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Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation, use or maintenance of the equipment. Disclaimer Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly stated, but does not accept liability for any errors or omissions. Support information If you require maintenance or repair, contact Kongsberg Maritime’s...
Installing the SCU......................14 Installing the transducer....................14 CABLING ................15 Cable plan ........................16 List of cables ........................17 Installing the ACS500 cables...................17 OPERATING PROCEDURES ............. 18 Opening the cable drum ....................19 Closing the cable drum ....................20 Turning on the SCU ......................21 Turning on the ACU ......................22 Starting normal operation ....................23...
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Case 5: Executing a function when a valve function is still active ...62 Disarm Simulation and test......................63 Connecting the test equipment ................63 Testing the transducers ...................65 Testing the system ....................65 Testing ACS500 in APOS ..................66 SPARE PARTS ................ 68 Ordering spare parts......................69 937128/F...
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Instruction Manual ACU spare part ........................69 ACU panel computer spare part..................69 ACU battery spare part ....................70 TDD30V Spare part ......................70 TDD303 Spare part ......................70 TDD180 Spare part ......................71 SCU complete unit spare part ..................71 SCU battery spare part .....................71 SCU spare part kit for top cap..................71 SCU top cap spare part ....................72 SCU bracket spare part ....................72 SCU serial line cable spare part ..................72...
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ACS500 SECTION 6: Accidental release measures..............96 SECTION 7: Handling and storage .................96 SECTION 8: Exposure control and personal protection ..........97 SECTION 9: Physical and chemical properties ..............97 SECTION 10: Stability and reactivity................97 SECTION 11: Toxicological information ...............98 SECTION 12: Ecological information ................98 SECTION 13: Disposal considerations ................98...
Target audience This manual is intended for all users of the system. Online information All relevant end-user documentation provided for your ACS500 system can be downloaded from our website. https://www.kongsberg.com/maritime Registered trademarks Observe the registered trademarks that apply.
ACS500 System description ACS500 is designed for optimal control of subsea valves. It is pressure rated to 4000 metres depth. ACS500 may be used to control a blowout preventer as an emergency system or other subsea valve control functions. 937128/F...
ACS500 Instruction Manual System diagram The system diagram identifies the main components of a basic ACS500 system. Only the main connections between the units are shown. Detailed interface capabilities and power cables are not shown. Dunking transducer Acoustic Command Unit...
ACS500 System units Acoustic Command Unit The ACU is a computer with a touch screen in a splash proof portable case. This is the main interaction unit of the system. It has a rechargeable battery with approximately 10 hours continuous operation on a fully charged battery.
Support information Should you need technical support for your ACS500 system you must contact a Kongsberg Maritime office. A list of all our offices is provided on our website. You can also contact our main support office in Norway. Manuals and technical information can be downloaded from our support website.
ACS500 Instruction Manual Installing the SCU The SCU is delivered on a mounting bracket. Prerequisites You need 4 M12 bolts with nuts and spring washers, appropriate for the subsea structure where you are hanging up the bracket. Procedure Mount the bracket onto the subsea structure by the hooks behind the SCUs.
ACS500 Instruction Manual Cable plan The cables are part of the delivery with the main units. Dunking transducer Acoustic Command Unit Subsea Control Unit Transducer Customer solenoid package External quad battery unit Field simulator 937128/F...
For deck testing, using HiPAP transducer From SCU to customer’s solenoid package Installing the ACS500 cables All cables are provided in the delivery or with the relevant item. Procedure Connect the cable from the transducer to the SCU. (C2, C3) Connect the cable from the quad battery to the SCU.
Checking the communication, page 26 Checking the system status, page 27 Checking the sensor input, page 27 Checking the current software version, page 27 Emergency sequence, page 28 Enable Auto Shutdown, page 29 Operating ACS500 from APOS, page 30 937128/F...
Operating procedures Opening the cable drum Context Closed locking clip Bars Closed locking clip Cover plate Cable from dunking transducer to ACU, 1.5 m long Handle Drum lock Procedure Pull the locking clip towards you to open the unit. Unlock the transducer cable by pulling the drum lock slightly out.
