VAF instruments Shapoli 620 User manual

Technical Manual
Instructions for installation, operation and maintenance
Publication nr TIB-620-GB-0622
Supersedes TIB-620-GB-0322
620
Shapoli
SDB-3 and Bridge Panel PC

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TABLE OF CONTENTS
1. PREFACE......................................................................................3
1.1 General........................................................................................................3
1.2 Symbols.......................................................................................................3
1.3 Copyright......................................................................................................3
2. SYSTEM DESCRIPTION...............................................................4
2.1 VAF ShaPoLi solution..................................................................................4
2.2 System security............................................................................................4
3. TECHNICAL SPECIFICATIONS ....................................................5
4. SAFETY INSTRUCTIONS..............................................................7
5. UNPACKING..................................................................................7
6. INSTALLATION AND FIRST USE..................................................7
6.1 Record SDB-3 and Bridge Panel PC system data .......................................7
6.2 Installation diagram......................................................................................8
6.3 Installation instruction of the SDB-3 and Bridge Panel PC system ..............8
6.4 Configuration and connection of the SDB-3...............................................11
6.4.1 Earthing of the SDB-3 enclosure.......................................................11
6.5 Cable specifications...................................................................................11
6.5.1 Flame-retardant.................................................................................11
6.5.2 Halogen free .....................................................................................12
6.5.3 Low smoke emission.........................................................................12
6.5.4 Specifications cables inputs and outputs SDB-3...............................12
6.6 Modbus input for T-Sense®and TT-Sense®...............................................13
6.7 Analog inputs for 3rd party Torque meter....................................................14
7. OPERATING PRINCIPLES..........................................................15
7.1 General......................................................................................................15
7.2 Displayed parameter and engineering units...............................................15
7.3 Explanation of parameters.........................................................................15
7.3.1 Shaft torque ......................................................................................15
7.3.2 Shaft speed.......................................................................................15
7.3.3 Shaft power.......................................................................................15
7.3.4 Speed Over Ground (SOG) via NMEA 0183.....................................16
7.3.5 Speed Through Water (STW) via NMEA 0183..................................16
7.4 How to operate...........................................................................................17
7.5 Explanation of the menus...........................................................................18
7.5.1 ShaPoLi Home screen......................................................................18
7.5.2 Event Logs........................................................................................20
7.5.3 Alarms...............................................................................................21
7.5.4 Signals..............................................................................................24
7.5.5 Settings.............................................................................................25
8. MAINTENANCE...........................................................................25
9. REPAIR........................................................................................25
10. TAKE OUT OF SERVICE.........................................................25
11. REMOVAL AND STORAGE OF EQUIPMENT.........................25
12. MALFUNCTION AND SEND FOR REPAIR..............................26
13. ENVIRONMENT.......................................................................26

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14. DISPOSAL...............................................................................26
15. TROUBLE SHOOTING ............................................................26
16. CLASSIFICATIONS OF THE SDB-3 AND BRIDGE PANEL PC26
17. DRAWINGS .............................................................................27
18. ABBREVIATIONS ....................................................................33
19. SPARE PARTS........................................................................33
20. WARRANTY CONDITIONS......................................................34

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1. PREFACE
1.1 GENERAL
The VAF ShaPoLi solutions is an unique solution to reduce CO2 emissions according to the new IMO
EEXI & CII. This completely unique and compact total solution can be used for activating an alarm when
the shaft power is exceeding the EEXI power limit.
The VAF ShaPoLi solution consists of a ShaPoLi Data Box (SDB-3) together with a Bridge Panel PC.
The Bridge Panel PC is a microprocessor based instrument for use with the T-Sense®Optical Torque
Measuring System and TT-Sense®Optical Thrust and Torque Measuring System. The T-Sense®is
providing torque, shaft speed and power as input for the ShaPoLi system. The SDB-3 starts logging the
data when the EEXI power limit is exceeded.
The robust ShaPoLi Data Box (as prescribed by the IMO EEXI regulations), can be connected to a large
number of extra inputs like GPS or one additional T-Sense® or TT-Sense®in case of twin screw vessels.
Alternatively one or two 3rd party torque sensors can be connected to the SDB-3 system.
To ensure safe and correct installation and operation, read this manual completely before
installing the equipment and starting operations.
The (micro) SD card should not be exposed to computer viruses, since this could
contaminate the (micro) SD card. Contamination could disturb good working of the system.
For any additional information contact:
VAF Instruments B.V.
Tel.
[phone]
Vierlinghstraat 24, 3316 EL Dordrecht
Fax
[phone]
P.O. Box 40, NL-3300 AA Dordrecht
E-mail
[email protected]
The Netherlands
Internet
www.vaf.nl
Or your local authorized VAF dealer.
Their addresses can be found on www.vaf.nl
1.2 SYMBOLS
The following symbols are used to call attention to specific types of information.
A warning to use caution! In some instances, personal injury or damage to the instrument
or control system may result if these instructions are not followed properly.
An explanation or information of interest.
1.3 COPYRIGHT
This Technical Manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for errors or
omissions is assumed. Neither is any liability assumed for damages resulting from the use of the
information contained herein. Specifications can be changed without notice.

