Rutter VDR-100G3 User manual

VDR-100G3/G3S Installation Manual
RUT-TD-10-001, Rev.1.4
Rutter Technologies Inc
70 Brookfield Road
St. John’s, NL Canada
A1E 3T9
Tel: [phone]
Fax: [phone]
www.ruttertech.com

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Rutter Technologies Inc
VDR-100G3/G3S Installation Manual
RUT-TD-10-001, Rev. 1.4
Revision Issue Date: 15 January 2009
© Copyright Rutter Technologies Inc, 2009
All rights reserved. This document contains CONFIDENTIAL information that is PROPRIETARY to Rutter Technologies
Incorporated. This commercially sensitive information is being provided to the recipient solely for the purpose specified
and shall not be reproduced, disclosed or supplied, in whole or in part, to any other person without the prior written
consent of Rutter Technologies Inc.
Although every precaution has been taken in the preparation of this manual, Rutter Technologies Inc assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of information
contained herein.

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Amendment Record
The details of any amendment made to this documentation should be recorded in the table below.
These details should include the signature of the person responsible for inserting the latest
amendment.
Description Date Inserted Initials/Sig.
Release Version 1.1 June 10, 2008 WK
Release Version 1.2 October 08, 2008 WK
Release Version 1.3 December 05, 2008 WK
Release Version 1.4 January 15, 2009 KK/WK
VDR-100G3/G3S Installation Manual 15/01/2009
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Safety Precautions and Warnings
High Voltage Warning! High voltages are present in the Voyage Data Recorder. Only Rutter
Technologies Certified Technicians should undertake work on the VDR-100G3/G3S.
GENERAL
Only a Rutter Technologies Inc. Certified Technician should access the interior components of
the VDR-100G3/G3S equipment.
To ensure compliance with the IMO standards, installation of the VDR-100G3/G3S must be
performed by a Rutter Technologies Inc. approved installation technician.
The following precautions and warnings are general safety measures that personnel should
understand and apply during installation, operation, and maintenance of all VDR-100G3/G3S
system equipment.
Wear proper safety attire and use the proper equipment while handling the VDR during transport
and installation.
GROUNDING
All cable shields must be grounded to avoid interference from AC wiring, fluorescent lights, or
other high magnetic or RF fields.
NMEA data cables should be grounded at the source. All other cables should be grounded at
both ends. The equipment in the VDR-100G3/G3S Data Processing Unit (DPU) and Data
Acquisition Unit (DAU) is grounded to the rack. All other peripheral equipment should be
grounded.
CABLING
The cable sizes and types recommended for use with the VDR-100G3/G3S must be utilized to
ensure its proper operation.
POWER SUPPLY
Prior to connecting the power supply of the VDR-100G3/G3S to the emergency ship power,
ensure the emergency ship power breaker is switched off. Always shut down the system and turn
off the power before removing or installing any equipment.
LIFTING
Some VDR components are heavy; ensure you carry out proper lifting procedures while changing
or transporting components.
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Electrostatic Discharge
Digital devices are susceptible to damage from electrostatic discharge (ESD); certain precautions
must be taken when handling circuit cards, integrated circuits (ICs), and other sensitive devices.
The maintenance technician should conform to the following guidelines when handling ESD
sensitive devices:
1. Always wear a static protection wristband prior to contact with any electrostatic
sensitive device;
