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Kobelt 6300-0100-1 Owner's Operation, Installation & Maintenance Manual

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Kobelt 6300-0100-1
Steering Controller
Owner's Operation, Installation & Maintenance Manual

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  • Page 1 Kobelt 6300-0100-1 Steering Controller Owner’s Operation, Installation & Maintenance Manual...
  • Page 2 Kobelt Steering System Kobelt Manufacturing Co. Ltd. NOTES RECORD DATA BEFORE INSTALLATION FOR FUTURE REFERENCE Model #: Serial #: Date of Purchase: Date of Installation: rev A MNL-6300-0100.docx 2 of 66...

  • Page 3: Table Of Contents

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. ABLE OF ONTENTS Introduction ........................8 Contact ..........................8 Compliant Use ........................8 Copyrights & Trademarks ....................8 Safety ..........................9 Safety Alerts ........................9 Notice to Installer ......................9 Product Hazards....................... 10 Scope ..........................
  • Page 4 Kobelt Steering System Kobelt Manufacturing Co. Ltd. 8.10 Recommended Spare Parts ..................... 58 Troubleshooting ......................59 Monitoring Screens ......................59 Fault Resolution ....................... 63 10 Warranty ........................65 rev A MNL-6300-0100.docx 4 of 66...
  • Page 5 Kobelt Steering System Kobelt Manufacturing Co. Ltd. IGURES Figure 1: Single Rudder Steering System Block Diagram (Simplified) ............... 13 Figure 2:Dual Rudder Steering System Block Diagram (Simplified) ................14 Figure 3: Controller Overview ..........................15 Figure 4: Serial Number ............................17 Figure 5: Rail Mounting ............................
  • Page 6 Kobelt Steering System Kobelt Manufacturing Co. Ltd. Figure 48: Smart Helm Settings ..........................41 Figure 49: Station Setup Screen ..........................42 Figure 50: Station Name Setting ..........................42 Figure 50: smart Helm Settings ..........................42 Figure 52: NFU Input Screen ........................... 42 Figure 53: FFU Input Screen ...........................
  • Page 7 Kobelt Steering System Kobelt Manufacturing Co. Ltd. IST OF ABLES Table 1: Technical Specifications Controller and Head .................... 16 Table 2: NMEA Cable Properties ..........................18 Table 3: KNet Network Connector .......................... 19 Table 4: KNet Network Properties .......................... 20 Table 5: Valve Power Connector ..........................

  • Page 8: Introduction

    Kobelt recommends that customers visit our website to check for updates to this Manual. Once a product has been selected for use, it should be tested by the user to ensure proper function in all possible applications. For further instructions, please contact our distributors or visit our website.

  • Page 9: Safety

    • Never put the product into service before fully completing installation and commissioning. • Do not carry out any modifications to the product. • Only use authentic Kobelt spare parts. • Observe all local regulations, directives, and laws during the installation of this product.

  • Page 10: Product Hazards

    (MNL-6300-0200 and MNL-6301-0100). Instructions on the basic version of the Kobelt digital steering system can be found in manual MNL-002. Information on electric and hydraulic systems present on the vessel requires knowledge not covered within this document.

  • Page 11: Terminology And Definitions

    Kobelt Manufacturing Co. Ltd. ERMINOLOGY AND EFINITIONS Before proceeding with the configuration and operation of the Kobelt Steering System, it is important for the user to become familiar with the terminology and basic functions used throughout this manual. Station Physical locations around the vessel where steering controls are located. Some common station locations include: •...

  • Page 12: Product Description

    The system is interconnected by the KNet network for communications and power. The Kobelt steering system controls one or two directional solenoid valves for a single rudder, or two independent rudders. The valve outputs may be configured as on-off type, or proportional control.

  • Page 13: Figure 1: Single Rudder Steering System Block Diagram (Simplified)

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Figure 1: Single Rudder Steering System Block Diagram (Simplified) rev A MNL-6300-0100.docx 13 of 66...