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2. SYSTEM DESCRIPTION
2.1 VAF ShaPoLi solution
VAF ShaPoLi solution is a data collection, calculation, and presentation box, intended to handle data
from a ships shaft power meter. This manual describes the combination of the Bridge Panel PC with the
SDB-3 (ShaPoLi Data Box). The SDB-3 can calculate torque, speed, and power output data. The Bridge
Panel PC in combination with the SDB-3 can manage two T-sense/TT-sense sensors. Alternatively, it is
also possible to connect one or two 3rd party torque meters. The GPS and NMEA signals are required
signals and are used for position and speed.
The SDB-3 converts all these input signals to one RJ45 Ethernet signal for monitoring purposes through
a Bridge Panel PC.
The digital output signal is available for connection an external system like an Alarm and Monitoring
System.
Functions, which can be performed with the SDB-3 and Bridge Panel PC system are:
•Measurement of the torque, shaft speed and power with one or two VAF T-Sense®or TT-Sense®
sensors.
•Measurement of the torque, shaft speed and power with one or two 3rd party Torque sensors.
•Displaying of the actual shaft speed, shaft power and the EEXI power limit.
•Triggers a visible and audible alarm when EEXI power limit is exceeded by the shaft power.
•Activates a digital output when the EEXI power limit is exceeded by the shaft power.
•Starts logging data when the EEXI power limit is exceeded.
•Other inputs are included in the logfile like for example GPS and NMEA-inputs.
The SDB-3 can be installed in the vicinity of the T-Sense/TT-sense/3rd party Torque meter or inthe engine
control room (ECR).
The Bridge Panel PC can be installed on the bridge.
2.2 SYSTEM SECURITY
Besides checking the status of the torque measurement system, the SDB-3 also checks itself
continuously for program and configuration data integrity, normal program flow and power supply
conditions. All alarm messages will be logged in a dedicated alarm screen on the Bridge Panel PC.

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3. TECHNICAL SPECIFICATIONS
SDB-3
Drawing 0815-1130 (section 17)
Supply voltage
115 - 230 VAC
Power consumption
24 W max.
Ingress Protection
IP44
Net weight
Approx. 8 kg
Operating temperature
-20 to 55 °C
Dimensions
400 x 300 x 155 mm (w x h x d)
CPU
1GHz, SDRAM 512MB DDR3L 800 MHZ, On board flash 2GB, 8bit
embedded MMC
Signal input
(J1) T1 or T1+T2
Input signal from T-Sense®,TT-Sense®sensors.
RS485 (2-wire), Baud rate: 19200, Data bits: 8, Parity: none, Stop bits: 2,
Flow control: None
(max 1200m cable length)
Signal input
(J2) T2
Input signal from T-Sense®, TT-Sense®sensors.
RS485 (2-wire), Baud rate: 19200, Data bits: 8, Parity: none, Stop bits: 2,
Flow control: None
(max 1200m cable length)
Modbus output
(J3)
Modbus connection
RS485 (2-wire), Baud rate: 57600, Data bits: 8, Parity: none, Stop bits: 1,
Flow control: None, Function code 3 (Holding Registers), Modbus slave
address 1
(max 1200m cable length)
NMEA input
(J4)
NMEA 0183 (SOG and STW)
SDB-3 requires the following strings:
•$--RMC sentence (SOG)
•$--VHW sentence or $--VBW sentence (STW)
RS422 (2-wire), Baud rate: 4800, Data bits: 8, Parity: none, Stop bits: 1,
Flow control: None (max 1200m cable length)
Ethernet output
(J10)
One RJ45 Ethernet connection to the Bridge Panel PC (max. 100m cable
length)
Digital Output
(J5)
Galvanically isolated, voltage free contact, Normally Closed
Analog inputs
(Optional)
Max. 2x analogue inputs (Max. 2x 3rd party Torque meters)
(2 analogue modules with 3 analog inputs each)
Range per analog input 4-20mA each. Ri = 100Ω
Used for:
•Max. 2x 3rd party torque meters - Torque/speed/power
(3 analog inputs each)