ACS500 Instruction Manual Closing the cable drum Context Closed locking clip Bars Closed locking clip Cover plate Cable from dunking transducer to ACU, 1.5 m long Handle Drum lock Procedure Roll up the cable and place it under the cover Pull inn the dunking transducer.
Operating procedures Turning on the SCU The batteries are delivered separate from the SCU for safety reasons. Context The battery must be inserted and connected before deploying the SCU. Procedure Pull out the locking cord. ( Open the top cap. The two M5 screws between the units can be used to push open the top cap.
ACS500 Instruction Manual Switch the on/off switch inside the top to on. Replace the top. Make sure the alignment marks meet. Insert the locking cord by pushing it sideways around the body. Further requirements Perform a watertightness test. Testing the watertightness, page 46 Turning on the ACU The Acoustic Control Unit is the topside computer for the system.
Operating procedures Starting normal operation Prerequisites The subsea part of the system is started and operating. Procedure Place the ACU in a suitable location. Turn on the ACU. Turning on the ACU, page 22 Place the cable drum with the dunking transducer close to the ACU. Opening the cable drum, page 19 Pull out the cable and lower the transducer to a depth at least 10 metres below the lowest draft of the platform or vessel.
ACS500 Instruction Manual The LED lights green for a fully charged battery, orange for half full and red when the battery is almost empty. Checking the battery status on the SCU Check the battery level to see if the unit needs recharging or new batteries.
Operating procedures Setting the telemetry power for the ACU You should always try the default setting before changing the power level. Context When you increase the power level, always increase one step at a time before sending a command to the SCU. Caution When you are using the Maximum power level, the dunking transducer must be connected and deployed to minimize risk for electronic and transducer damage.
ACS500 Instruction Manual Changing the acoustic mode Change between FSK and Cymbal acoustic mode. One or the other might work better under different acoustic conditions. Procedure Select the tab. System Configuration Select the SCU you want to change in the section.
Operating procedures Checking the system status Always try to read the battery status as a check before starting any valve operations. Procedure Turn on the ACU. Select the tab with the SCU you want to use. in the section. Read System Status Checking the sensor input Always try to read the battery status as a check before starting any valve operations.
ACS500 Instruction Manual Wait for the dialog box with all the relevant software versions from both the ACU and the selected SCU. Emergency sequence The emergency sequence is a redundancy operator function for emergencies. There is a predefined sequence of valves that are closed with a two hands two buttons operation.
Operating procedures Enable Auto Shutdown The Auto Shutdown system is a predefined automated shutdown sequence. When the ASHD inputs are triggered, the system will execute a predefined sequence of valves designed to automatically shut down the controlled system or BOP. Prerequisites The Auto Shutdown must be predefined in the system.
ACS can be controlled both from the ACU and APOS. Procedure Start APOS. Select in the main menu. Control Select ACS500 The ACS500 program is the same as on the ACU. Notice The two hand operation is clicking Execute and pressing F2. Select to close the session. Finished 937128/F...
ACS500 Instruction Manual Acoustic Command Unit The ACU is a computer with a touch screen in a splash proof portable case. Serial line connector for service personnel only Dunking transducer connector USB and LAN connectors for service personnel only ON/OFF switch...
User interface Charger connector Springs Battery charger cable is stored in the folder Battery level Execute button Exit button This will only turn off the computer, the hardware will still drain the battery. Use button to power off the system. Online help button User interface familiarization Main menu...
ACS500 Instruction Manual Main menu menu is located at the top of the presentation. Main Description • SCU tab The SCU tabs have the operational functions for the two subsea control units. SCU tab description, page 34 • Operation Log tab All commands and replies are logged here.
User interface Battery Status Select to check the battery of the current SCU. Read Sensor Input The status of the sensors in your system. Valves view This is an overview of all the valve applications and their status. Auto shutdown status description The Auto Shutdown system is a predefined automated shutdown sequence.
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ACS500 Instruction Manual Description is an optional function that has to be activated. The conditions for starting Auto Shutdown an auto shutdown is defined in the registration form. When these conditions are met, the system starts moving the valves in a predefined sequence to close down the system. The function has to be activated as well as predefined.