2. Ensure that the wristband cable clip is firmly attached to a grounding point;
3. Keep all sensitive components in their protective pouches until required.
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List of Abbreviations
The following abbreviations may be in common use throughout this document:
ADPCM – Adaptive Differential Pulse-Code Modulation
AIS – Automatic Identification Systems
BNC – Bayonet Neil-Concelman (or sometimes British Naval Connector)
CD-ROM – Compact Disc-Read Only Memory
COTS – Commercial Off-the-Shelf
CPU – Central Processing Unit
dB – Decibels
DAU – Data Acquisition Unit
DMM – Data Management Module
DPU – Data Processing Unit
ECDIS – Electronic Chart Display and Information System
ECS – Electronic Chart System
EPIRB – Emergency Positioning Indicating Radio Beacon
FRM – Final Recording Medium
g – Grams
GB – Gigabyte
GMT – Greenwich Mean Time
GPS – Geographical Positioning System
HBS – Horizontal Back Sync
HVR – Hardened Voyage Recorder
Hz - Hertz
IBS – Integrated Bridge System
IDEA – International Data Encryption Algorithm
IEC – International Electrotechnical Commission
IMO – International Maritime Organization
kg – Kilogram
LCD – Liquid Crystal Display
LED – Light Emitting Diode
m – Metres
mA – milliamps
MB – Megabyte
mm – Millimetres
MMSI – Maritime Mobile Service Identity
NMEA – National Marine Electronics Association
OAU – Operation & Alarm Unit
O/S – Operating System
oz – Ounces
PC – Personal Computer
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PMC – Protective Memory Capsule
QA – Quality Assurance
RGB – Red, Green, Blue
RMS – Root-Mean-Square
RPM – Revolutions Per Minute
ROV – Remotely Operated Vehicle
RSM – Remote Storage Module
SFRM – Simplified Final Recording Medium
SOLAS – International Convention for the Safety of Life at Sea
STP – Shielded Twisted Pair
SVDR – Simplified Voyage Data Recorder
TCP/IP – Transmission Control Protocol/Internet Protocol
TJB – Terminal Junction Box
UHF – Ultra High Frequency
UPS – Uninterruptible Power Supply
UTC – Coordinated universal Time
V – Volts
Vac – Volts AC
VDC – Volts DC
VDR – Voyage Data Recorder
VHF – Very High Frequency
Specifications
IEC 61996:1999 Ship borne Voyage Data Recorder – Performance requirements – methods of
testing and required test results.
IEC 60945:1996 Maritime navigation and radio communication equipment and systems – General
requirements – methods of testing and required results
IEC 61162 Maritime navigation and radio communication equipment and systems – Digital
interfaces
IEC 61996-2 Shipborne voyage data recorder (VDR) - Part 2:- Simplified voyage data recorder
(S-VDR) Performance requirements - methods of testing and required test results
Dimensions
Dimensions in this document are shown in mm (millimeters) unless otherwise stated.
Software Note!
Software procedures in this manual are based upon a PC running a Windows XP operating
system. There may be minor differences depending on the operating system and configuration in
use on the Client PC.
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VDR-100G3/G3S Installation Manual 15/01/2009
RUT-TD-10-001 Rev. 1.4 V
Rutter VDR-100G3/G3S Installation Manual
Table of Contents
Chapter 1: System Overview, Rev. 1.1 – page 1-1
Chapter 2: Technical Specifications, Rev. 1.1 – page 2-1
Chapter 3: Installation Planning, Rev. 1.1 – page 3-1
Chapter 4: Data Processing Unit, Rev. 1.2 – page 4-1
Chapter 5: Data Acquisition Unit, , Rev. 1.1 – page 5-1
Chapter 6: Initial Power-up, Rev. 1.1 – page 6-1
Chapter 7: VDR Record Operating Instructions, Rev. 1.1 – page 7-1
Chapter 8: Audio Module, Rev. 1.1 – page 8-1
Chapter 9: Video Module, Rev. 1.2 – page 9-1
Chapter 10: NMEA Module, Rev. 1.3 – page 10-1
Chapter 11: Operation & Alarm Unit Test & User Guide, Rev. 1.1 – page11-1
Chapter 12: Final Recording Medium Setup, Rev. 1.5 – page 12-1
Chapter 13: Remote Storage Module (Optional) and USB Memory Stick
Rev. 1.1 – page 13-1
Chapter 14: General and Corrective Maintenance, Rev. 1.2 – page 14-1
Appendix 1: Installation Checklist, Rev. 1.2
Appendix 2: System Configuration File, Rev. 1.1
Appendix 3: VDRPARAMS.INI File, Rev. 1.2
Appendix 4: Data Retrieval, Rev. 1.1
Appendix 5: Playback Software, Rev. 1.1
Appendix 6: External Interface Modules, Rev. 1.1
Appendix 7: Approved Drawings, Rev. 1.3

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Rutter VDR-100G3/G3S Installation Manual
Chapter 1: System Overview, Rev. 1.1
Table of Contents
1SYSTEM OVERVIEW.....................................................................................................................1-1
1.1 VDR-100G3 SYSTEM COMPONENTS............................................................................................1-1
1.1.1 Base System .........................................................................................................................1-1