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Figure 1 SDB-3 ShaPoLi Data Box
Bridge Panel PC
Drawing 0815-1128 (section 17)
Supply voltage
115-230 VAC to power supply unit
Dimensions
218 x 163 x 47 mm (w x h x d)
Cut out
170 x 120 mm (w x h)
Cut out depth
32 mm
Front panel thickness
17 mm
Ingress Protection
IP44
Connections
RJ45 Ethernet connection on the back-bottom side of the Bridge Panel PC
Temperature range
-10ºC to +50ºC
Display
Color TFT LCD, Touch screen 8” (1024 x 600) with adjustable backlight
Net weight
940 g
Figure 2 VAF Bridge Panel PC

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4. SAFETY INSTRUCTIONS
There are no special safety instructions for the equipment.
5. UNPACKING
Let the equipment acclimatize inside the closed box for at least one hour at the location where thesystem
will be installed.
When the equipment is taken out of the box, please leave the special protection supplied with the
equipment if possible in place to avoid any damage.
The special protection should be stored for the unlikely event the equipment has to be sent for repair.
Dispose of the packing material should be done according to the laws of the country where the equipment
is installed, or according to the rules that are applicable on the vessel.
•Be careful when unpacking the electronic equipment. The content is fragile.
•Do not press on the Bridge Panel PC.
•Be careful not to damage any of the connectors, control modules or wiring.
6. INSTALLATION AND FIRST USE
The SDB-3 and Bridge Panel PC will be delivered with the software and correct data settings installed.
First connect all the inputs and outputs to the components. The power supply wires should be connected
at last.
Note: The Bridge Panel PC turns on automatically when power supply is connected and active.
Check if the inputs are connected correctly through the Signals menu.
In case of any errors the connection(s) or connected equipment(s) should be checked and corrected.
6.1 RECORD SDB-3 AND BRIDGE PANEL PC SYSTEM DATA
This information is required when contact the supplier for any reason.
SDB-3 nameplate:
Type No.
SDB-3
Serial No.
Supply voltage
V
Frequency
Hz
Var. No.
Power Cons.
W
Bridge Panel PC info:
Software No.
Serial No.
Hull No.
Delivery date

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6.2 INSTALLATION DIAGRAM
Below the configuration where two T-/TT-sense sensors are connected to the SDB-3. The Bridge Panel
PC is connected to the SDB-3 via the Ethernet cable as shown in below figure.
Figure 3 –Installation diagram SDB3 to the Bridge Panel PC with two T-/TT-Sense
6.3 INSTALLATION INSTRUCTION OF THE SDB-3 AND BRIDGE PANEL PC SYSTEM
The VAF ShaPoLi solution consists of a SDB-3 and a Bridge Panel PC. T-Sense®or TT-Sense®
sensors or 3rd party Torque meters, NMEA inputs will be connected to the SDB-3. The SDB-3 will
perform all calculations and data processing to the Bridge Panel PC.
The Bridge Panel PC is connected to the SDB-3 via the Ethernet cable as shown in below figure.
Figure 4 –Connection diagram SDB-3 to the Bridge Panel PC

