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Maintenance Manual
SMART Chief II
Doc. No. 925.D016
Rev. Date Description Exec. Contr. Appr.
1.1 29.11.05 First edition FIL SS FIL
Bjorge Marine Automation AS
SMART Chief II
Maintenance Manual 2/12
Doc. No. 925.D016
Innhold
1 Intention and Extent............................................................................................................. 3
1.1 Intention ................................................................................................................................. 3
1.2 Extent ..................................................................................................................................... 3
2 Definitions and Abbreviations ............................................................................................. 4
2.1 Definitions.............................................................................................................................. 4
2.2 Abbreviations ......................................................................................................................... 4
2.3 Test Equipment ...................................................................................................................... 4
3 Reference Documents .......................................................................................................... 5
3.1 Det norske Veritas as ............................................................................................................. 5
3.2 SOLAS ................................................................................................................................... 5
3.3 Regulations for Electrical Maritime Installations 1990 ......................................................... 5
4 Responsible for the Procedure ............................................................................................. 5
5 Maintenance Manual SMART Chief II ............................................................................ 6
5.1 Daily Maintenance ................................................................................................................. 6
5.2 3- or 6- Monthly Maintenance ............................................................................................... 6
5.2.1 Operator Stations ............................................................................................................... 7
Computers ................................................................................................................................... 7
Monitors ...................................................................................................................................... 7
Printers ........................................................................................................................................ 7
Keyboards / Mouse / Tracker-ball ............................................................................................... 7
Power supply ............................................................................................................................... 8
5.2.2 Extension Alarm System (EAS) ........................................................................................ 8
EAS Panels .................................................................................................................................. 8
5.2.3 Deadman System ............................................................................................................... 8
Push Button Boxes ...................................................................................................................... 8
5.2.4 IO-Cabinets........................................................................................................................ 9
Power supply ............................................................................................................................... 9
IO-modules .................................................................................................................................. 9
Fan ............................................................................................................................................... 9
5.2.5 UPS .................................................................................................................................... 9
5.3 Yearly Maintenance ............................................................................................................. 10
5.3.1 Process Equipment .......................................................................................................... 10
Temperature Sensors ................................................................................................................. 10
Pressure Sensors ........................................................................................................................ 11
Other Type of Analogue Sensors .............................................................................................. 11
ON / OFF sensors ...................................................................................................................... 12
Output Signals ........................................................................................................................... 12
Bjorge Marine Automation AS
SMART Chief II
Maintenance Manual 3/12
Doc. No. 925.D016
1 Intention and Extent
1.1 Intention
The intention of this procedure is to ensure that the SMART Chief II main alarm system and
equipment belonging to this system continues to operate as close to maximum efficiency as possible.
The SMART Chief II has a highly reliable, accurate and durable microprocessor system made up of
components that require very little adjustment.
Nevertheless regular inspections, on-line tests, routine checks and calibrations are necessary to prevent
major problems, as well as guidelines for locating and correcting faults that may occur.
1.2 Extent
The extent of this procedure is limited to the main components included in a common
SMART Chief II alarm, monitoring and control system delivered by Bjorge Marine Automation.
Following main components are described in this procedure:
1. Operator station
2. Extension alarm system ( EAS )
3. Deadman system
4. Distributed I/O-system (STI2000)
5. Process equipment
Bjorge Marine Automation AS
SMART Chief II
Maintenance Manual 4/12
Doc. No. 925.D016
2 Definitions and Abbreviations
2.1 Definitions
SMART Chief II is an Integrated Automation System monitoring the main engine and auxiliary
equipment on a vessel, and gives alarms if abnormal conditions occur.
When configured as a process control system, it controls valves, pumps and fans and other systems or
equipment through user friendly graphical pictures.
2.2 Abbreviations
This is a list of special abbreviations used in this procedure.
A Ampere
EAS Extended Alarm System
I/O Input / Output
LED Light Emitting Diode
mA Milliampere
NiCr/Ni Nickel-Chromium/Nickel ( type of temperature sensor )
NO/NC Normally open/normally closed
PT100 Type of resistant temperature sensor
RS422/232 Receive Send ( RS-... is a communication standard )
UPS Un-interruptible Power Source
VAC Voltage Alternating Current
VDC Voltage Direct Current
V Volt
2.3 Test Equipment
To perform the sensor test, following certified /calibrated test equipment are required.