  • Page 14: Figure 2:Dual Rudder Steering System Block Diagram (Simplified)

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Figure 2:Dual Rudder Steering System Block Diagram (Simplified) rev A MNL-6300-0100.docx 14 of 66...

  • Page 15: Controller Overview

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 4.2 C ONTROLLER VERVIEW The figure below identifies the key features of the steering controller referenced in this manual. Figure 3: Controller Overview rev A MNL-6300-0100.docx 15 of 66...

  • Page 16: Technical Specifications

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 4.3 T ECHNICAL PECIFICATIONS Table 1: Technical Specifications Controller and Head ELECTRICAL OPERATING VOLTAGE 10-24Vdc OPERATING CURRENT Max 0.2A (at 24VDC) VALVE OPERATING VOLTAGE 12-32VDC VALVE OPERATING CURRENT 0-3.0A (Per Terminal) REVERSE POLARITY PROTECTION...

  • Page 17: Installation

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. NSTALLATION 5.1 R ECEIPT Upon receipt of the device ensure that the model number and serial number are noted in the table on page 2 of this manual. The serial number can be found in the location noted at right.

  • Page 18: Figure 6: Steering Controller Connectors

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Figure 6: Steering Controller Connectors Each system is required to have the ability to override the control system with a local backup. This can be accomplished by switching control over the steering valves to an NFU jog switch connected directly to the solenoids thereby giving manual control over the valves.

  • Page 19: Figure 7: Knet Male Connector Pinout For The Controller

    Running larger gauge wire will reduce total impedance. This is an important consideration when running backbone cables. Contact Kobelt sales for connector components. Do not use Light Cable (Micro) for back bone connections. The resistance of the wire is too high for all but minimal installations.

  • Page 20: Table 4: Knet Network Properties

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. The network design is dependent upon the voltage supplied at each station. With the voltage drop along the backbone wiring it can take several calculations to design the network properly. If the main power source is 24Vdc, and with sufficient voltage drop in the network it is possible for the steering station to drop below its operating voltage and experience a station brown out.

  • Page 21: Figure 8: Electrical Connector For Valve Power

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 5.3.2.1 Valve Power Connector Connector Type: 6-pin 5mm Pluggable Terminal Block Figure 8: Electrical Connector for Valve Power • Power supply input for all four coil drivers (Valve #1 and #2) • Power can come from any supply suitable for driving the solenoid valves. Note that: Valve power is isolated from KNet power supply, and they do not need to share a ground Valve supply voltage may be different than the KNet supply voltage, to a maximum of 24Vd.c.

  • Page 22: Figure 10: Electrical Connector For Valve #2 (Channels C/D)

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Table 6: Valve #1 Connector Membrane Pin # Pin Designator Pin Type Function Symbol Coil A+ Output Valve #1, CHA, Positive Output Coil A- Output Valve #1, CHA, Negative Output Coil B+ Output...

  • Page 23: Figure 12: Valve Wiring For Solenoid Valves (Common Negative)

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 5.3.2.4 Alternate Wiring Schemes Figure 12: Valve Wiring for Solenoid Valves (Common Negative) Figure 13: Valve Wiring for Solenoid Valves (Common Positive) 5.3.3 RFU Connections The steering controller is supplied with two sets of terminals, labelled “RFU rudder 1” and “RFU rudder 2”, along the bottom side dedicated to the rudder feedback units.

  • Page 24: Figure 14: Electrical Connector For Rfu #1

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Use of a 4-20 mA RFU requires an external voltage supply greater than 18VDC 5.3.3.1 RFU #1 Connector (Channels A/B) Connector Type: 7-pin 5mm Pluggable Terminal Block Figure 14: Electrical Connector for RFU #1...

  • Page 25: Figure 16: Electrical Connector For Rfu #2

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 5.3.3.2 RFU #2 Connector (Channels C/D) Connector Type: 7-pin 5mm Pluggable Terminal Block Figure 16: Electrical Connector for RFU #2 Table 9: RFU #2 Connector Membrane Pin # Pin Designator Pin Type Function...