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1. Always install the SDB-3 with cable glands facing downwards. Do not take electronics out of the
cabinet.
Figure 5 –SDB-3 positioning
2. Install the SDB-3 in the engine room (ER) or engine control room (ECR) but as much as possible free
from moisture, free from large fluctuations of temperature and particularly free from vibration and
shock. Also influences such as large magnetic fields must be avoided. Ambient temperature should
under all circumstances belower than 55°C.External dimensions drawings of the SDB-3 can be found
in section 17.
3. A. Connect the RS485 Modbus output from the stator control box of one T-/TT-Sense®sensor to the
SDB-3 in accordance with drawing 0815-2054 in section 17.
When available, the second T-/TT-Sense®sensor cable needs to be connected as well.
B. In case of 3rd party Torque meters, connect the 4-20mA output of the Torque meter to the SDB-3
in accordance with drawing 0815-2054 in section 17.
When available, the second 3rd party Torque meter cable needs to be connected as well.
4. Connect the signal inputs to the SDB-3 in accordance with drawing 0815-2054 in section 17.
Cable shields should always be connected to the SDB-3 side only.
5. Connect the RJ45 Ethernet output from the SDB-3 to the Bridge Panel PC in accordance with drawing
0815-2054 in section 17.
6. Ensure that all relevant signal cables are properly connected and grounded.
7. Connect the ground at the gland plate of the SDB-3 to an earth point close to the SDB-3.
8. Connect the power supply to the SDB-3 and Bridge Panel PC in accordance with drawing 0815-2054
in section 17.
9. Check if the output data is available on the Bridge Panel PC through menu Signals. If any applicable
output data is not available on the Bridge Panel PC a pop-up alarm screen describing the failure(s)
will show up.

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Important notes
•Never connect cable shields at both ends to ground, but at one end only, to avoid
earth loops.
•Avoid interference on the signal cables by installing them as far as possible away
from electric power cables.
•Ensure that the ambient temperature at the SDB-3 never exceeds 55⁰C.

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6.4 CONFIGURATION AND CONNECTION OF THE SDB-3
Figure 6 –SDB-3 Cabinet lay-out
6.4.1 Earthing of the SDB-3 enclosure
The SDB-3 enclosure must be earthed externally. Therfore a dedicated earth connection is installed in
the gland plate of the SDB-3 enclosure. This earth connection must be connected to a dedicated earth
connection close to the SDB-3 enclosure.
Figure 7 –A dedicated earth connection on the SDB-3 enclosure
6.5 CABLE SPECIFICATIONS
All cables connected to the SDB-3 and Bridge Panel PC shall comply with the following requirements:
6.5.1 Flame-retardant
All electrical cables and wiring external to equipment shall be at least of a flame-retardant type. A single
cable shall be flame retardant according to IEC 60332-1-1 & IEC 60332-1-2.
Processor module
Backplane with analogue input
modules (Optional)
24 VDC Power supply
DIN-rail connectors power & Earthing
External earth on gland-plate
Dedicated earth connection on gland-plate

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6.5.2 Halogen free
In areas where equipment sensitive to corrosion is installed or kept, use of Halogen free cables should
be considered to avoid corrosive smoke in case of a fire, as far as is practicable. This is according to IEC
60754-1.
6.5.3 Low smoke emission
Use of cables with low emission of smoke in case of a fire, should be considered for all indoor
installations. This is according to IEC 61034.
6.5.4 Specifications cables inputs and outputs SDB-3
Make sure that the cables you are using for power supply to the SDB-3, Modbus, Analog 4-20mA,
Ethernet, NMEA and Digital Output signal or the optional analog outputs, meet with the following
specification:
Description:
Cable specification:
Power supply 115/230VAC (single phase):
3 x 1.5 mm²
Screened
Modbus, RS485:
1 x 2 x 0.75 mm²
Twisted pair
Individually screened
Braid shielded
4-20mA analog output signal (optional):
3 x 2 x 0.75 mm²
Twisted pair
Individually screened
Braid shielded
Connection cable Ethernet:
CAT5e, RJ45 plug
Braid shielded
NMEA, RS485:
1 x 2 x 0.75 mm²
Twisted pair
Individually screened
Braid shielded
Digital output:
1 x 1 x 0.75 mm²
Twisted pair
Individually screened
Braid shielded
Earth cable SDB-3 enclosure
1 x 1.5 mm²
Single core

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Figure 8 –Connection diagram of SDB-3 and Bridge Panel PC
All screens to be connected under the cable gland on the SDB-3 side only.
Cable glands are M20 for cable dia. 7-12 mm.
6.6 MODBUS INPUT FOR T-SENSE®AND TT-SENSE®
The T-Sense®or TT-Sense®signal will be connected to the J1 Modbus input connection (Channel 1).
When a second T-Sense®or TT-Sense®is installed, the signal will be connected to the J2 Modbus input
connection (Channel 2).
The T-Sense®or TT-Sense®stator control box slave address is factory set by VAF Instruments.
The SDB-3 termination resistor can be set by way of a jumper switch in “on”-position.
The termination resistor of the last device depends on the device. This can be done using a resistor or
by way of a switch. Please contact your supplier.

