VOYAGE EVENT RECORDER®
VER 3000®
COMMISSIONING
MANUAL
Issue 03a
5TH FEBRUARY 2002
Broadgate Limited, Broadquay House, Orpen Park, Ash Ridge Road, Almondsbury, Bristol
BS32 4QD, United Kingdom.
Telephone: +44 (0) 1454 618585 Fax: +44 (0) 1454 617310 Telex: 94020617 BLG G
Website:
Issue 03a Commercial in ConfidencePage 1
CONTENTS
Preface
Document History and Minor Update Record
1Introductory Notes
Quality Standards
Environmental Standards
Glossary
Commissioning Documentation
2System Commissioning
Signal Processor Unit function
Test Equipment
Commissioning
Configuration Editor
Video Input Level
Microphone Setting Up
VHF Setting Up
3Optional Interfaces
61162 Analogue Interface
Video Buffer
VHF Buffer
61162 Digital Interface
Remote Alarm
4Illustrations
Photographs
5Appendix
5.1Pixel Count
5.2User ID and Password
5.361162 Analogue Interface Commissioning Form
5.4Alarm Sentences
5.5Type Approval Certificate
6Drawings
VER3000 – Overview
VER3000 – Cable terminations
VER3000 – MEE and CPM block diagram
VER3000 – SPU block diagram
Preface
The Broadgate Ltd Voyage Event Recorder (VER) is designed to provide a recording of various operational events in a ship over the previous 12 hours. These include voice, radar information and data in 61162 format. The purpose of these recordings is to be able to analyze the events leading up to a casualty or near miss situation involving the vessel in which the equipment is fitted. In order to facilitate the analysis of the recorded information a Playback Suite is provided at a location ashore.
The following outlines the commissioning of the VER3000 and describes the checks that are required to ensure that the relevant information is recorded correctly.
The Main Electronics Enclosure (MEE) contains all the electronics that processes the data required by IEC specification 61996. The data sources are nine audio channels, sixteen data channels and a video source. Eight of the audio sources are from Microphones and one from the ships VHF. The data channels must conform with IEC 61162 and be RS422 in nature. The video input must consist of three colours (Red, Green and Blue) and each must be 1V peak to peak, positive going. The sync signal can be either a 1V peak to peak negative going composite sync or separate horizontal and vertical negative going TTL level sync.
The Protective Capsule (PC) is the only part of the VER3000 designed to survive a major incident and contains the Crash Protected Memory (CPM). The PC contains enough memory to store more than twelve hours of VER3000 data. The CPM communicates with the MEE via two duplex RS422 links and also receives power from the MEE.
Document History and Minor Update Record
Minor changes to this manual will be instigated by the issue of update pages. These are to be inserted in the manual as indicated with the changes. These changes are to be recorded in the table below.
Issue No. / Date / Pages Affected / Comments / Date Entered in Manual / Entered By01 / 1/12/00 / Initial Issue to DERA (Fraser) Type Approval Authority / N/A / N/A
02 / 14/5/01 / Changes as per CRF 129 / N/A / N/A
03 / 17/08/01 / Changes as per CRF 159 / N/A / N/A
03b / 5/02/02 / 1, 4, 55, 57, 59, 60
1INTRODUCTORY NOTES
1.1Quality Standards
All assembly must meet standards set out in the Broadgate Ltd Procedures and Work Instructions Manual and the outline criteria in the Broadgate Ltd Quality Manual.
1.2Environmental Specification
The equipment supplied will meet all the applicable requirements of IEC specification 60945.
Performance requirements are complied with in meeting IEC Specification 61996.