  • Page 26: Figure 18: Rfu Wiring For 1 Rudder With 1 Current Sensor

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 5.3.3.3 Current Output RFUs Single Rudder with 1 Current Sensor Figure 18: RFU Wiring for 1 Rudder with 1 Current Sensor RFU 1, ChA RFU 1, ChB RFU 2, ChC RFU 2, ChD...

  • Page 27: Autopilot Connection

    Kobelt Manufacturing Co. Ltd. 5.3.4 Autopilot Connection The Kobelt steering system routes autopilot signals through the controller to permit an integrated dodge function from a either a jog lever or SBW wheel at the steering stations. Only non-follow up, jog type autopilots are permissible.

  • Page 28: Alarm Output Connection

    Reversing Pump Connection Figure 23: Reversing Pump Autopilot Wiring 5.3.5 Alarm Output Connection The Kobelt steering controller has a set of alarm outputs along the top side for; Form C alarm relay output b. Transistor type buzzer output The alarm relay works on the fail-safe principle: the relay is energized when the controller is healthy (not in an alarmed state).

  • Page 29: Table 11: Alarm Output Connector

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Table 11: Alarm Output Connector Pin # Pin Name Pin Type Function ALRM_NC Output Dry contact normally closed (connected to COM in alarmed state) ALRM_COM Dry contact common ALRM_NO Output Dry contact normally open (Connected to COM in...

  • Page 30: Table 13: Utility Input Connector

    To conform to EMC Standards in IEC60945, a power Line filter must be installed on to the main power supply line of the system as well as to the main power supply line of the valve. Kobelt recommends Schaffner EMC power line filters.

  • Page 31: Figure 28: Schaffner Powe Liner Filter

    5.3.8.3 Cable Routing In areas of extreme EMC interference, care should be taken in arranging the cabling of the Kobelt Steering system to maintain proper system performance. To achieve adequate system performance from the rudder feedback readings, the cable lengths should be kept to a minimum.

  • Page 32: Commissioning

    The system should be configured to match the physical hardware attached to the Mighty Helmsman steering system. After completion Kobelt recommends saving the configuration to the SD card. 6.1.1 Navigating the controller screens Use the Keypad on the controller to navigate through the Controller HMI.

  • Page 33: Figure 40: Root Menu Structure

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. The configuration screens that allow configuration and calibration of this system and components are accessed through a password screen. Below is a diagram displaying the layout of the controller menu choices available. Figure 30: Root Menu Structure rev A MNL-6300-0100.docx...

  • Page 34: Menu Structure

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.2 Menu Structure The ‘Home’ screen is the first screen in the set of monitoring screens. Pressing enter from the ‘Home’ screen will call the passcode screen. The menu structure is accessed after successfully entering the passcode.

  • Page 35: Figure 42: Steering System Configuration Menu Overview

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Figure 35: Steering System Configuration Menu Overview 6.1.3.1 Set Valve Type The first configuration item to set is the valve type. Select between a single speed on/off directional valve, two on/off directional valves for two speed operation or a proportional directional valve.

  • Page 36: Figure 38: Dual Rudder Enable

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.3.3 Dual Rudder Enable If it is desired to have independent rudder control on two rudder vessels, the Dual Rudder parameter must be set to ‘Enable’. Do not enable dual rudder functionality for twin rudder vessels that will always operate synchronously.

  • Page 37: Figure 41: Station Activation

    Digital input B should be closed with a dry contact to eliminate any faults generated on the Kobelt steering system. 6.1.3.7 Number of Stations The number of steering stations on the vessel must be set in this parameter. Only include the Kobelt digital steering stations: Do not include manual steering stations. 6.1.3.8 Station Activation...

  • Page 38: Figure 43: Controller Purpose

    Figure 45: Configuration Management Screen Factory Reset Pressing reset will change all the Kobelt Steering System parameters to the factory defaults. After pressing the Enter button, there are two layers of confirmation screens. Press ENTER twice to accept the warnings.
  • Page 39 Kobelt Steering System Kobelt Manufacturing Co. Ltd. Restore Configuration Selecting this function allows system parameters to be loaded from a configuration file on the SD card. Before restoring the configuration, please make sure the SD card is inserted properly. After selecting the Restore Configuration and pressing the Enter button, there is one layer of confirmation screen before a saved configuration is restored.

