable dunking TD

Figure 9 TD Patch cable ACS 400 to portable dunking TD

Figure 10 BOP Simulator indicating test cable connector (A)

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

ACC 401 Control Unit

Dunking Transducer Unit

TDD 303 MF Dunking transducer

TDD 301 MF Dunking transducer

TDD 103 LF Dunking transducer

Hull mounted dunking 301 w/adapter plate

TDA 324 MF subsea transducer

TDA 331 MF subsea transducer

Dimensions: on page 156 Material: aluminium-bronze

TDA 133 LF subsea transducer

Test cable w/cable drum

BOP Simulator Unit

ACS 400 BATTERY LIFE

ACS 400 Battery life

Assistance from Kongsberg Maritime

Surface system installation

Subsea system installation

Bracket dimensions and mounting holes on page 155

Subsea transducer installation

Solenoid interface cable

Pre-commissioning tests and checks

Transducer field of view

Welding procedures for the Subsea Control Unit

Execute the welding

Supplier Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime

Subsea Control Unit (SCU) Customer specified Customer BOP

Supplier Kongsberg Maritime Kongsberg Maritime Kongsberg Maritime

Charging the ACC battery on page 88

Figure 11 Cable drum w/transducer

How to open the cable drum

How to close the cable drum