1. Temperature oil bath for 0-600°C thermocouple testing.
2. Pressure pump for generating pressure 0-40 Bar.
3. Sensor/Transducer Simulator for generating a sensor / transmitter signal during testing.
( mA, PT100, V )
Bjorge Marine Automation AS
SMART Chief II
Maintenance Manual 5/12
Doc. No. 925.D016
3 Reference Documents
3.1 Det norske Veritas as
Rules for Classification of Ships, volume 1, part 4, chapter 5, section 1C
220 Maintenance manual ( Documentation type 180 )
A document intended for regular use on board providing information about:
· Maintenance and periodical testing
· Acceptance criteria
· Fault indication and repair
· List of the supplier's service net.
3.2 SOLAS
Chapter II-1, Part D Electrical installations.
Regulation 45 Precautions against shock, fire and other hazards of electrical origin.
Chapter II-1, Part E Additional requirements for periodically unattended machinery spaces.
Regulation 45 General, Regulation 51 Alarm system.
3.3 Regulations for Electrical Maritime Installations 1990
Section 10 The rules purpose, area of application, inspection, notification, dispensations, criminal
liability and coming into force.
§1014. Insufficient maintenance.
Section 34 Internal control and maintenance.
§3401. Internal control and maintenance.
Supplement I Statute off the 24th of May 1929 Inspection of electrical installations.
Supplement II Specification of the documentation to supervisory authorities.
4 Responsible for the Procedure
R&D Department at Bjorge Marine Automation is responsible for the work out and revision of this
procedure.
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SMART Chief II
Maintenance Manual 6/12
Doc. No. 925.D016
5 Maintenance Manual SMART Chief II
Bjorge Marine Automation recommends this maintenance routine for the SMART Chief II Alarm,
Monitoring and Control System. Equipment / sensors connected to the Bjorge Marine Automation
system by serial communication lines are not to be maintained in accordance to tests described in this
procedure.
5.1 Daily Maintenance
Check the system for normal operating conditions.
Check that no abnormal readings are displayed, and that the readings are within normal operation
limits.
5.2 3- or 6- Monthly Maintenance
The classification Societies, Det norske Veritas and/or the Ship's Maintenance Plan should be referred
to for obtaining a recommended preventive maintenance schedule to test the alarms. These societies
normally recommend a 3-monthly to 6-monthly schedule.
To check the operation of alarms according to the Alarm List located in the Bjorge Marine
Automation SMART Chief II Project Documentation, the following brief description are given how to
simulate the alarm condition for :
ON/OFF channel giving alarm when open:
Disconnect the sensor connection to create an open circuit.
ON/OFF channel giving alarm when closed:
By using a small jumper, short-circuit the sensor connection to create a closed circuit.
ANALOGUE input:
Disconnect the sensor to create an abnormal reading ( to high or to low ).
Each 6-months period, the following checks should be performed on the entire system:
1. Check all cables and cable entrances in connection with the SMART Chief II.
No damages to cables or open cable entrances can be accepted.
2. Check all electrical screw terminals by pulling the wires for detection of loose
connections.
If retightening is required do not use oversized screwdriver or to much tightening strength.
3. Check all plug connections.
Check for loose connectors or fastening screws.
4. Clean equipment outside with a soft brush and remove dust by use of a vacuum cleaner.
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SMART Chief II
Maintenance Manual 7/12
Doc. No. 925.D016
5.2.1 Operator Stations
Computers
1. Check for solid mechanical mounting to the foundation.
2. Check all plug connections.
Check for loose connectors or fastening screws.
3. Make sure that all cable clamps are in proper position and solid attached to the rails or to the
grounding bar.
It is important that the cable screens have good electrical connection to the
chassis.
4. If supplied, verify that all fans are blowing properly and replace all air filters on Computer and
cabinet.
If the Computer is installed inside a cabinet, make sure the door is properly closed, and that the
cabinet is clean inside ( No unconcerned parts ).
Monitors
1. To keep the screen clean and free for static electricity, it is an advantage to use a cleaning set
consisting of a wet and a dry serviette.