1.1.2 Optional Components..........................................................................................................1-2
1.1.3 Data Processing Unit .......................................................................................................... 1-4
1.1.3.1 Data Management Module..............................................................................................................1-4
1.1.4 Power Distribution and Reserve Power ..............................................................................1-5
1.1.4.1 Power Input and Output ..................................................................................................................1-5
1.1.4.2 Power Control Centre......................................................................................................................1-5
1.1.4.3 Reserve Power.................................................................................................................................1-5
1.1.5 Data Acquisition Unit..........................................................................................................1-5
1.1.5.1 Audio Module.................................................................................................................................1-5
1.1.5.2 Video Module .................................................................................................................................1-5
1.1.5.3 NMEA Input Modules.....................................................................................................................1-6
1.1.6 Operation & Alarm Unit......................................................................................................1-6
1.1.7 Final Recording Medium (FRM/SFRM)..............................................................................1-6
1.1.7.1 Fixed Capsule..................................................................................................................................1-6
1.1.7.2 Float-Free Capsule..........................................................................................................................1-7
1.1.8 Remote Storage Module (RSM) ........................................................................................... 1-7
1.1.9 External Data Interfaces...................................................................................................... 1-7
1.1.10 VDR Software......................................................................................................................1-8
1.2 CLIENT/PLAYBACK PC.................................................................................................................1-8
1.2.1.1 Recommended (Minimum) Requirements ......................................................................................1-9
List of Figures
FIGURE 1-1 -STANDARD INTERCONNECTION ARRANGEMENT ......................................................................1-3
FIGURE 1-2 -STANDARD DATA PROCESSING UNIT ......................................................................................1-4
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1SYSTEM OVERVIEW
1.1 VDR-100G3 System Components
The VDR-100G3 is a modular data storage system for marine vessels. It is designed to collect
and maintain a secure, retrievable record of information related to the vessel’s position,
movement, physical status, and command and control.
While this manual references the VDR-100G3, it is also applicable to the Simplified Voyage Data
Recorder (VDR-100G3S) unless otherwise stated.
There are 3 types of information recorded by a Voyage Data Recorder (VDR):
1. Audio data acquired from microphones mounted in the immediate vicinity of a vessel’s
main bridge workstations and a primary VHF radio is required to be recorded. The
VDR-100G3 has the capability to record public address systems, internal
communications, additional radios, or audio data from other areas of the ship if
necessary.
2. Video data captured at 15 second intervals from one of the ship’s master displays. The
VDR-100G3 can record images captured from multiple radars, electronic chart, or
CCTV displays at various capture intervals. A Simplified Voyage Data Recorder (SVDR)
is required to capture video data but if no output is available AIS may be connected
instead.
3. NMEA 0183/IEC 61162 data related to the position, heading, speed, wind, water depth,
hull openings, bulkhead doors, alarm status, maneuvering commands, and responses
can be recorded with the VDR-100G3. Through the implementation of an interface
module, non-standard data can be converted to this format.
For a complete list of data items to be recorded, refer to the IEC 61996.2.and
MSC.163(78) performance standards.