1.3Glossary of Terms
ARPAAutomatic Radar Plotting Aid
CPMCrash Protected Memory
EMCElectromagnetic Compatibility
HSMHull Stress Monitoring
IDCInline Dual Connector
IECInternational Electronic Commission
IMOInternational Maritime Organisation
MEEMain Electronic Enclosure
PCProtective Capsule
PCBPrinted Circuit Board
PSUPower Supply Unit
RHDDRemovable Hard Disk Drive
SCSISmall Computers System Interface
SPUSignal Processing Unit (PCB)
TIUTransition Interface Unit
VERVoyage Event Recorder
VDRVoyage Data Recorder
1.4Commissioning Documentation
On completion of the Commissioning of the VER3000 the following information is to be forwarded to :-
The Installation and Maintenance Manager,
Broadgate Ltd,
Broadquay House,
Orpen Park,
Almondsbury,
Bristol BS32 4QD
England
The Following Information is to be included :-
1)Ship Configuration File (See section 2.4)
2)Installation Report and Registration Card (See appendix 5.3)
3)61162 Digital Interface Commissioning Forms (See appendix 5.3)
4)61162 Analogue Interface Commissioning Forms (See appendix 5.3)
2SYSTEM COMMISSIONING
2.1Signal Processor Unit Function
The recording process involves the transmission of data packets (2 kilobytes in length) from each of the front-end processors – Audio, Data, Video – to the Control processor. The Control processor then sends each packet to both the CPM and SCSI processors. At this point the CPM and SCSI processors check each packets checksum and indicate to the Control processor whether the checksum is correct or not. The SCSI processor contains two large data buffers, each slightly less than 2 megabytes in size. Each buffer can hold 1008 packets, if the SCSI processor receives a packet with a valid checksum it is inserted into the next available buffer slot in a sequential manner. Similarly, the CPM stores each valid packet in its own buffer, approximately 1.5 gigabytes in size. Both the CPM and SCSI processors reject, that is do not store, packets received with incorrect checksums.
Once a SCSI buffer is full, that is the Control processor has received acknowledgement from the SCSI processor that 1008 packets have been correctly received, the Control processor signals the SCSI processor to write the contents of the buffer to the RHDD. The SCSI processor transfers the data to the RHDD and them immediately reads them back into the same buffer. At this point the SCSI processor requests from the CPM its copy of the packets in its buffer. During this process the other SCSI data buffer is used to receive new packets from the Control processor.
The SCSI processor compares its copy of a packet with that of the CPM on a bit wise basis and records any bits in error. The IEC 61996 specification permits an error rate of 1 bit in 108, if this is exceeded an alarm is activated both visually and audibly. In practice this means that a single bit error in 1008 packets is not sufficient in itself to warrant an alarm, however, 2 bits in error is an alarm condition. The SCSI processor checks every bit in each of the 1008 packets of the current buffer until either 2 bits have been found in error or the entire buffer has been checked. The result of this operation is then saved and reported back to the Control Processor immediately prior to the next buffer save. The Control Processor accumulates these buffer errors and if the specified bit error rate is exceeded, an alarm is raised.
2.2Test Equipment
The following test equipment is required during the commissioning: -
IBM compatible computer, 500 Mhz Pentium or better, 64Mhz Ram or better, a stereo sound card, capable of 1024 x 768 or better, running Windows 98 2nd Edition or NT.
9 way D female to male straight through serial connector lead.
100 MHz Oscilloscope
Digital Multimeter
Stereo Headphones with 3.5mm jack or suitable Speakers
61162 Analogue Programmer
RS485 to RS232 Converter
2.3Commissioning
2.3.1Pre-Commissioning Check
Ensure that the installation conforms to the Broadgate VER3000® Installation Manual.
Remove front cover from the MEE and pull out Tamper Switch on the inside top of the MEE to disable the alarm.
Refer to the Broadgate VER3000® Operation & Shipboard Maintenance Manual for the Control Functions and Operation of the unit.
On the SPU set links to suit incoming radar sync as follows
CN6 link 1 to 2 for combined sync, 2 to 3 for separate H & V sync.
CN1 link 1 to 2 for analogue sync, 2 to 3 for digital sync
Connect the computer RS232 serial port using a serial connector lead to PL5 on the SPU board. PL5 is the install/debug port located bottom centre of the SPU board.
On your computer run the VER3000 Terminal Mode program.
Open ‘File’
Select ‘Connect’
Switch on the VER3000® and let it go into Record Mode – refer to Operation & Maintenance Manual section 2.2 for LCD screen displayed information.
2.3.2Computer Display
The following screen will now be displayed on the computer, refreshed every second.
(Example Only)
Clk: 0000011A
Time in seconds elapsed since last reset. Example shows 282 seconds or 4.7 minutes since last reset in hexadecimal.