  • Page 40: Station Setup

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.4 Station Setup The diagram at right is an overview of the steering station configuration layout. Figure 46: Station Configuration Menu Structure rev A MNL-6300-0100.docx 40 of 66...

  • Page 41: Figure 48: Connected Stations Screen

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.4.1 Station Addressing The first step in configuring the stations is locating and addressing the stations. In this step the station number will be allocated to a physical steering station. Follow the steps below: Step 1: Select ‘Station Addressing’...

  • Page 42: Figure 49: Station Setup Screen

    Figure 52: NFU Input Screen 3. Select ‘2 Speed’ if using two speed jog levers such as the Kobelt 7196 jog lever. 4. Select ‘Dual 1 Speed’ if using two separate jog levers for twin independent rudder control.

  • Page 43: Figure 53: Ffu Input Screen

    3. Select ‘Dual Sync FFU’ if the vessel is using independent rudder control. 4. Select ‘Dual Aux FFU’ if using a separate FFU device such as the Kobelt 7176 Walk-about control head. When selecting ‘Dual Aux FFU’ ensure that the FFU stations are within sight of the steering panel.

  • Page 44: Figure 56: Led Strip Enable Screen

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.4.10 LED Strip Style Use this screen to turn off the LED rudder angle indicator (RAI) strip. Default is on. Figure 55: LED Strip Enable Screen 6.1.4.11 Station Backlight Colour The steering station backlight can be either set to;...

  • Page 45: Figure 57: Rudder Setup Menu Structure

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.1.5 Rudder Setup The diagram below is an overview of the rudder configuration menu structure: Figure 57: Rudder Setup Menu Structure 6.1.5.1 Rudder #1 Select ‘Rudder #1’ to configure the virtual end stops. The rudder...

  • Page 46: Calibration

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Selecting the optimal slew rate may be an iterative process. Vessels with fast rudders will work better with low slew rates whereas slow rudders will benefit from having higher valve responsiveness. Dither amplitude is the magnitude of the superimposed signal. If a dither amplitude of 5% is selected, then the super imposed signal will oscillate around the main valve output signal by a max of 2.5%.

  • Page 47: Figure 70:Valve Dead-Band Graph

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.2.1.1.1 Automatic Valve Dead-band Calibration Navigate to the valve dead-band calibration menu in the rudder group of menus and select automatic calibration. The automatic calibration takes 30-60 seconds, and the valve LED indicates which valve is being driven to find the dead-band.

  • Page 48: Tuning

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.2.2 RFU Calibration After the valves have been calibrated move on to calibrating the RFUs. The Port and Starboard end stops should be in place and the RFU travel limit switches wired and tested before RFU calibration is performed.
  • Page 49 Kobelt Steering System Kobelt Manufacturing Co. Ltd. Before allowing access to this menu, a caution message is displayed, acknowledge the inherent risk when modifying Parameters: System tuning should only be performed by qualified personnel. Contact an installation representative to assist as required.

  • Page 50: Set Date And Time

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 6.3.1 Active Menu Overview Figure 61: Active Menu Overview 6.3.2 Set Date and Time The controller uses the internal clock to properly log alarms and events. The time and date will initially need to be set for the desired time zone.

  • Page 51: Figure 62: Set Date/Time Screen

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. button to confirm the change for each digit and go to the next digit, or the BACK button to go back to the previous digit. Figure 62: Set Date/Time Screen 6.3.3 Position Control Parameters This set of parameters determines the system’s response to rudder...