1.1.1 Base System
The VDR-100G3 is a fully IMO compliant VDR. The base system consists of the following
components:
1. Data Processing Unit (DPU), consisting of:
Data Management Module (DMM)
Power Supply Module
Power Control Centre
2 x 12Ah 12V batteries
Cooling Fan
4GB USB Memory Stick
2. Interfaces *, consisting of:
4-Channel Audio Module: upgradeable
1-Channel Video Module: upgradeable
8-Channel NMEA Module: upgradeable
*The Data Acquisition Unit (DAU) is an optional component. The above interfaces can
optionally be installed in a DAU cabinet.
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Chapter 1: System Overview, Rev. 1.1
3. Operation and Alarm Unit (OAU) is incorporated into the DPU or, as an option. It can
be installed away from the unit.
4. Final Recording Medium (FRM) includes fixed and/or float free.
5. Internal and External Microphones
1.1.2 Optional Components
The VDR-100G3 can also be supplied with the following upgradeable/optional features
1. The base 4-channel audio module may be replaced by an optional 6-channel or 8-
channel audio module.
2. The base 1-channel video module can be upgraded with up to 3 additional video
channels (for a maximum of 4 video channels).
3. The base 8-channel NMEA module may be upgraded in increments of 8 channels.
4. Remote Storage Module (RSM) implemented for additional data backup storage retrieval.
5. Data interfaces (to convert non-standard signals to NMEA format). The VDR-100G3 has
an interface to convert analogue signals to digital data acceptable for the NMEA module
and includes
discrete/contact;
synchro/gyro; and
speed log/depth sounder.
NOTE: Interfaces for VHF and radar may also be necessary. Refer to the VHF and Radar
documentation supplied with those units to determine the applicable interface.
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Chapter 1: System Overview, Rev. 1.1
Figure 1-1 - Standard interconnection arrangement
.
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Chapter 1: System Overview, Rev. 1.1
1.1.3 Data Processing Unit
The Data Processing Unit (DPU) receives and processes information provided from the various
Audio, Video, and NMEA modules. This information is processed in the Data Management
Module (DMM) for archiving on the DMM’s internal hard drive and the Final Recording Medium
(FRM).
The VDR-100G3 power system is housed in the DPU, and accepts universal AC from the ship’s
emergency power while providing 24VDC to the VDR-100G3 modules. The power system
includes batteries to provide uninterrupted power to the audio recording system, OAU and FRM in
the event of a blackout.
Figure 1-2 - Standard Data Processing Unit
The VDR 100G3 hard drive capacity in the base DPU system is partitioned into 3 segments:
1. A segment for the current 12-hour data set;
2. A segment for secured 12-hour data sets; and
3. A segment for archived data sets.
1.1.3.1 Data Management Module
The Data Management Module (DMM) is a rugged, small form factor Pentium computer. It is
equipped with Ethernet ports, serial ports and USB ports, a high capacity hard disk drive, and a
compact flash card.
The DMM compresses and stores data received from the interface modules and, simultaneously,
outputs processed data to the FRM and real-time display (as described below).
The DMM communicates via a serial port with the OAU and the Power Control Centre.
The DMM can be configured to provide data for real-time display via an Ethernet connection. In
addition to the most current data set, the base model DMM can store numerous previously
recorded full data sets in a secure location. This secure location helps protect (but cannot
completely prevent) previously recorded data sets from being overwritten.
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Chapter 1: System Overview, Rev. 1.1
1.1.4 Power Distribution and Reserve Power
1.1.4.1 Power Input and Output
The VDR-100G3 is powered by AC supply. For details see Chapter 2: Technical Specifications.
1.1.4.2 Power Control Centre
The Power Control Centre (PCC) monitors the power system and communicates the power
system status information to the DMM. It provides a means to supply external power through
circuit breakers and terminal blocks for connection to system modules. The PCC contains power
and data connections as well as associated circuit breakers/fuses. To reduce cabling the PCC
can supply power for the Audio, Video and NMEA modules over an Ethernet cable.
1.1.4.3 Reserve Power
The VDR-G3100 has two 12V, 12Ah lead acid batteries that provide up to two hours of audio
recording, FRM storage, and alarm events if there is a power failure.