User interface Operation Log tab description All commands and replies are logged here. The log is common for both SCUs. How to open Select the tab. Operation Log Description The operation log shows the last 500 operations for both SCUs. All operations are saved to disk, so even if many more operations have been done, there is still a log.
Maintenance Charging the ACU Charging the battery is connected with some risk, please read the information and follow the charge procedure carefully Context The charger cable is stored in the folder Procedure Place the ACU near a standard power socket. Get the charger cable from the folder Connect the charger cable to connector and to a power socket.
ACS500 Instruction Manual Changing the ACU battery The rechargeable battery needs to be replaced typically every 10 years. This depends on use. Procedure Open the suitcase. Take off the supports on both sides of the lid by unscrewing one screw on each side.
Insert the new battery. Follow the instructions in the reverse order. Replacing the panel computer The panel pc must be replaced with a Kongsberg model with the ACS500 program installed. Context This procedure describes how to replace the panel pc.
ACS500 Instruction Manual Insert the new USB rollerball cable in the strain relief. Make sure the metal clamp for the earthing is fitted inside the strain relief ( Insert the cable strain relief and tighten the nut. Insert the plug ( Insert the new panel computer and fasten it with the 4 screws.
Maintenance Make sure that the protective cap is connected to the drum and is fitted to the surface connector when the unit is not in use. Put a few drops of oil on the drum and roller bearings, around the winding handle and on the break screw thread.
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ACS500 Instruction Manual Note Read the lithium batteries safety procedure before handling batteries. Do not connect the + and – electrodes on the batteries with metal or wire.. Procedure Pull out the locking cord. ( Open the top cap. The two M5 screws between the units can be used to push open the top cap. Insert the screws in the holes on the top cap and screw until the cap is off.
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Maintenance Switch the on/off switch inside the top to on. Replace the top. Make sure the alignment marks meet. Insert the locking cord by pushing it sideways around the body. 937128/F...
ACS500 Instruction Manual Testing the watertightness This procedure describes using our interseal test kit. The same principles can be used for other tests. Context Inlet for reservoir (not used) Outlet port (connect to Digital pressure indicator) Volume adjuster Limit adjuster...
Maintenance Verify that the O-rings on the fittings are lubricated properly. Connect the flexible pipe between the interseal test kit and the unit to be tested. Start the Digital pressure indicator by pressing the power on button 10 If the pressure unit is not Bar, see the Digital pressure indicator manual to change it.
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Select the tab. System Configuration 10 Select Replace SCU 11 Type the code received from Kongsberg Maritime. 12 Select 13 Select the SCU you are about to replace. 14 Select communication port. This is normally COM 1. 15 Select report location.
Status messages 18 Select to get the Duplication report. View 19 Email the Duplication report to Kongsberg Maritime Customer Support. 20 Select 21 Remove the serial line cable. 22 Connect all cables. Result The new SCU is ready for operation.
ACS500 Instruction Manual If the unit is not to be dismounted from the valve package before performing maintenance, erect a protective cover over the unit to prevent water and dirt coming inside the unit when the lid is opened. Unscrew the 6 screws from the top cap.
Maintenance System status • Unknown – Read System status. • OK – Normal operation • Telemetry failed – The last telemetry command was not confirmed OK from the SCU. Check the connection to the transducer and repeat the telemetry function. •...
ACS500 Instruction Manual When a battery has less than 20 % capacity, there is a yellow background in the value. When a battery has less than 10 % capacity, there is a red background in the value. Try to operate the other SCU.
Maintenance • ARMED, System shows BOP is ARMED – Check if this is the expected status for the BOP. • DISARMED, System shows BOP is DISARMED – Check if this is the expected status for the BOP. Battery status • When a battery has less than 20 % capacity, there is a yellow background in the value. When a battery has less than 10 % capacity, there is a red background in the value.
ACS500 Instruction Manual More status This group of functions is used to show an overview over the status (active/passive) of all digital readbacks. Check real time clock values. Check last executed solenoid current and possible leakage value. SCU environment gives the current temperature and humidity inside the SCU unit.