  • Page 52: Figure 63: Toe-In Position

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Fast dead-band parameter only applies to systems that have a two-speed solenoid setup. 6.3.4 Toe-in The steering controller permits offsetting the two rudders by up to +/-5 degrees. Select the ‘Toe-in-out’ parameter from the Setup Position Control menu. Start with a small angle and then increment during sea trials.
  • Page 53 Kobelt Steering System Kobelt Manufacturing Co. Ltd. Do not put the vessel into service until the steering system has been tested. During the sea trials the positional control parameters will be tuned to ensure acceptable responsiveness and accuracy without introducing rudder oscillations.

  • Page 54: Operation

    The controller operates autonomously and therefore has no operator interface. Reference the steering station manual, document number MNL-6300-0200 for instruction on operating the Kobelt digital steering system. Before exiting local control mode, return the rudder to midship and ensure all FFU lever positions are at center.

  • Page 55: Maintenance

    LOCK The Kobelt Steering Controller has a real time clock that will continuously run from an internal battery. The real time clock is used to properly log alarms and events. The clock will need to be checked periodically and corrected if necessary.

  • Page 56: Battery Replacement

    ATTERY EPLACEMENT The Kobelt steering controller has an internal, CR2032 battery on the device. This battery is required for the real time clock to keep track of time when control power has been removed. The battery will require replacement on approximately a yearly basis.

  • Page 57: Update Firmware

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 8. Once the back plate is off and the PCB board is exposed, electrically ground yourself and then simply replace the battery with a new CR2032. Removal of the low battery can be done by levering one end of the battery.

  • Page 58: Usb Port

    Table 17: Recommended Spares RECOMMENDED SPARES ITEM KOBELT PART # Male Network Terminator 6015-1011 Female Network Terminator 6015-1012 CR2032 Coin Battery 9870-0001 To purchase spare parts Contact Kobelt for list of parts numbers available rev A MNL-6300-0100.docx 58 of 66...

  • Page 59: Troubleshooting

    The user must not attempt to repair the unit themselves. It is strongly recommended that any required service work on a Kobelt unit be performed by a factory authorized service representative. Please contact the nearest Kobelt authorized distributor for assistance.

  • Page 60: Figure 67: Rudder Feedback Screen

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. 9.1.2 Rudder Feedback Screen Two Rudder Feedback screens are available to view the RFU output. • Angle – The determined angle from the RFU in degrees. • Norm – The normalized angle (in percent) from the Port to Starboard end stops.

  • Page 61: Figure 71: Controller Health Screen

    9.1.9 KNet IO Status Screen If the Kobelt 6300-0300 I/O Module is connected for interfacing with the 6511-APS10 steering alarm panel, this screen can be used to monitor the state of the inputs and outputs. This screen is available when the External Alarm parameter is enabled.

  • Page 62: Figure 74: I/O Module Status

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Output 2 – Loop Fault. ▪ RFU fault ▪ NFU Fault ▪ SBW Wheel ▪ Valve Current Fault Output 3 – Control System Fault ▪ Over Temperature ▪ Internal Voltage fault ▪ KNet Power Fault ▪...

  • Page 63: Fault Resolution

    Kobelt Steering System Kobelt Manufacturing Co. Ltd. Date and time that the fault cleared, third row. This may have occurred on power up. • A letter to indicate the severity: ’W’ for Warnings ‘C’ for Cautions ’A’ for Alarms •...
  • Page 64 Kobelt Steering System Kobelt Manufacturing Co. Ltd. Station x SBW wheel Input The communication problem Check Wheel connection between the station Failure between the Head and SBW and the wheel. (Loop Failure) wheel Replace drop cable or Y connector. 1. The FFU lever is wire break.

  • Page 65: Warranty

    If any part is found to be defective, Kobelt will replace said part FOB the Kobelt factory provided that any such defective part is returned by the Buyer with freight and applicable forwarding charges prepaid by the Buyer.
  • Page 66 Kobelt Steering System Kobelt Manufacturing Co. Ltd. A: I PPENDIX NSTALLATION IMENSIONS B: P PPENDIX INOUT rev A MNL-6300-0100.docx 66 of 66 Heiko Digitally signed by Heiko Epkens Epkens Date: 2024.10.24 14:53:38 -07'00'...

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