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6.7 ANALOG INPUTS FOR 3RD PARTY TORQUE METER
It is possible to connect a 3rd party Torque meter (torque-, speed- and power) to the SDB-3. This 3rd party
torque meter needs to be equipped with analogue 4–20mA outputs.
The analogue 4–20mA signals can be connected to the SDB-3 representing the torque-, speed- and
power-signal.
Analog input:
Signal
Type of input signal
Terminal number on SDB-3
Shaft torque signal
4–20mA - active
Terminal nr. X1 and X2
Shaft speed signal
4–20mA - active
Terminal nr. X3 and X4
Shaft power signal
4–20mA - active
Terminal nr. X5 and X6
When passive analogue outputs must be connected to the SDB-3 please contact VAF Instruments.
NOTE:
Do not connect the signal ground to the ship hull.
NOTE:
The maximum number of analog inputs is 6 inputs, divided across two IO-modules.
Figure 9 –Termination resistor switch
Termination resistor switches.
Set the switch in “on”-position to activate
the termination resistor for the
corresponding connection.

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7. OPERATING PRINCIPLES
7.1 GENERAL
A zero-setting procedure is always necessary in order to obtain a correct measurement and reading of
the T-Sense®Torque sensor or TT-Sense®Thrust & Torque sensor.
For more detailed information see section 6.4 of TIB-661 T-Sense®or TIB-664 TT-Sense®.
The SDB-3 and Bridge Panel PC is an integrated solution for monitoring shaft power and triggers audible
and visible alarm when the EEXI power limit is exceeded. The menu structure of the SDB-3 and Bridge
Panel PC is self-explanatory, and the system is easy to operate.
Several conditional messages will inform you about error/fault conditions if applicable.
Setups determining functionality are subdivided in two levels and access is only possible via a right-of-
access code. All setups and computations are stored in a battery backup RAM. The SDB-3 and Bridge
Panel PC system is self-explanatory as for correct functioning of its memories, program run and existence
of supply voltage.
7.2 DISPLAYED PARAMETER AND ENGINEERING UNITS
The following parameters are available
Unit
•Shaft torque
kNm
•Shaft speed
rpm
•Shaft power
kW
•Time-base
Year, month, day, hour, minute, second
•GPS NMEA Ship’s SOG (Speed Over Ground)
knots
•GPS NMEA Ship’s STW (Speed Through Water)
knots
7.3 EXPLANATION OF PARAMETERS
7.3.1 Shaft torque
The shaft torque is measured in the T(T)-Sense®rotor part and sent wireless to the stator control box.
The shaft torque output of the stator control box is connected to SDB-3 via RS485 Modbus. When a 3rd
party Torque meter is connected to the SDB-3, the shaft torque output of the Torque meter is connected
to the SDB-3 via a 4-20mA analog connection.
7.3.2 Shaft speed
The shaft speed is measured via a gravity sensor in the T(T)-Sense®rotor part and sent wireless to the
stator control box. The shaft speed output of the stator control box is connected to SDB-3 via RS485
Modbus.
When a 3rd party Torque meter is connected to the SDB-3, the shaft speed output of the Torque meter is
connected to the SDB-3 via a 4-20mA analog connection. When multiple Torque sensors are connected
to the SDB-3, the shaft speed of Torque meter one displayed in the Bridge Panel PC.
7.3.3 Shaft power
The measured torque and shaft speed are the input values to the power calculation, which is performed
in the T(T)-Sense®stator control box. The shaft power output of the stator control box is connected to
SDB-3 via RS485 Modbus.
When a 3rd party Torque meter is connected to the SDB-3, the shaft power output of the Torque meter is
connected to the SDB-3 via a 4-20mA analog connection.
When two Power sensors are connected to the SDB-3, the shaft power from engine 1 and the shaft
power of engine 2 are summed together.