1.1.5 Data Acquisition Unit
The Data Acquisition Unit (DAU) is an optional component that can house up to 4 main data
interface modules:
Audio Module.
Video Module.
2 NMEA Modules.
(See Chapter 5 for full DAU details)
1.1.5.1 Audio Module
The Audio Module receives audio information from microphones, VHF and other optional line
inputs. All audio data is routed to the DMM for processing, storage, and retrieval. The Audio
Module also features:
Efficient cable management.
Up to 16 input ports for capturing any combination of microphones and radio
communications channels.
(See Chapter 8 for full Audio Module details.)
1.1.5.2 Video Module
The Video Module is a video capture and broadcast device capable of recording video input from
a variety of ship’s video output devices including radar and chart displays and other optional
devices. The module digitizes the video signals and outputs the video data through an Ethernet
port. The Video Module also features:
Up to 4 input ports for capturing images from the main radar display and 3 additional
displays.
Capability to accommodate 1600 x 1200 x 24-bit colour images.
Refresh rates up to 85Hz.
Configurable for a capture interval as short as 3 seconds.
(See Chapter 9 for full Video Module details.)
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Chapter 1: System Overview, Rev. 1.1
1.1.5.3 NMEA Input Modules
The NMEA Input Modules capture data items in IEC 61162 (NMEA 0183) and limited ASCII data
formats. NMEA modules accept up to 8 NMEA-0183 data streams from shipboard systems and
multiplexes them for simultaneous output to an Ethernet connection and a single RS-232/422
serial data channel. Captured data is sent to the DMM via an Ethernet connection for storage and
retrieval. The NMEA module also features:
8 available inputs with each module.
Capability to daisy-chain (cascade) optional modules.
Output to bridge alarm systems for data in IEC 61162 (NMEA 0183) format.
Output to bridge alarm systems for direct connection of Automatic Identification System
(AIS).
Output to bridge alarm systems from additional cascading (DC) or Rutter interface data
outputs.
(See Chapter 10 for full NMEA Module details.)
1.1.6 Operation & Alarm Unit
The Operation & Alarm Unit (OAU) provides a visible and audible alarm to alert the ship’s officer
on watch of any detected failure within the VDR-100G3. The alarm unit is also used to initiate a
download operation on the VDR-100G3. This allows a user to:
Save recorded data. The user should save and secure this recorded data within 12 hours
of any incident to prevent the recording from being overwritten;
Disconnect the optional Remote storage Module (RSM) and download USB drive;
Copy secured, archived, or current data to the download USB drive.
(See Chapter 11 for full OAU details.)
The OAU is integrated into the Data Processing Unit of the VDR-100G3, but a
remotely mounted OAU module is also available as an option. It is preferable
that the optional remotely mounted OAU be specified when the VDR-100G3 is
ordered but it can be field mounted.
1.1.7 Final Recording Medium (FRM/SFRM)
The Final Recording Medium (FRM/SFRM) is a solid-state storage unit capable of storing 12
hours of VDR-100G3 data in compliance with IMO resolution A.861(20). It can be either a fixed or
float-free capsule.
Additional information:
The primary function of the FRM/SFRM is to provide a protective capsule for the IMO-
required data recorded by the VDR. In the event of an incident, this data can be used by
the accident investigation team.
The FRM/SFRM is mounted on the exterior deck of the ship and connected to the DMM.
The FRM/SFRM receives data from the VDR via an Ethernet link.
1.1.7.1 Fixed Capsule
Fixed capsules are designed to ensure that critical voyage data can survive the following
environmental conditions:
Impact shock: 50 half sine-wave pulse for 11 milliseconds (NOTE: The Fixed SFRM
capsules do not meet this specification.);
Penetration: 250 kg mass dropped 3 metres impacting with 100 mm diameter pin;
Fire Exposure: 1,100 degrees centigrade for one hour and 26 degrees centigrade for 10
hours;
Deep Sea Pressure: 30 days under water at MPa (equivalent to 6,000 m depth).
(See Chapter 12 for full FRM/SFRM details.)
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