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Maintenance Message Description Action confirmation from the SCU. Valve operation executed OK, correct readback status confirmed. Solenoid current measurement within defined limits. Failed Valve operation may Check details including be executed correctly. current values in More Readback status received is Status.
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ACS500 Instruction Manual Message Description Action Timeout-Force? When starting up a Proceed with ACU Execute command and not receiving message by pressing the acoustic confirmation from Execute buttons for 5 SCU then we get a Timeout seconds. Alternatively, warning. repeat the complete function.
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Maintenance Message Description Action Timeout General message when Try to read System Status no final confirmation of a in More Status. Changes in valve operation is received the SCU/BOP status? from the SCU. The Red background colour occurs when Status: VALVE ERROR.
ACS500 Instruction Manual Message Description Action Current leakage Try to read leakage value Caution in More Status. Check Fatal Error detected. SCU other valve functions will not execute the valve and/or the other SCU Unit. function due to current Service/exchange of Unit leakage in the system.
Maintenance Valve 1 is the first function that has been executed correctly with an OK readback and current measurement status. Valve 2 is executed OK, but readback sensor does not confirm OK. Valve status after execution, is sensor OK? Valve 3 and Valve 4 is executed OK, but current readback value is not within specified window, showing either a Low or High current warning.
ACS500 Instruction Manual Case 3: Getting no status reply after execution of a valve In this figure we are waiting for a missing status reply from the SCU, giving a warning: "Timeout-Force?. Note In a critical operational phase we may still try to execute the function (in Cymbal only, regarding timeout window setup values), without receiving any status read back info from the valve/SCU.
Maintenance Case 4: Trying to activate the function twice This figure illustrates the case were we try to execute ARM when the valve readback sensor indicates that the valve package is already armed. This is only a yellow warning. Press and tap both execute buttons for 5 seconds in order to perform the function. 937128/F...
ACS500 Instruction Manual Case 5: Executing a function when a valve function Disarm is still active Executing a Disarm function when a valve function is still active after Disarm. In this figure a possible critical error situation has occurred, giving status "VALVE ERROR".
Maintenance Simulation and test Connecting the test equipment The simulator can be connected directly to the SCU or via the dunking transducer. Directly to the SCU is the preferred method. Context Connecting via the dunking transducer is not preferred. The transducer is not made to function in air.
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ACS500 Instruction Manual Procedure For testing the complete system in air, place the dunking transducer close to the transducer and connect the cable C1 from the dunking transducer to the ACU. For testing without the transducers, connect the test cable C6 from the ACU to the SCU and the field simulator test cable C7 from the simulator to the y-split cable C10.
Checking the battery status on the SCU, page 24 Further requirements Testing the system, page 65 Testing ACS500 in APOS, page 66 Testing the system Test the rest of the Acoustic Control System with a cabled connection to the SCU.
15 Remove cable C7 between the field simulator and the y-split cable. 16 Connect y-split cable C10 to the proper system. 17 Repeat all test with the proper solenoids connected. Testing ACS500 in APOS Testing the system is also possible using APOS and HiPAP. Context Systems with dynamic switches can read the valve status when the solenoid function has been carried out.
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Maintenance When the green LED for the valve operation lights up on the simulator (this might take some minutes), wait for a second or two, then 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.
Spare parts Ordering spare parts To make the order process as short and efficient as possible, you must provide accurate information about the product, the part you need, and yourself. The following information must be provided with your order: • Part name and/or description •...
ACS500 Instruction Manual ACU battery spare part The Acoustic Control Unit is the topside computer for the system. • : ACU battery spare part Part name • : 460655 Part number TDD30V Spare part The dunking transducer is the part that is lowered into the water to send signals down to the subsea part of the system and retrieve signals back.
Spare parts TDD180 Spare part The dunking transducer is the part that is lowered into the water to send signals down to the subsea part of the system and retrieve signals back. • : TDD180 Spare part Part name • : 320822 Part number SCU complete unit spare part...