It is also possible to use a lint-free, non-abrasive cloth and an alcohol-based, non-abrasive
cleaning solution or glass cleaner for this purpose.
Printers
1. Remove the access cover on the printer and take out possible paper bits and waste from inside
of the printer.
2. When changing ribbon cartridge, also clean the print head by using a Q-tip immersed in an
alcohol-based, non-abrasive cleaning solution to remove ink-settlings on the print head.
Keyboards / Mouse / Tracker-ball
1. Clean surface with a lint-free, non-abrasive cloth and an alcohol-based, non abrasive cleaning
solution.
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Maintenance Manual 8/12
Doc. No. 925.D016
Power supply
1. Check the electrical connections for overheating and loose connection.
2. Verify that the power supply is clean and dry.
Dust can in worst case induce overheating and malfunction of the power
supply.
5.2.2 Extension Alarm System (EAS)
EAS Panels
1. Unscrew the four screws on the panel and lift the panel out. Check for proper connections and
if required tighten the termination plug.
Put the panel back to its proper position.
2. Clean surface with a lint-free, non-abrasive cloth and an alcohol-based, non-abrasive cleaning
solution.
3. Check that all panel-light (including the display backlight and the buzzer) are intact by
pressing and holding the LIGHT button for about 3 seconds.
4. Check that the communication and power supply for all the EAS panels are OK by pressing
and holding the MENU button for about 3 seconds. Also verify that all lines are showing
correct information while the menu-page is displayed.
5.2.3 Deadman System
Push Button Boxes
1. Turn the Dead man system on by operating the green lamp pushbutton on the ON/OFF box.
Green light will appear.
2. After a predetermined time, usually 27 minutes, has passed check that the red light appear in
the ON/OFF box (es) and RESET box(es), and that rotating light is activated in the engine
room.
When pushing the reset push button the red light will disappear, and only the green light are left
on. The rotating light is stopped. The dead man system is deactivated by pressing the ON/OFF
pushbutton. The green light in the button will then be switched off indicating that the system has
been turned off.
3. Testing of the Emergency Call push button in the ECR:
Check that you get an Engineers Alarm, siren and rotating light in the engine room and that
EMERGENCY CALL is activated in the Bridge panel and on all cabin / mess panels.
Bjorge Marine Automation AS
SMART Chief II
Maintenance Manual 9/12
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5.2.4 IO-Cabinets
Power supply
1. Check the electrical connections for overheating and loose connection.
2. Verify that the power supply(ies) is(are) clean and dry.
Dust can in worst case induce overheating and malfunction of the power
supply.
3. Verify that the fuse(s) is(are) switched to on and that the power supply(s) is(are) indicating
OK by a green LED on the power supply.
IO-modules
1. Check all signal cables and cable entrances in the cabinet.
No damages to cables or open cable entrances can be accepted.
2. Check all electrical screw terminals by pulling the wires for detection of loose connections.
If retightening is required do not use oversized screwdriver or to much tightening strength.
Fan
1. Verify that the fan is blowing properly.
2. Replace all air filters for the cabinet.
Chocked filters can in worse case induce overheating and malfunction of the
power supply and IO-modules.
5.2.5 UPS
1. Verify that the fan is blowing properly and that the air in- and outlets are free.
2. Check the control panel for alarms or error messages
In case of alarms or error messages, refer to the Maintenance section in the UPS User Manual
for proper action.
Be aware that shutting down an UPS prior to establishing a proper bypass
connection, may cause parts of the SMART Chief II system non functional.
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Maintenance Manual 10/12
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5.3 Yearly Maintenance
1. Calibrate the input transducers according to the manufacture's instructions.
2. Calibrate possible output transducers according to manufacture's instructions.
If a calibration is needed, please check the manufacture's instructions.
5.3.1 Process Equipment
Temperature Sensors
1. Disconnect the sensor from the process.
2. Connect the sensor / transducer simulator instead of the sensor to provide the voltage, current
or resistance, as applicable to the process.
3. Adjust the sensor / transducer simulator to the Zero range value given in the SMART Chief II
Project Documentation Alarm List for this particular sensor.
4. All readings before and after calibration have to be registered in the Ship Alarm Testing
Formula.