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7.3.4 Speed Over Ground (SOG) via NMEA 0183
A GPS signal can be connected to the SDB-3 through the RS422 port (J4).
The ship’s speed over ground is transmitted via the NMEA 0183 protocol. The SDB-3 and Bridge Panel
PC will read out the $--RMC sentence (“Speed Over Ground”) and the value will be displayed in knots.
The ship’s through water is transmitted via the NMEA 0183 protocol. The SDB-3 and Bridge Panel PC
will read out the $--VHW or $--VBW sentence (“Speed Through Water”) and the value will be displayed
in knots.
7.3.5 Speed Through Water (STW) via NMEA 0183
The ship’s through water is transmitted via the NMEA 0183 protocol. The SDB-3 and Bridge Panel PC
will read out the $--VHW or $--VBW sentence (“Speed Through Water”) and the value will be displayed
in knots.

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7.4 HOW TO OPERATE
The VAF Bridge Panel PC is designed in such a way that it is easy to operate and self-explaining. By
touching the keys on the touch screen gently the next menu is selected, or specific values can be
changed.
Browsing through the sections and submenus by touching the relevant keys at the touch screen will help
you to find the information you are looking for.
Entering values
Via a numeric keypad you will be able to change specific values.
This keypad will be displayed after touching the values in the light grey sections at the Bridge Panel
PC.
The value will change when a new value is entered.
Figure 10 –Onscreen Keypad
Backlight
By touching the Settings tab at the top right of the touch screen you will find the buttons to change the
brightness of the Bridge Panel PC. The intensity of the backlight can be changed by touching the <
DIM- > and < DIM+ > buttons.
Figure 11 –Login and Backlight Settings
NOTE:
It is not possible to dim the screen of the Bridge Panel PC completely black

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7.5 EXPLANATION OF THE MENUS
The Bridge Panel PC is divided into 5 submenu’s: ShaPoLi, Event Logs, Alarms, Signals and Settings.
By touching the relevant tab, the specific menu will be displayed.
7.5.1 ShaPoLi Home screen
By touching the ShaPoLi tab in the top left corner you will be guided to the ShaPoLi home screen. The
ShaPoLi home screen is showing all important actual information regarding Shaft Power Limitation. The
actual shaft power indicator is visualised on the left. On the right the actual Shaft Speed, actual Shaft
Power and the EEXI Power limit are indicated.
In every submenu except “Settings”, the current status of the system can be seen via the ShaPoLi bar.
A green ShaPoLi bar shows that the actual shaft power is below the EEXI limit, and no other alarms are
present.
Figure 12 –ShaPoLi home screen –Power below limit
The green bar in the ShaPoLi home screen will change to red when one of the following alarms occur:
- Power is over the EEXI Shaft Power Limit
- T-Sense/TT-sense (over MODBUS) communication failure
- NMEA communication failure
- Some of the expected power sensors have not been enabled
- Individual sensor (Torque, Speed, Power) communication failure if using an analogue power
sensor
- Missing encrypted ShaPoLi settings
- IO communication failure
The message in the red bar depends on the alarm. The speaker in the Bridge Panel PC will be activated
for half a second, every second and the SDB-3 software starts logging immediately. The Digital Output
which is Normally Closed, will open. The tabs “ShaPoLi” and “Alarms” will be coloured red and will blink.

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Figure 13 –ShaPoLi home screen when Shaft power is
above EEXI limit
Figure 14 –ShaPoLi home screen when communication with
Power sensor is lost
Figure 15 –ShaPoLi home screen when NMEA
communication with SDB-3 is lost
Figure 16 –ShaPoLi home screen when one of the expected
power sensors have not been enabled
Figure 17 –ShaPoLi home screen when there is a
communication failure of an individual sensor. Only if using
an analog power sensor (Torque, Speed or Power)
Figure 18 –ShaPoLi home screen when encrypted ShaPoLi
settings are missing
Figure 19 –ShaPoLi home screen when IO communication
is lost
When two power sensors are connected and one sensor has a failure, the Power sensor number is also
shown in the red bar. More detailed information can be viewed in submenu Alarms.
These alarms can be silenced and/or accepted. This will be explained in chapter 7.5.3.