ACS500 Instruction Manual • : SCU spare part kit for top cap Part name • : 341594 Part number SCU top cap spare part The subsea control unit is mounted on the subsea structure. • : SCU top cap spare part Part name •...
Spare parts SCU external quad battery unit spare part • : SCU external quad battery unit spare part Part name • : 347007 Part number TDR180 34GT Spare part • : TDR180 34GT Spare part Part name • : 336616 Part number TDR30V 34GT Spare part •...
ACS500 Instruction Manual Performance specifications These performance specifications summarize the main functional and operational characteristics of the system. Subsea Control Unit • : 4000 m Depth rating • : 23.6–27.6 kHz Operating frequency • : M53/M54 Wake up codes, Cymbal •...
4000 metres. The ACS500 communication system consists of a modem implemented in both the ACU surface unit and the SCU subsea unit. An acoustic telegram is sent from the ship/rig. The signal is received by one of the subsea transducers depending on which SCU the operator has addressed.
ACS500 Instruction Manual Weights and outline dimensions These weights and outline dimension characteristics summarize the physical properties of the system. Acoustic Command Unit • Outline dimensions – : 386 mm Depth – : 488 mm Width – : 185 mm Height •...
Diameter – : 947.5 mm Height • : 165 kg Weight Power specifications These power characteristics summarize the supply power requirements for the ACS500 system. Acoustic Command Unit • : 100-240 VAC, 50/60 Hz Voltage requirement • : 10-18 VAC Operating voltage •...
ACS500 Instruction Manual Environmental specifications These environmental specifications summarize the temperature and humidity requirements for the ACS500 Acoustic Control System. Acoustic Command Unit • : -5 to 55 °C Operating temperature • : -30 to 70 °C Storage temperature •...
Battery safety SECTION 1: Identification The specification describes the technical parameters for the xxx. The ACS500 contains a custom made Li-Ion xxx. • : L14.4 (48) SCU battery Battery name • : 319554 Part number • : Kongsberg Maritime AS Manufacturer •...
ACS500 Instruction Manual • Water ingress: Internal pressure, thermal runway and chemical reactions may be the consequence. The SCU is fitted with a pressure relief valve. The relief valve prevents overpressure. Noxious gases and ingredients will then leak out of the SCU until the chemical reactions have stopped.
Battery safety SECTION 4: First aid measures The battery will release toxic fumes if burned or exposed to fire. If subjected to gas from a burning battery, remove the source of contamination or move yourself and any victims to fresh air. Seek medical advice. •...
ACS500 Instruction Manual SECTION 6: Accidental release measures During normal operation, accidental release measures are not applicable. Extreme mechanical abuse to the battery may result in a ruptured seal and exposure. As an immediate precautionary measure, isolate the spill or leak area at least 25 metres (75 feet) in all directions.
Battery safety SECTION 8: Exposure control and personal protection Airborne exposures to hazardous substances are not expected when the battery is used for its intended purpose. No protection (respiratory, skin and/or eye) is then required. If the battery is damaged, and you are exposed to the chemicals inside, proper personal protection is required.
ACS500 Instruction Manual Do not open, dissemble, crush or burn the battery. Do not expose the battery to water, sea water or other high-conductivity liquids. Avoid mechanical or electrical abuse. Do not expose the battery to temperatures outside the range of -40 °C to +80 °C.
Battery safety SECTION 14: Transport information Transportation must be performed in accordance with rules and regulations stated for transportation of dangerous goods in the applicable countries. : UN 38.3 Certification Transport identification codes: • Aircraft: IATA DGR • Sea transport: IMDG •...
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ACS500 Instruction Manual Index about description document downloads ........7 Main menu..........34 online information ........7 Operation Log tab........37 purpose of this manual ........7 SCU tab ........... 34 registered trademarks........7 system ............9 target audience ..........7 System configuration tab .......
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Index support offices ..........12 outline dimensions how to technical specifications........78 charge the battery ........39 outline dimensions drawing install the SCU ........... 14 computer ..........85 replace the computer ........41 transducer ..........83–84 turn on ............. 21 overview humidity computer ..........
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