5. Adjust the sensor / transducer simulator output to the Maximum range value given in the
SMART Chief II Project Documentation Alarm List.
If the alarm system is reading incorrect, adjustments can be made according to
SMART Chief II User's Manual.
After changing the sensor adjustments, point 3 and 4 have to be re-checked until correct readings are
achieved.
If the temperature sensor can be removed from its normal position and immersed in the temperature
tester without disconnecting electrical, this is the best way for testing the sensor and the entire loop.
The same procedure for calibrating the alarm system has to be done for this testing method.
If the sensor gives an ON- or OFF signal when the temperature passes a certain value ( thermostat ),
the signal from the tester have to be adjusted slowly past this temperature.
6. Disconnect the sensor/transducer simulator.
Remove the temperature sensor from the tester and re-fit it to its normal position.
7. Connect the sensor electrical to the process.
Be aware of a possible polarity.
8. Calibration procedure for temperature sensor is now finished.
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SMART Chief II
Maintenance Manual 11/12
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Pressure Sensors
1. Disconnect the sensor from the process.
2. Connect the sensor / transducer simulator in stead of the sensor, to provide the voltage or
current, as applicable to the process.
3. Adjust the sensor / transducer simulator to the Zero range value given in the SMART Chief II
Project Documentation Alarm List for this particular sensor.
4. All readings before and after calibration have to be registered in the Ship Alarm Testing
Formula.
5. Adjust the sensor / transducer simulator output to the Maximum range value given in the
SMART Chief II Project Documentation Alarm List.
If the alarm system is reading incorrect, adjustments can be made according to
SMART Chief II User's Manual.
After changing the sensor adjustments, point 3 and 4 have to be re-checked until correct readings are
achieved.
If the pressure sensor can be removed from its normal position or if the sensor can be isolated from the
process and connected to a pressure testing device without disconnecting electrical, this is the best way
for testing the sensor.
Then the sensor itself together with the entire loop can be tested.
The same procedure for calibrating the alarm system has to be done for this testing method .
If the sensor gives an ON- or OFF signal when the pressure passes a certain value ( pressure state ),
the testing pressure of the tester has to be adjusted slowly past this pressure.
1. Disconnect the sensor/transducer simulator.
Remove pressure sensor from the testing device and re-fit it to its normal position.
2. Connect the sensor electrical to the process.
Be aware of the polarity.
3. Calibration procedure for pressure sensor is now completed.
Other Type of Analogue Sensors
Different type of sensors can be connected to the alarm system.
The principal for testing is the same as described in chapter Temperature Sensors and Pressure
Sensors.
Be aware of that some sensors are connected to an external transmitter to make the measurements
readable for the alarm system.
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Maintenance Manual 12/12
Doc. No. 925.D016
ON / OFF sensors
To test ON/ OFF sensors in the process it is recommended to make the test full scale by changing the
process. E.g. change level in tanks, fault simulations, start/stop pumps or similar.
If this way of testing is not possible, following brief description can be used for simulating alarm
conditions in the sensor end of the alarm system:
ON/OFF channel giving alarm when open (fail safe):
Disconnect the sensor connection to create an open circuit and an alarm.
ON/OFF channel giving alarm when closed (normally not used):
By using a small jumper, short-circuit the sensor connection to create a closed circuit and an
alarm.
Output Signals
Make sure not to activate output signals which may interfere with the process,
unless the process has been shut down, set to local operation or in some other
way set to a non-operative state.
To check the signal out from a control function, following procedure can be followed:
1. Disconnect the control device electrical from the process.
2. Connect the sensor / transducer simulator in stead of the sensor, to measure the voltage or
current.
3. Adjust the control output to the Zero range value given in the SMART Chief II Project
Documentation Alarm List for this particular output..
4. Check readings on the sensor /transducer simulator and register the readings in the Ship Alarm
Testing Formula.
5. Adjust the control output to the Maximum range value given in the SMART Chief II Project
Documentation Alarm List.
If the alarm system is reading incorrect, adjustments can be made according to
manufacturer procedure for the device.
6. Disconnect the sensor/transducer simulator.
7. Connect the control device electrical to the process.
Be aware of the polarity.
8. Calibration procedure is now completed.
Bjorge Marine Automation AS