TotalErr: 00000000
Accumulated number of buffer errors. These are the bit errors between the SCSI processor’s and CPM processor’s copies of the data packets. This figure is updated each time a buffer is saved, that is when the HDD is accessed every 2 minute.
All zeros indicate no bit error detected
The eight bit total error code is divided into two sections of four, known as nibbles. Only the right hand digit of each nibble will change
Top NibbleBottom Nibble
0 0 0 00 0 0 0
Top Nibble
8-No response from CPM
4-SCSI and CPM Packets out of sync
2-Bad checksum from CPM microprocessor
1-Bad checksum from SCSI/HDD microprocessor
0-No errors detected
Bottom Nibble
8 -SCSI (Bad checksum)
4-BNEC (Bad Not Error Corrected)
2-BECC (Bad but Error Corrected)
1-RVOK (Returned Value OK)
0-No error detected
Example: TotalErr: 00090004
Means No response from CPM and Bad checksum from SCSI/HDD microprocessor and Bad Not Error Corrected.
LastErr: 00000000
The time in (hex) seconds when the last buffer error occurred. This is expressed relative to the commencement of recording.
BufPkts: 000000D6
A decrementing count of the number of packets until the current SCSI buffer is filled. Each SCSI buffer can hold 1008 packets (3F0 in hexadecimal). This counter therefore starts from 3F0 and decrements as packets are written into the current SCSI buffer. When zero is reached TotalErr is updated with the error count from the previous SCSI/CPM comparison and the current buffer is then transferred to disk and checked against the CPM copy.
DiskFail: 00000000
The eight digits of this field contain two separate measures – the rightmost four digits are a count of the number of retries which have been required during SCSI disk transfers. The leftmost four digits count the number of times an invalid write position has been read from the SCSI disk. The SCSI processor writes sequential blocks onto the hard disk and also records the position of the last block written, subsequent writes starting from this point. In case an error is encountered on reading the write position from the disk the SCSI processor maintains a copy of the write position in memory. Should the disk and memory copy differ this counter is incremented and the SCSI processor corrects the write position from its memory copy.
BadBytes
Each front-end processor (Audio, Data, Video) sends a 4 byte STOR (store) command followed by a 2048 byte data packet. If the Control does not receive a STOR command every 2052 bytes from a given processor the relevant processor’s Badbyte count is incremented until a STOR command is received. This provides a check that the front-end and Control processors are in sync with each other.
Audio – Packets received from the audio processor since last reset
Data - Packets received from the data processor since last reset
Video - Packets received from the video processor since last reset
Total – Total number of packets received from the three processors since last reset
CPM+/SCSI+
The number of valid packets received by the CPM and SCSI processors for each front-end processor. A valid packet is defined as a packet with correct checksum. These packets are stored by the CPM and SCSI processors.
CPM-/SCSI-
The number of invalid packets received by the CPM and SCSI processors for each front-end processor. An invalid packet is defined as a packet with an incorrect checksum. These packets are not stored by the CPM and SCSI processors.
Undefined 00000000
A count of the packets that are not of a recognized type. Each packet contains a 12 byte header in which a packet type is indicated – Audio, Data or Video. Should a packet be transmitted that is not of one of these types the Undefined count is incremented. This counter provides an indication that the front-end processors are transmitting genuine data.
2.3.2LCD Display
First Line
Status: OK - VER3000® is not in alarm
* Indicates that the system is recording. It will step 6 places left to right
or
(example)
First Line
Status: Alarm - VER3000® is in alarm
Second Line
Displays letter denoting which alarm is activated
2.3.3Alarm Codes
Any combination of the following Alarm Codes can be displayed on the computer screen and the LCD display: -
A -Audio Processor not responding to Control processor commands
D -Data Processor not responding to Control processor commands
V -Video Processor not responding to Control processor commands
C -CPM Processor not responding to Control processor commands
S -SCSI Processor not responding to Control processor commands
B -Buffer error detected between RHDD Buffer and CPM memory
X -SCSI Checksum error - failure of Buffer RAM
P -24 V IN power failure - Running in battery mode
T - Tamper switch activated
R -Retry to Hard Disk - RHDD not responding to attempt to download (RHDD could be removed or key switch not made)
M** -Indicates which microphone(s) has failed. See below.
In the above example the LCD is indicating an audio processor failure (A), a SCSI processor failure (S), a buffer error (B) and a failure in the microphone system (M).
Microphone Alarm Indication
The microphone alarm indication is on the LCD display and is in the form ‘M = **’, where **indicates which microphones are in alarm, as per the following table.
The least significant digit indicates microphones 1 to 4 and the most signification digit indicates microphones 5 to 8, both count in the hexadecimal format.
Note ‘M = 00’ is never displayed.
M = * *
Indication
/ Faulty Microphone /Indication
/Faulty Microphone
0 / No fault / 0 / No Fault1 / 5 / 1 / 1
2 / 6 / 2 / 2
3 / 5 and 6 / 3 / 1 and 2
4 / 7 / 4 / 3
5 / 5 and 7 / 5 / 1 and 3
6 / 6 and 7 / 6 / 2 and 3
7 / 5, 6 and 7 / 7 / 1, 2 and 3
8 / 8 / 8 / 4
9 / 5 and 8 / 9 / 1 and 4
A / 6 and 8 / A / 2 and 4
B / 5, 6 and 8 / B / 1, 2 and 4
C / 7 and 8 / C / 3 and 4
D / 5, 7 and 8 / D / 1, 3 and 4
E / 6, 7 and 8 / E / 2, 3 and 4
F / 5, 6, 7 and 8 / F / 1, 2, 3 and 4
2.3.4LCD and Computer Menu
When running in record mode, the buttons have no function or effect, when pressed.
The menu system can only be accessed at switch on while the VER3000® is booting up.
On switch on the following will be displayed: -
CPxx is the software version number.
If no button is pressed within five seconds, the VER3000® will automatically go into Record mode.
Record – Manually starts recording (normally only used when exiting Set Up or Test menu).
Setup – Enters Setup Menu (VER3000® does not record when in this mode)
Test –Enters Test Menu (VER3000® does not record when in this mode)
Setup Menu
Video – Enters Video Setup menu
Clock – Enters Clock Setup menu
Info – Shows software version and last date Setup menu was updated
Quit – Returns to previous LCD display and will automatically start recording after three seconds, if no button pressed.
Video Setup Menu
Hratio - Allows the installer to enter the number of pixels for the type of
Radar being recorded from. Default setting will be 1024 pixels.
Sync -Allows the installer to select positive or negative sync polarity
Quit -Returns to previous LCD display
Hratio Setup Menu
> Moves to the next menu level
< Returns to previous menu level > Moves to the next menu level
Note: The Total Horizontal Pixel can also be set up in the Installers Configuration File on the computer
Sync Setup Menu
Press appropriate button to change polarity to suit incoming Sync signals
- Enters next display
Save – Saves Sync Setup configuration and returns to Video Setup menu
Cancel – Returns to Video Setup menu without saving
Note: The sync polarity can also be set up in the Configuration File on the computer.
Clock Setup Menu
Press appropriate button to select nearest 4 year increment, then press ‘’ to enter next menu option
Press appropriate button to select nearest 4 week increment, then press ‘’ to enter next menu option
Press appropriate button to select correct date, then press ‘’ to enter next menu option
Press appropriate button to select correct hour, then press ‘’ to enter next menu option
Press appropriate button to select correct next minute and press ‘Done’ to enter next menu option
Set – Updates time as selected
Cancel – Exits from Clock menu without updating time
Both of these options return you to the main LCD menu and will automatically start recording after three seconds, if no button pressed.
Test Menu
SCSI –Once entered, automatically commences downloading of recorded data via serial lead to computer.
MIC - Enters a microphone test menu which sends a tone every 3 seconds as an aid to testing microphones.
VIDEO - Enters the Video test menu. Allows testing of video levels and signal to Noise (SNR) levels. This test menu is for the use of by the Software Engineer but can be of help to the Commissioning Engineer in determining whether the SPU is recording radar or not.
SCSI Test
** - Will be the number of packets of data transferred and the time in seconds.